Light-Duty Technology Cost Analysis
   Pilot Study
United States
Environmental Protection
Agency

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                   Light-Duty  Technology  Cost Analysis
                                        Pilot Study
                                   Assessment and Standards Division
                                  Office of Transportation and Air Quality
                                  U.S. Environmental Protection Agency
                                         Prepared for EPA by
                                              FEV, Inc.
                                      EPA Contract No. EP-C-07-069
                                       Work Assignment No. 1-3
                   NOTICE

                   This technical report does not necessarily represent final EPA decisions or
                   positions.  It is intended to present technical analysis of issues using data
                   that are currently available. The purpose in the release of such reports is to
                   facilitate the exchange of technical information and to inform the public of
                   technical developments.
SER&
United States
Environmental Protection
Agency
EPA-420-R-09-020
December 2009

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                                         CONTENTS
Section                                                                              Page

    Executive Summary	ES-1
    1    Introduction	1-1
         1.1   Objectives	1-1
         1.2   Process Methodology and Key Supporting Documents	1-3
         1.3   Manufacturing Assumptions	1-7
    2    Technology Selection	2-1
    3    Comparison Bill of Materials	3-1
         3.1   Overview	3-1
         3.2   Main Sections of Comparison Bill of Materials	3-1
    4    Costing Methodology - Teardown, Process Mapping, and Costing	4-1
         4.1   Cost Methodology Fundamentals	4-1
         4.2   Serial and Parallel  Manufacturing Operations and Processes	4-2
         4.3   Design Profit® Software Overview	4-5
         4.4   Teardown Process Overview	4-8
         4.5   Identifying Materials, Primary and Secondary Processes	4-9
    5    Cost Model Overview	5-1
    6    Indirect OEM  Costs	6-1
    7    Costing Databases	7-1
         7.1   Database Overview	7-1
         7.2   Material Database	7-3
               7.2.1    Overview	7-3
               7.2.2    Material  Selection Process	7-6
               7.2.3    Pricing Sources and Considerations	7-7
               7.2.4    Material Price Forecasting, Accuracy and Variation	7-8
               7.2.5    In-process Scrap	7-9
               7.2.6    Purchase Part - Commodity Parts	7-10
         7.3   Labor Database	7-11

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           7.3.1    Overview	7-11
           7.3.2    Direct Versus Total Labor, Wage Versus Rate	7-11
           7.3.3    Contributors to Labor Rate and Labor Rate Equation	7-13
     7.4   Manufacturing Overhead Database	7-17
           7.4.1    Overview	7-17
           7.4.2    Manufacturing Overhead Rate Contributors and Calculations	7-19
           7.4.3    Acquiring Manufacturing Overhead Data	7-20
     7.5   Mark-up (Scrap, SG&A, Profit, ED&T)	7-23
           7.5.1    Overview	7-23
           7.5.2    Mark-up Rate Contributors and Calculations	7-25
           7.5.3    Assigning Mark-up Rates	7-29
     7.6   Packaging Database	7-30
           7.6.1    Overview	7-30
           7.6.2    Types of Packaging and Selection Process	7-31
           7.6.3    Support for Costs in Packaging Database	7-31
8    Shipping Costs	8-1
9    Manufacturing Assumption and Quote Summary Worksheet	9-1
     9.1   Overview	9-1
     9.2   Main Sections of Manufacturing Assumption and Quote Summary Worksheet	9-1
     9.3   Manufacturing Assumption and Quote Summary Detail Review	9-5
10   Marketplace Validation	10-1
11   Cost Model Analysis Templates	11-1
     11.1   Subsystem CostModel Analysis Templates	11-1
     11.2   System CostModel Analysis Template	11-5
12   Operating and End-of-Life  Costs	12-1
13   Results for Case Study #0101	13-1
14   Sensitivity Analysis	14-1
15   GLOSSARY OF TERMS	15-1
                                          11

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                              LIST OF APPENDICES


A. 1 Powertrain - Vehicle Class Summary Matrix Excerpt - Case Study #0101

B. 1 Powertrian Package Proforma - Case Study #0101

C.I Comparison Bill of Materials Excerpt- Case Study #0101, Mini Cooper 1.6L 14
    Turbo, Direct Injection

D. 1 Design Profit® Mapping Symbols

E. 1 Material Database Excerpt

E.2 Labor Database Excerpt

E.3 Manufacturing Overhead Database Excerpt

E4. Manufacturing Overhead Calculator Template

E5. Mark-up Database Excerpt

E6. Packaging Database Excerpt

F.I Manufacturing  Assumption and  Quote Summary  (MAQS)  worksheet detailed
    reference guide

G.I MAQS Worksheets (Sections A,B,E & F) - Case Study #0101

H. 1 Subsystem Cost Model Analysis Templates - Case Study #0101

H.2 System Cost Model Analysis Template - Case Study #0101
                                      in

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                                  LIST OF FIGURES
Number                                                                         Page
Figure 1 -1:      Cost Analysis Process Flow Steps & Document Interaction	1-3

Figure 4-1:      Fundamental Steps in Costing Process	4-4

Figure 4-2:      Screen Shot of Process Mapping Using Design Profit® Software	4-7

Figure 4-3:      Property Window for a Part Symbol Used in Process Mapping	4-8

Figure 4-4:      Injection Molded Primary Processing Map	4-11

Figure 4-5:      Operations Library - Design Profit® Database	4-13

Figure 4-6:      Tool Library - Design Profit® Database	4-14

Figure 4-7:      Material Modification Library - Design Profit® Database	4-15

Figure 4-8:      Fastening Library - Design Profit® Database	4-16

Figure 4-9:      Example Illustrating the Various Levels Associated with Process Mapping a
               Vacuum Pump Base Support	4-18

Figure 5-1:      Unit Cost Model - Costing Factors Included in Analysis	5-1

Figure 7-1:      Illustrates  the change in Labor Rates between  2008 and 2015, Assuming a
               Negative 5% Annual Adjustment Factor (AFF)	7-2
Figure 7-2:      Price Data for Significant Materials Identified in Case Study #0101	7-4

Figure 7-3:      Price Data for Significant Materials Identified in Case Study #0101 (Materials
               Database Excerpt #2B)	7-5
Figure 7-4:      Historical  304 Stainless Steel Prices	7-7

Figure 7-5:      Projected Pricing for 304 Stainless Steel	7-9

Figure 7-6:      Labor  Database  Excerpt  Highlighting  Occupation  Classification   Codes,
               Descriptions, and Mean Hourly Wages	7-12

Figure 7-7:      Labor Database Excerpt Showing Contributors to Total Labor Rate for Various
               Direct Labor Occupations	7-16
Figure 7-8:      Manufacturing Overhead Database Excerpt Showing Standard Overhead Rates
               for CNC Turning	7-18
Figure 7-9:      Mark-up Database Excerpt Highlighting the Rate Differences ( End Item Scrap,
               SG&A, Profit, and ED&T), for Three (3) Levels of Injection Molding,  Based
               on Part Size and Complexity	7-24
                                          IV

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Figure 9-1:      Excerpt Illustrating Automated Link between OEM/T1 Classification Input in
               MAQS Worksheet and the Corresponding Mark-up Percentages Uploaded from
               the Mark-up Database	9-2

Figure 9-2:      Example of Packaging Cost Calculation for a High Pressure Fuel Injector	9-5
Figure 11-1:   Excerpt from Subsystem Cost Model Analysis Template Illustrating Subsystem
              Cost Roll Up for the Fuel Induction Subsystem - New Technology Configuration
              -Case Study #N0101	11-3

Figure 11-2:    Excerpt from Subsystem Cost Model Analysis Template Illustrating Subsystem
               Cost Roll Up for the Fuel Induction Subsystem - Base Technology Package -
               Case Study #B0101	11-4

Figure 11-3:    Excerpt from System Cost Model Analysis Template Illustrating the Incrmental
               Subystem Cost Roll Up for Case Study #0101  - 2.4L 14, 16 Valve, DOHC, NA,
               PFI downsized to 1.6L 14, DOHC, Turbo GDI	11-6


Figure 13-1:    System Cost Model Analysis Template Illustrating the Incremental Subsytem
               Costs Roll Up for 14, Turbo, GDI Downsizing, Case Study #0101 	13-2
                                          v

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                                        LIST OF TABLES

Number                                                                      Page
Table ES-1: Case Study #0101 Incremental Unit Cost Impact - Downsizing from a 2.4L 14, 16
           Valve, DOHC, NA, PFI Engine to a 1.6L 14, 16 Valve, DOHC, Turbo, GDI Engine
           	ES-2


Table 7-1:  Tier 1 Published SG&A and ED&T/R&D Rates for 2007 and 2008	7-27

Table 7-2:  Standard Mark-up Rates Applied to Tier 1  and Tier 2/3  Suppliers Based on Size
           and Complexity Ratings	7-28

Table 7-3:  Generic Mark-Up Rate Classification Based on Component  Size and Complexity
            	7-30

Table 13-1: Summary of Cost Analysis Assumptions for Case Study #0101	13-3

Table 14-1: Cost Model Sensitivity Study Results	14-1
                                        VI

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               Light-Duty Technology Cost Analysis Pilot Study

Executive Summary

The United States Environmental Protection Agency (EPA) contracted with FEV, Inc. to
determine incremental direct manufacturing costs for a set of advanced light-duty vehicle
technologies.  The technologies selected are on the leading edge for reducing emissions
of greenhouse gases in the future, primarily in the form of tailpipe carbon dioxide (CO2).

In contrast to comparable cost analyses done in the past, which rely heavily on supplier
price quotes for key components, this study is based to a large degree on teardowns of
vehicles or vehicle systems that employ the new technologies, and of similar vehicles or
systems without the new technologies.  Analysts with expertise in automotive design,
materials, and manufacturing then compare the teardown components and evaluate  the
differences.  Using databases for materials, labor, manufacturing overhead,  and mark-up
costs, the overall cost to manufacture individual parts are calculated and summed into
final results.   A model consisting  of an extensive set of  linked spreadsheets and
associated macros has been developed to perform the calculations, to track the input data,
identify sources of information, describe assumptions used in the case study, and provide
analysis tools (such as forecasting to future years).

This report describes the study methodology in detail, and presents results for the first
technology evaluated: stoichiometric, gasoline direct injection (GDI) with turbocharging
on a downsized 14  engine, compared to an equivalent conventional 14  engine.  These
results are summarized in the following Table ES-1.

As shown in Table  1, the two  (2) subsystems having the greatest impact on incremental
costs were the air induction subsystem ($258.89) and fuel induction subsystem ($107.32).
In the case of the air induction subsystem, all components included in the  cost analysis
were absolute component costs (i.e., there were no cost offsets from the base technology
configuration). The major cost contributors to the air induction subsystem included  the
turbocharger assembly ($151.85), tubes and hoses ($52.21), charged air cooler assembly
($18.65),  and the OEM engine  and vehicle  assembly  of air induction components
($25.70).  The major cost contributors associated with the adoption of a high pressure
fuel induction subsystem included the addition of a high pressure fuel pump  ($69.61),
four (4) high pressure fuel injectors ($13.13/each) and a high pressure fuel rail ($20.76).
These  cost  additions were  offset  by the base technology  configuration  costs  which
included four (4) low pressure fuel injectors ($8.77/each) and a low pressure fuel rail
($5.83).

Complete cost details  for  all subsystems referenced in Table ES-1 can  be  found in
Appendices  G. 1 (individual component  cost sheets), H. 1 (subsystem cost roll ups) and
H.2 (system cost roll up).
                                   ES-1

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Table ES-1:    Case Study #0101 Incremental Unit Cost Impact - Downsizing from a 2.4L 14, 16
     Valve, DOHC, NA, PFI Engine to a 1.6L 14, 16 Valve, DOHC, Turbo, GDI Engine
Engine Subsystems
Engine Frames, Mountings & Brackets Subsystem
Crank Drive Subsystem
Counter Balance Subsystem
Cylinder Block Subsystem
Cylinder Head Subsystem
Valve Train Subsystem
Timing Drive Subsystem
Accessory Drive Subsystem
Intake Subsystem
Fuel Induction Subsystem
Exhaust Subsystem
Lubrication (Oil Pans/Sumps) Subsystem
Cooling Subsystem
Induction Air Charging Subsystem
Exhaust Gas Re-Circulations Subsystem
Breather Subsystem
Engine Management, Engine Electronic and
Electrical Subsystem
Accessory (e.g. Starter Motor, Power Steering
Pump, Air Conditioning Compressor) Subsystem

TOTAL UNIT COST
Net Incremental
Component/Assembly Cost
Impact to OEM
$0.00
$0.00
($35,95)
$0.44
$16.55
$10.06
$1.60
$0.00
($12.73)
$107.32
$37.77
$34.46
$41.56
$258.89
$0.00
$4.17
$56.61
$16.95

$537.70
                                    ES-2

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1   Introduction

1.1   Objectives

This report describes the methodology used for the light-duty vehicle technology cost
study performed for the  Environmental Protection  Agency (EPA) by  FEV and  its
subcontractors. Because the methodology is most readily understood in the context of an
actual case study, this report also presents details  and results for  the first technology
studied:  stoichiometric gasoline  direct  injection (GDI)  with turbocharging  on  a
downsized 14 engine, compared to an equivalent  conventional 14  engine  (Case  Study
#0101).  Detailed analysis working  documents for the case study  are provided  in the
Appendix; however, the very large size of some of the analysis spreadsheets precludes
their inclusion in the report itself and these are being made  available in CD form or on
EPA's website (http://www.epa/gov/otaq/).  Costing  results and details for additional
technologies and vehicle classes will be provided in subsequent reports.

The objective of this work assignment is to determine incremental direct manufacturing
costs for a set of advanced light-duty vehicle technologies.  The technologies selected are
on the leading edge for reducing emissions of greenhouse gases in the future, primarily in
the form of tailpipe carbon dioxide (CO2).  Such reductions generally correspond to fuel
economy improvements.   Each  technology selected is  evaluated  against a  baseline
vehicle technology configuration, representative of the current state of design, and having
similar overall driving performance.  To obtain cost results across the diverse light-duty
vehicle  fleet,  application  of the  new technologies in five  (5) vehicle size classes is
considered, though no  costing is performed for cases in which a technology  is  not
generally considered applicable to a vehicle class. The vehicle size classes are:

•   Small car: a subcompact or compact  car typically powered by an in-line 4  cylinder
    engine

•   Midsize car: a midsize or large passenger car typically powered by a V6  engine

•   Large multi-purpose vehicle:   a minivan or large cross-over vehicle with a large
    frontal area, typically  powered by a V6 engine,  capable  of carrying  ~ 6  or more
    passengers

•   Small truck: a small or mid-sized sports-utility or cross-over vehicle, or a small pick-
    up truck, powered by a V6 or V8 engine

•   Large truck: large sports-utility vehicles and large pickup  trucks, typically powered
    by a V8 engine
                                      1-1

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Currently, the new technologies under consideration for study are:




•  Downsized turbocharged gasoline direct-injection (GDI) engines




•  Hybrid electric vehicles




•  Advanced transmissions (6-speed, dual clutch)




•  High-efficiency, low-leak air conditioning




•  Advanced diesel engines




•  Plug-in hybrids




•  Full electric vehicles




•  Homogenous charge compression ignition engines




•  Lean-burn GDI engines
                                       1-2

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1.2   Process Methodology and Key Supporting Documents
1. Technology
Selection
Powertrain Vehicle
Class Summary Matrix
(P-VCSM)
^ '
2. Hardware
Selection
Powertrain Package
Proforma
^ '
3A. Generate Bill of
Materials - Phase 1
Comparison Bill of
Materials (C-BOM)











^^^

                             4. System/Subsystem
                              Disassembly and
                             Process Mapping -
                                  Phase 1

                               (Design Profit®)
                                    I
                             5. Cross Functional
                                Team (CFT)
                                  Reviews
   Databases (Material, Labor, Manufacturing
       Overhead, Mark-up, & Packaging)
  6. Component/
    Assembly
  Disassembly &
Process Mapping -
    Phase 2

  (Design Profit®)
                                3B. Update Bill of Materials - Phase 2

                                  Comparison Bill of Materials (C-BOM)
  Process Flow
  Manual & Automated
  Document Links
  7. Generate
Manufacturing
Assumption and
Quote Summary
   (MAQS)
  Worksheets
                                                                               8. Market Place
                                                                                Cross-check
                         9. Subsystem Cost
                             Roll Up

                        Subsystem Cost Model
                          Analysis Template
                         (Subsystem CMAT)
                                                                               10. System Cost
                                                                                  Roll Up

                                                                               System Cost Model
                                                                               Analysis Template
                                                                               (System CMAT)
         Figure 1-1:    Cost Analysis Process Flow Steps & Document Interaction
                                               1-2

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The overall process methodology is comprised often (10) major steps, described briefly
below and in Figure 1, and in more detail in subsequent sections.

 Step 1; Using the Powertrain-Vehicle Class Summary Matrix (P-VCSM) a technology
is selected for cost analysis.

      The P-VCSM identifies the technologies being evaluated, the applicable vehicle
      classes for each technology, and key parameters for vehicles or vehicle systems
      that  have been  selected  to  represent  the  new  technology  and  baseline
      configurations in each vehicle class to be costed. As the defining input to the cost
      analysis, it is developed through extensive discussions with EPA. A portion of the
      P-VCSM for this case study is provided in Appendix A. 1.  This document may be
      modified as the study progresses. Note that some closely associated technologies
      are bundled; for example: gasoline direct injection and turbocharging.

Step 2; Existing vehicle models are identified for teardown, to provide the basis for
detailed incremental cost calculations.  The teardown vehicles are chosen in collaboration
with EPA to represent  the base and new technology cases on the P-VCSM. For many
technologies being studied the vehicle systems involved are not extensive, so that entire
vehicles need not be torn down or costed out, but rather engines, transmissions, or other
major components are  targeted instead.  In doing  so, close scrutiny is paid to vehicle
components that might be indirectly affected by the addition of a new technology, such
as those needed for noise, vibration, and harshness (NVH) mitigation.  The system and
performance details of the selected new and base technology configurations are recorded
in the Powertrain Package Proforma.

      The Powertrain  Package Proforma is a summary worksheet comparing the key
      physical and  performance attributes of the technology  under study with those  of
      the corresponding base configuration.  The Powertrain Package Proforma for case
      study #0101 may be found in Appendix B.I.

Step 3; Pre-teardown Comparison Bills of Materials (CBOM) are developed, covering
hardware that  exists in the  new and base technology configurations.  These high level
CBOM's are informed by the team's understanding of the new and base technologies and
serve to identify the major systems and components targeted for teardown.

      The  CBOM is  a bill of  materials  which  lists  out  all the  subsystems and
      components associated with the technology configurations under evaluation.  It
      may include subsystems or components of the new technology vehicle that are not
      used on the base vehicle.

      The CBOM provides a means of identifying  all the parts that are different between
      the base and new technology configurations,  as a result of adoption of the new
      technology.  Also the CBOM is the document used to capture  alternative design

                                       1-4

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      and  manufacturing innovations, which can be  binned to either material cost
      reduction (MCR)  ideas  or new  technology  advances  (NTAs),  within  the
      technology configurations  under evaluation.  These ideas, if found to  be  of
      significant value, are then  evaluated  in terms  of performance  and/or cost
      improvements over the base assessment.

      In addition, the CBOM documents sources of the quote assumptions made for the
      cost analysis, e.g., parts,  drawings or specifications, actual parts  or  surrogate,
      make or buy  (purchase), validation quote required, etc.  In the context of this
      study,  "quote" generally refers to  the analytically determined cost  of a part or
      assembly, not a price provided by a supplier.  A portion of the new technology
      configuration CBOM for case study #0101 may be found in Appendix C.I.

Step 4;  Phase 1 (high level) teardown is conducted for  all subsystems identified in Step
3 and the assemblies that comprise them.  Using Design Profit® software, all  high level
processes (e.g. assembly process of the high pressure fuel pump onto the cylinder head
assembly) are mapped during the disassembly.

      Process mapping is the sequential identification and orderly documentation of all
      the steps involved in a making  an assembly or component.  A single component
      may be  manufactured using a  number of processes (die casting, machining,
      washing, heat treating,  anodizing, testing, etc).   Each process may by  further
      divided into several operations.  Thus for a given assembly, often  consisting of
      twenty (20) or more components, keeping track of processes and operations in a
      logical manner is very critical.

      Fundamental  to process mapping  is identifying the materials and  the  primary
      processes required to manufacture a part.  This is  followed by  selecting  the
      optimal  manufacturing  inputs (tools,  equipment,  etc.)  based  on   certain
      manufacturing  assumptions  (see Section 1.3), such  that a series of operations
      defining the process can be mapped.  All parts requiring a detailed cost  analysis
      undergo this process.

Step 5; A cross functional team (CFT) reviews all the data generated from the high level
teardown.  This CFT, with an average relevant experience level of 23 years, employs
technology expertise from several areas including: engine design and development, NVH
and driveline subsystems, vehicle integration,  production development, manufacturing
engineering (supplier and OEM),  cost estimating and product benchmarking.  Where
appropriate, personnel changes are made to the CFT to ensure matching expertise to the
technology under analysis.

The  CFT captures  the  assessments  in the  CBOMs, identifying the component and
assembly  differences between  the  new  and  base  technology configurations.    All
                                       1-5

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components requiring cost analysis are identified, as well as any base assumptions where
applicable (e.g. material selection, primary and secondary manufacturing processes).

Step 6; Phase 2 (component/assembly level) teardowns are done, based on the updated
CBOM's.  Components and assemblies are disassembled, and processes and operations
are mapped in full detail.  The process mapping generates key process information for the
quote worksheets.   Several  databases, containing critical costing  information, provide
support to the mapping process.

Step 7;   Manufacturing Assumption and Quote Summary (MAQS) worksheets are
generated for all parts undergoing the cost analysis.  The MAQS details all cost elements
making up the final unit costs:

   •  material

   •  labor

   •  burden

   •  end item scrap

   •  selling, general & administrative (SG&A)

   •  profit

   •  engineering design & testing (ED&T)

   •  packaging

In addition the MAQS worksheet has active links to all key costing parameters.

      The MAQS worksheet is basically a standard original equipment manufacturer
      (OEM) quote sheet modified with some extra sections to display additional details
      as well  as provide ease and flexibility for updating specific cost factors.  The main
      feeder documents to the MAQS worksheet include the Design Profit® maps and
      costing databases.

      Two (2) key  sections to the MAQS worksheet are the manufacturing assumption
      section and the quote summary section. In the manufacturing assumption section,
      key output variables from the process maps created by Design Profit® software
      are imported into the MAQS worksheets.  Calculations are made with these inputs
      developing a mass production processing methodology.

      Outputs from the manufacturing assumption section of the MAQS worksheet are
      uploaded  into the quote summary  section along with various inputs  from the
      various costing databases to arrive at a final estimated manufacturing cost.
                                       1-6

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Step 8; Parts with high or unexpected cost results are subjected to a marketplace cross-
check  such as comparison with  supplier price quotes, or wider  consultation with
company and industry resources beyond the CFT.

Step 9; All costs calculated in the MAQS worksheets are automatically inputted into the
Subsystem Cost Model Analysis Templates (CMAT).  Some examples  of subsystems,
contained within the  engine  system, include the following:  crankdrive subsystem,
cylinder head subsystem, fuel induction subsystem, and air induction subsystem.

       The Subsystem CMAT is used to  display and roll up all the differential costs
       associated  with a  subsystem.  All  parts in a subsystem  that are identified for
       costing in the CBOM are entered into the Subsystem CMAT. Also both the base
       and new technology configurations  are included in the same CMAT to facilitate
       differential cost analysis.

Step 10;  The final step in the process is creating the System CMAT which rolls up all
the subsystem differential costs to establish a final system unit cost. For case  study
#0101, the engine system was the only vehicle system requiring analysis.

       The System CMAT, similar in function to the subsystem CMAT, is the  document
       used to display and roll-up all the subsystem costs associated within a system, as
       defined by the CBOM.  Within the scope of this cost analysis, the  System CMAT
       provides the bottom line  incremental unit  cost, between the  base  and  new
       technology configurations  under evaluation. All  Subsystem  CMAT  totals are
       linked directly to the System CMAT.

1.3  Manufacturing Assumptions

When  conducting the  cost analysis for the various technology configurations,  a number
of assumptions are made in order to establish a consistent framework for all costing. The
manufacturing  assumptions can  be  broken  into  generic  and  specific  case  study
assumptions.

The  generic manufacturing assumptions apply to all technology configurations under
analysis. Listed below are the fundamental assumptions:

    1)  All OEM  and  supplier manufacturing  locations are  in North America,  unless
       otherwise  stated.  This serves  to make the  resulting costs conservative to the
       extent that OEMs use offshore suppliers to reduce costs.

    2)  OEMs and suppliers have  manufacturing equipment and  facilities capable of
       handling required  manufacturing  processes  and capacities, unless  otherwise
       stated.
                                       1-7

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    3) All manufacturing processes and operations are based on standard/mainstream
       industrial practices.

    4) Supplier mark-up rates (End-Item Scrap, SG&A,  Profit,  ED&T) are based  on
       mature technology and manufacturing methods (e.g. mature product designs, high
       production   volumes,   significant   marketplace   competition,   established
       manufacturing processes) unless otherwise specified.

    5) All OEM mark-up will be applied using indirect cost (1C) multipliers.  These are
       not within the scope of this analysis, but  should  be  separately determined and
       applied to  the results  of this analysis  to obtain  total  (direct +  indirect)
       manufacturing costs.

    6)  Manufacturing rates are considered high volume (450,000  units per year for case
       study #0101) and maintained throughout the product life.  The engine volume
       assumption for case  study #0101  is  based on  published data from Ward's
       Automotive Yearbook 2008, in which annual  engine volumes for 2007 model
       year US domestic  light-vehicle production ranged  from  350K  to  480K for
       moderate to high volume consumption applications.
The  specific  case  study  assumptions  are those  unique  to  a  given  technology
configuration.  These include volume assumptions, weekly operation assumptions (days,
shifts, hours, etc.), packaging  assumptions, and Tier 1 in-house manufacturing versus
Tier 2/3 purchase part assumptions. Details on the case study specific assumptions can
be found in the individual MAQS worksheets.
                                       1-8

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2   Technology Selection

The Powertrain-Vehicle Class Summary Matrix (P-VCSM) summarizes the technology
configurations and vehicle classes to be evaluated. Using the design parameters listed in
the P-VCSM, the best-suited hardware is chosen for the new technology and base
configurations. The performance attributes being matched in these configurations, along
with other pertinent vehicle/system details, are listed in the Powertrain Package Proforma
for each case study.

As discussed in Section 1.1, five (5)  vehicle classes were  considered for this work
assignment.  Costing based on full teardowns in every relevant vehicle class would be
prohibitively expensive and  time consuming.   Fortunately, reliable results  can be
obtained through judicious scaling of the teardown-derived costs, up or down, across the
relevant vehicle classes.  In  some cases, teardown of a limited set of key components
from a vehicle in a particular class assists in scaling costing results to that class.

Proper scaling of teardown results is a complex but critical part of the  overall  analysis,
and the methodology for it can vary, component by  component.  Some parts are  best
scaled by  engine  displacement  (cylinder  block,  turbocharger  assembly,  oil pump
assembly, for example) and some by number count (number of pistons, for example) or
other parameters. The P-VCSM identifies which case studies have been conducted using
the full teardown and cost  analysis method  and those  which have  used the scaling
methodology. The scaling assumptions for individual components are documented in the
quote assumption section of the CBOM.
                                     2-1

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3   Comparison Bill of Materials

3.1   Overview

The CBOM's function as the case study road maps, detailing what is being quoted and
why.  The CBOM  records all the high level  details of the technology configurations
under study, identifies those items which have cost implication as a result of the new
versus base technology differences, documents the study assumptions, and captures input
from the cross functional team.

The CBOM's are considered working documents, and as such are updated and referenced
throughout the  different phases of the  analysis.  All costing documents are referenced
back to the CBOM's, linking all components of the analysis.

In addition to the manufacturing cost  impact on components and  assemblies directly
associated with new technologies, the  "ripple  effect" on neighboring  systems must be
considered.  These  effects may have positive  or negative consequences on the overall
vehicle costs for the new technologies.

When a new case study is initiated, the cross functional team meets to discuss the primary
differences between the base and new technology configurations being studied as well as
the  surrounding systems, which  may  be  affected by the technology  differences.  A
Comparison Bill of Material is generated as a starting point to track all potential system,
subsystem  and component/assembly costs directly or indirectly associated  with  the
technology  change.   Thus,  regardless  of what system  or subsystem  an  affected
component or assembly  resides  in, it  is tracked and quoted using the same  costing
methodology.  It should be noted that in this case study, where a naturally-aspirated 1-4
engine is replaced by a downsized, turbocharged 1-4 engine, the team concluded that no
additional costs were  involved outside the engine system ( e.g. the firing frequency and
overall power level of the two (2)  engines are similar).  In future studies, where there is a
quantifiable  difference in NVH or other characteristics between the base case and  the
new technology, the components required to address them will be identified and costed.

3.2   Main Sections of Comparison Bill of Materials

The CBOM consists of the following sections:

The  General Part Information  section lists  out  all the  systems,  subsystems,  and
components potentially  affected  by going  from the base  configuration to  the new
technology configuration under consideration.  The goal at this stage of the process is a
conservative (long) list, with the expectation that detailed examination will subsequently
eliminate some  components from  further consideration, as described below.  The layout
                                     3-1

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structure of the  CBOM is  top level down (system, subsystems, assemblies, etc.)  All
components and assemblies within subsystems, and all subsystems within systems, are
grouped according to design function.

The Design Difference section is where parts are identified as not needing cost analysis.
All parts initially listed in the CBOM are identified as requiring cost analysis; represented
with a red  check box.  Only after the cross functional team has reviewed the parts and
determined they can be excluded from the study is the box checked off, turning it green
to indicate no cost analysis  is required.  If exclusion of a part is not obvious, remarks are
added identifying the team's assumptions. If a checkbox is left red, identifying that the
part requires cost analysis,  the attribute  differences  are identified along with any study
and  costing  assumptions.  In several circumstances,  the  systems,  subsystems,  and
components under comparison, between the base and new  technology configurations,
will be different in variety of ways: part existence, material selection, part geometry,
manufacturing methods, etc.  It is the job of the cross functional team to determine if
these  differences are driven by  the  change in technology, or are  exclusive of the
technology and the result of a  supplier and/or OEM  design  and/or  manufacturing
preference. These decisions are documented in the CBOM.

The Potential Material Cost Reduction  (MCR) section captures potential design and/or
manufacturing optimization for the hardware being evaluated.   These savings could
potentially reduce or increase the differential costs between the new and base technology
configurations,  depending  on whether  an  MCR idea is for the new  or  the  base
technology. Typically base technology MCR actions are associated with efforts to share
components across common platforms.

The New Technology Advances (NTA) section captures alternative advance technology
ideas  which could be substituted for some of the  existing  hardware being evaluated.
These advanced technologies, through improved function and performance, and/or cost
reductions, could help increase the overall value of the technology configuration.

The MCR and NTA sections are intended to provide for cost optimization in the model
from  improvement opportunities  explicitly  identified  in the teardown  evaluations.
However, this cost  study uses these sections  sparingly,  emphasizing hardware "on the
floor", and therefore does  not negate the appropriateness of applying "learning curves"
for projecting future cost reductions in maturing technologies.

The Quote Assumptions section provides the  cost analysis roadmap  for each part. The
roadmap includes some of the following general items:

   1) "Make Versus Buy"  indicates if a part is quoted with a full analysis,  as if it were
      being made by the manufacturer,  or is treated  as  a "buy", with surrogate costs
      pulled from an applicable database.
                                       3-2

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   2) "Marketplace Validation" identifies which components should be cross-checked
      with market place data.

   3) "Component Information Source", identifies what type of information is available
      for the quote,  e.g., part,  drawing,  marked-up drawing/sketch,  specification, or
      other.

   4) "Component Information  Requires  Assumption  Modifications", identifies for a
      given component what modifications  or assumption changes are required to the
      information before the item is quoted.

The Component Specification Assumptions  section identifies the basic material, finish,
functional and/or performance information associated with top level components where
applicable. The information listed in this section facilitates the process mapping stage by
identifying some of these core assumptions up front.  This  section  is typically more
beneficial for component type end items than for assemblies.  For example, the material
and heat treat level for a cylinder block can be identified up front, prior to the actual
mapping process. In contrast, a high pressure fuel pump, which would exist in the CBOM
as a complete assembly,  would require disassembly so all part materials, finishes, etc.,
can be identified.

The  Component  Manufacturing Assumptions  section  identifies the primary  and
secondary manufacturing processes  associated with top level components.  As  for the
Component Specification Assumptions, this information is used to help feed the process
mapping stage. In addition, this section is better suited for end-item components than for
assemblies.

The  Potential Component  Suppliers section lists  the typical  suppliers  who  may
manufacture similar types of parts as those identified  in the CBOM.  Understanding the
typical  supplier  size  and complexity characteristics  associated with  manufacturing a
particular type of component  facilitates  the  assignment of the mark-up rates  to  a
particular component.  Various mark-up rate groupings  are established (methodology
detailed in Section 7.5) based on supplier size and complexity.  During the cost analysis
suppliers are  binned to these various mark-up groups which in turn define  the mark-up
rates for a particular component.
                                       3-2

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4   Costing Methodology - Teardown, Process Mapping, and Costing

4.1  Cost Methodology Fundamentals

The costing methodology employed in this  analysis is based  on two  (2)  primary
processes: (1) the development of detailed production process flow charts (P-flows), and
(2) the transferring and processing of key information, from the P-flows, into standardize
quoting worksheets.  Supporting these two (2) primary processes with key input data, are
the costing databases (e.g. material "price/lb", labor "$/hour", manufacturing overhead
"$/hour", mark-up "% of manufacturing cost" and packaging "$/packaging type"). The
costing databases will be discussed in greater detail in Section 7.

Process flow charts, depending on their defined function and end user, can very widely in
the level of detail they contain; ranging  from simple block diagrams showing the general
steps involved in the manufacturing or assembly of an item, to very detailed process flow
charts  breaking  out each process  step in finite detail  capturing  key manufacturing
variables.  For this  cost analysis, detailed P-flows,  which will also be referred to as
process maps, are used to identify all the steps involved in manufacturing a product (e.g.
assembly, machining, welding, forming), at all levels (e.g. system, subsystem, assembly
and component). For example in a turbocharger  scenario, process flows would exist for
the following: (1) at the component level, the manufacturing of every component within
the turbocharger (unless considered a purchase part), (2) at the assembly level, the
assembly  of all the  individual  components to  produce the turbocharger,  (3) at the
subsystem level,  the assembly of the turbocharger onto the engine, and (4) at the system
level, the assembly of the engine into the vehicle.

In addition to detailing pictorially the process steps involved for a given manufacturing
process, having  key information (e.g. equipment type, material type and  usage, cycle
times, handling precautions, number of operators)  associated with each step is imperative.
Understanding the steps  and the key process parameters together  creates the costing
roadmap for any particular manufacturing process.

Due to the vast and complex nature of P-flows associated with some of the larger system
and subsystems  under analysis, having  specialized software which  can accurately and
consistently create and organize the abundant number of detailed P-flows becomes  a
considerable advantage.  For this cost  analysis Design Profit®  software is utilized for
producing and managing the process flows.  Information regarding the details of Design
Profit® software will be covered in the next section.

The second major step in the cost analysis process involves taking the  key information
from the process flows and uploading it into a standardized quote worksheet.  The quote
worksheet, referred to as the Manufacturing Assumption and Quote  Summary (MAQS)
                                     4-1

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worksheet, is essentially a modified generic  OEM  quoting template.  Every assembly
included in the cost analysis (excluding commodity purchased parts) has a completed
MAQS  worksheet capturing all the cost details for  the assembly.  For example all the
components and their associated costs, required in the manufacturing of a turbocharger
assembly, will be captured in Turbocharger Assembly MAQS worksheet.  In addition, a
separate MAQS worksheet detailing the cost associated with assembling the turbocharger
assembly to  the  engine, along  with  any other identified air induction  subsystem
components, would be created.

In addition to process flow information feeding into the MAQS worksheet, data is also
automatically linked in from the various costing databases.  More discussion  on the
MAQS worksheet, interfaces, and complete function  is captured in Section 9.

4.2  Serial and Parallel Manufacturing Operations and Processes

For purpose of this analysis, serial operations are defined as operations which must take
place in a  set  sequence;  one at a time.   For  example, fixturing  metal  stamped bracket
components before  welding  can  commence, both  the fixturing  and  welding  are
considered serial operations within the  bracket welding  process.  Conversely, parallel
operations are  defined as two (2) or more operations which can occur simultaneously on
a part. An  example of this would be machining multiple features into a cylinder block
simultaneously.

A process is defined as one (1) or more operations (serial or parallel) coupled together to
create a component, subassembly, or assembly. A serial process is defined as a process
where  all operations (serial and/or parallel)  are  completed on  a  part before work is
initiated on the next part.  For example, turning a check valve body on a single spindle,
CNC screw machine, would be considered  a  serial process.   In comparison, a parallel
process  is  where different  operations  (serial and/or parallel)  are  taking place
simultaneously at  multiple stations on more  than one (1) part.   A multi-station  final
assembly line,  for assembling together the various components of a vacuum pump, would
be considered a parallel process.

As discussed, the intent of a process flow chart is to  capture all the individual operations
and details required to  manufacture a part (e.g. component, subassembly, assembly).  In
many cases this results in a string of serial operations, generating a serial process, which
requires  additional analysis to develop a  mainstream mass production  process  (i.e.,
inclusion of parallel operations and processing). The Manufacturing Assumption section
of the MAQS worksheet, is where the base  assumptions for converting  serial operations
and processes, into mass production operations and processes, is captured.

For example, assume "Assembly M" requires fifteen  (15) operations to assembly all of its
parts together;  each operation on average taking  approximately ten  (10) seconds to
                                       4-2

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complete.  In a serial process (analogous to single, standalone work cell, manned by a
single operator) consisting of fifteen (15) serial operations, the total process time would
be 150 seconds to produce each part (15 operations x 10 second average/station). Taking
this serial assembly process, and converting it into a mass production parallel process, the
following scenarios could be evaluated (Note  rates and assumptions applied below are
fabricated for this example only):
   1. Scenario #1: 15 serial operation stations, all manned, each performing a single
      operation in parallel.
         •   Process Time 10 seconds/part, 360 parts/hour @ 100% efficiency
         •   Labor Cost/Part = [(15 Direct Laborers)*(Labor Rate $30/hour )]/360
             parts/hour = $1.25/part
         •   Burden Cost/Part = [(15 Stations)*(Burden Rate Average (Low
             Complexity Line) $15/hour/station)]/360 parts/hour =  $0.625/part

   2. Scenario #2: 15 serial operations combined into 10 stations, 5 with 2 parallel
      automated operations, 5 serial manual operations.
         •   Process Time 10 seconds/part, 360 parts/hour @ 100% efficiency,
         •   Labor Cost/Part = [(5 Direct Laborers)*(Labor Rate $30/hour )]/360
             parts/hour = $0.42/part
         •   Burden Cost/Part = [(10 Stations)*(Burden Rate Average (Moderate
             Complexity Line) $30/hour/station)]/360 parts/hour = $0.83/part

Assuming a high production volume in a North America manufacturing base (two key
study assumptions), scenario #2 would have been automatically chosen; higher level of
automation offsetting higher manual assembly costs.

For components whose typical mass production process is a serial process (e.g., injection
molding, stamping, die casting, selected screw machining) the manufacturing assumption
section of the MAQS worksheet requires far less consideration.  Analysis is usually
limited to determining the total number of pieces of equipment required for the defined
volume.

Figure 4-1 illustrates the fundamental steps incorporated into the cost methodology.
                                       4-2

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 1. Select Component
 Assembly,
 Subsystem, and /or
 System, for cost
 analysis
                                              Costing Databases Support Process Mapping and Quote Worksheet Phases of Cost Analysis
                                      Five (5) Databases store rates for all eight cost elements used within the cost analysis: Material, Labor, Burden, Mark-up (End-item
                                      Scrap, SG&A, Profit, and ED&T) and Packaging
2. Conduct
Controlled
Teardown Process
                  43-
  3  Develop Process Flow Charts
(Also referred to as Process Maps)

During all levels of the teardown, process flow
charts capturing every manufacturing
operation are generated, including all key
variables associated with each operation.

Examples of the operations and part details include:
> operation description, equipment specification, cycle times,
material composition/specification, component geometry, component
mass, etc.

Tools used to create Process Maps:
 Design Profit© Software using Lean Design© Module
 Munro & Associates Cost Estimator ModelfTools
4. Populate Standardized Quote Worksheets - Two Main Functional Sections
(Also referred to as Manufacturing Assumption and Quote Summary (MAQS) worksheet)
Manufacturing Assumptions
(Section D of MAQS)
Using the data generated from the Process
Flowcharts, multiple calculations are
performed establishing the mass
production manufacturing assumptions.

Examples included the following:
> OEM and Supplier classifications are selected, based on
component type and processes, establishing the applicable mark-
up rates
> Serial operations are combined into parallel operations where
applicable
> Operations, both serial and/or parallel, are grouped into high
volume parallel processes where applicable.
> Equipment numbers calculated to support capacity
requirements
> Final equipment selection and associated burden rates are
established
> Calculate number of operators required to support defined
manufacturing process
> Piece per hours calculated






















Quote Summary
(Sections B,C,E & F)
Using the data generated in the
Manufacturing Assumption Section of the
MAQS, along with data from the Costing
Databases, a net component/assembly cost
impact is calculated.

Information used in final calculations includes the
following:
Calculated pieces/hour
Material specification, quantity, and price/pound
Labor Classification, number of operators, and cost/hour
Burden Classification, number of machines, and cost/hour
OEM/Supplier Classification, percent of total manufacturing
costs
> Packaging Container, cost per container, number of parts per
container





                                                                                                                                                             5. Market Place Cross-
                                                                                                                                                             check on Selected
                                                                                                                                                             Assemblies through
                                                                                                                                                             solicitation of Industry
                                                                                                                                                             Experts	
                                                                                                                                                             6. Roll Up costs from
                                                                                                                                                              MAQS Assembly
                                                                                                                                                              Worksheets into Net
                                                                                                                                                              Incremental Subsystem
                                                                                                                                                              Costs
                                                                                                                                                              7. Roll Up each
                                                                                                                                                              Incremental Subsystem
                                                                                                                                                              Cost into a Net
                                                                                                                                                              Incremental System
                                                                                                                                                              Cost
                                                      Figure 4-1:    Fundamental Steps in Costing Process
                                                                                      4-4

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4.3  Design Profit® Software Overview

Design  Profit®  software, has been chosen as the primary tool for creating  detailed
process  flow charts,  also referred to as process maps, for the cost analysis. The Design
Profit®  software consists of several modules each providing unique application specific
functions. The process mapping module, within Design Profit® Software, is referred to
as Lean Design®.   Design Profit®, owned and developed by Design Profit, Inc., was
started  in  1995  to  encompass  the  Lean  Design®  and  Quality  Report  Card®
methodologies developed by Munro & Associates, Inc.

The Design Profit® methodology is a quantitative, analytical,  database-driven approach
to mapping manufacturing operations  and processes, providing a consistent means of
capturing  the essence of manufacturing.  The software resides  on a central server which
allows for multiple  users to work  within the same project  utilizing the exact same
databases.   This further ensures  consistency  through out the project as  additional
personnel can be added while minimizing the  learning curve typically associated with
most projects.

The  software provides a  visual  representation  of the product  through the use  of
symbology  depicting various assembly and manufacturing processes. Figure  4-2 is a
screenshot of the Design Profit®  software  and the mapping  process used to generate
product, process and operation metrics. There  are various  symbols used in developing
process  maps, each  having a unique meaning such as part type,  part level,  process,
operation, etc. Reference Appendix D.I for symbol examples and associated descriptions.

Each  symbol is generated  by  filling  out  a  properties window,  which  assigns key
manufacturing  information  to   the  symbol.   These  details include  operator-to-part
interfaces,  part-to-part interfaces,  machine  operations, etc., which provide the basic
assembly  time associated with the operation.  Additional data includes part name, part
number, part description, weight, quantity, material and supplier if known.  Figure 4-3 is
a screenshot of a part input screen.

The majority of manufacturing  information/specifications uploaded during the mapping
process   are  acquired  directly  from  pre-established  internal  libraries/databases
incorporated within the Design  Profit® software.  These internal  databases have been
loaded,  validated and  maintained  by Munro & Associates Inc.,  a partner in  the cost
analysis studies.

In addition to manufacturing information inputted directly from internal Design Profit®
software libraries, external costing tools are also used to generate manufacturing data for
the process maps.   These external  cost  estimating  models commonly handle all the
primary fabrication processes (e.g.  injection molding, stamping,  die casting).  More
details on these external cost estimating models are covered in Section 4.5.

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Design Profit® uses a combination of automated testing and dedicated developers who
test and develop test cases.  In addition to in-house testing and validation, the metrics and
algorithms in Design Profit® have gone through scrutiny over the last fifteen (15) years
and have proven to be accurate for automotive volume and small to medium size parts.
The  customized internal libraries have  been refined to include standard labor rates,
assembly processes, and manufacturing  processes. This  level of customization provides
repeatability and consistency in analysis. Design Profit®  also provides the ability to input
customer-known variables where component size and/or  difficulty of assembly are
outside the prediction abilities for Design Profit®.
                                       4-6

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                                                                                       4-7

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         ,.
         <-' Subassembly Properties
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      Figure 4-3:    Property Window for a Part Symbol Used in Process Mapping
4.4   Teardown Process Overview
The teardown methodology utilized for the analysis is a multi-tiered approach. First, a
high level teardown is initiated.  This process consists  of identifying  the high level
modules within  each  system/subsystem and mapping them  in the  Design Profit®
software.   This provides a means of determining when/where various components are
                                           4-8

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assembled and to what content level, providing insight to differentiate  OEM-  vs.
supplier-assembled components.  During the high level teardown process, updates  are
made to the CBOM to ensure all high level assemblies and assumptions are accurately
recorded.   The CBOM provides the first glimpse of what the true  differences  are
between the two vehicle technologies. At this point assemblies  are identified that will
require further disassembly to establish cost deltas.

After the  comparison review, the second level of teardown  commences. As with  the
high level reviews,  all steps associated with  the  assembly of the components  are
captured  within  the  Design  Profit®  software. Also  at  this  point all  primary
manufacturing processes are captured. The vast majority of the parts identified for cost
deltas are disassembled down  to individual components, each  manufactured from a
single material.

During both the high level  and the detailed teardowns, all  attributes of the parts  are
captured,  including assembly characteristics, materials, quantities, and weights; photos
are also taken.  Once the parts are disassembled in their entirety, they are  then  put
through the Design Profit® costing tools to develop the  serial manufacturing process
times.  Throughout the process a number of databases and costing tools are used to feed
essential data into Design Profit® Maps. These databases include but are not limited to:
raw material specifications and prices, OEM labor rates, machine burden rates, various
costed BOMs, and supplier processes and operations.

4.5  Identifying Materials, Primary and Secondary Processes

Key steps in the cost analysis, for each individual part, are identifying the materials and
the primary processes used in making  the  part. Once  these  have been identified,
appropriate  costing models are  selected to calculate the primary fabrication parameters
(e.g. raw material usage, cycle times, equipment size, number of cavities per tool). This
is  followed by capturing the  secondary processes  and parameters  associated with
manufacturing the part (e.g. machining, welding, assembly).

Material identification is accomplished in one of three ways. The simplest method is
observing material identification markings on the part itself.  Because  of recyclability
directives  set  in place in Europe, most  manufactures will  cast/mold  in the material
properties. For components which are not marked, such as pistons and crankshafts,  the
first approach to accessing the specific material composition is consultation with FEV's
and Munro's CFT members. If there are still materials which cannot be identified a
selection of publications are referenced,  and/or manufacturers and experts within  the
supplier community are contacted to establish credible material choices.

Next the primary manufacturing process must be established.  Most all of the processes
typically leave little tell-tale signs as to how the part is manufactured. If the part is  die
                                       4-9

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cast, for example, there will be ejector pin marks and distinct parting lines, while sand
and semi-permanent molding techniques are typically utilized when there are internal
hollow sections formed by cores.  A semi-permanent mold casting will have parting
lines and no ejector pin markings, while a sand  casting will typically have little to no
signs of parting lines or ejector pin markings.  In the case of no tell-tale signs (less than
2% of parts) of the primary processes, an outside  subject matter expert is contacted.

Once the primary material and manufacturing processes  have been identified the part
can then be cost  estimated.   To accomplish this  various  cost  estimating models,
developed by Munro & Associates Inc are utilized.  These models provide various key
outputs  including cycle times and equipment sizes for  the particular part being  cost
estimated.  All of the models require a number of manual input parameters which may
include  some  or all of the following  depending  on the primary process selected: part
length, width,  height, weight (or volume), material, nominal wall thicknesses, material
thickness,  number  of bends, number  of punched  holes, part projected area,  part
perimeter and the  number of cavities.  The  models also account for part variability
through a factoring methodology.  These include tolerances, appearance, parting lines,
complexity, number of planes with die lock, and profiles in the case of extrusions.
The models use these input factors within formulas to establish the output results.  The
fixed formulas also take into account various material  and processing specifications
including material density, tensile strengths, thermal diffusivity, injection pressures, die
temperatures, mold temperatures, ejection temperatures, press sizes, press  stroke rates,
extrusion rates etc.  The library of costing models used for the  study includes, but not
limited too, the following: aluminum (die casting, semi-permanent mold, sand casting,
metal injection molding and powdered  metal), plastics/composites (injection molded
and  extruded),  and  steel/iron  (casting, forging,  stamping,  investment cast,  and
powdered metal). Figure 4-4 provides a snap shot of the process mapping and how the
cost models are tied into the process maps for a large injection molded part.
All of the  cost models are put through a validation process  to ensure the results  are
reflective of current technologies and known  costs of components. An example  of this
process  would be validation of the injection molding module. Three (3) different size
parts with  assorted features are selected to  ensure diversity  of the model. The parts
selected are typically chosen from the most recent projects that had available cost data.
The part parameters are then input into the model and the results are directly compared
to the actual known costs of the current parts.
                                      4-10

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•> Resign Profit r Burden Rale Classification
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                .  H] "Inieution Molding ( Genera!, Station Based, Poten
                     [2] ' Injection Molding, Small Size and/or Low Compie:
                     |#j "Inipction Molding, Small-Medium Size and/or Low
                     2J "Inieution Molding, Medium Size and/or Moderate c
                     [J] ' Iniection Molding, Medium-Large Size and/or Moc
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                  |^] "Blow <»nd Rotational Molding (General, Station Bas
                  m "Pressure and Vacuum Forming General,Station Bas«
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                  U "Compression and Extrusion Molding (General, Siati
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                | CASTING PROCESS
                - B "Diecasting - Aluminum (General, Station Based )"
                     |U "Aluminum Diecasting, Small Size and/or Low Cot
                     ^ "Aluminum Diecasting, Small-Medium Size and/or
                     [2J "Aluminum Diecasting, Medium Size and/or Moder
                     m "Aluminum Diecasting, Medium-Large Size and/or
                     HH "Aluminum Diecasting, Large Size and/or High Co
                     HI "Aluminum Diecasting, Large, Complex Componer
                  HI "Diecasting - Magnesium (General, Station Based )"
                  I) "Permanent Casting (General, Line Based, Flat)"
                :; m Sand Casting General, Line Based
                   -; m Mold Making - Sand Castings
                        [ft] "Mold Making - Sand Casting, Large Size and.
                        m "Mold Making - Sand Casting, Medium-Large £
                        SH "Moid Making - Sand Casting, Medium Size an
                        U] "Mold Making - Sand Casting, Small-Medium S
                        [2] "Mold Making - Sand Casting, Small Size and/i
                   -, | Core Making - Sand Castings
                        |U "Core Making - Sand Casting, Large Size and
                        0 "Core Making - Sand Casting, Medium-Large ;
                        [2] "Core Making - Sand Casting, Medium Size ar
                        JU "Core Making - Sand Casting, Small-Medium S
                        H| "Core Making - Sand Casting, Small Size and/
                     {2J Melting & Pouring - Sand Castings
                     |jJH Shake Out - Sand Castings
                     H Degate/Trim - Sand Castings
                  [H "Sand Casting - Component & Material  Specific, Lin
                  H] "Sand Casting - Core and Mold Making, Component S|
                  r^a ,„   ,    ,        -         -.    ,        ^
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                                                                |^ "Injection Molding, Large Size and/or High Confilex (Wrapped) |
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                                                                                                                                                     Symbol
Aid notes
 forthe
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                                                                                       Raw
                                                                                    Material Req
                                                              Current Group: Drag a Group from the Project Explorer to show its coritents.
                                                              Figure 4-4:      Injection Molded Primary Processing Map
                                                                                                         4-11

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After the primary process analysis  has been completed, the secondary processes  are
addressed.  The Design Profit® software is utilized to capture all secondary operations
and processes to ensure consistency throughout the costing exercise. These secondary
processes include all aspects of machining, surface treatments, joining methods, etc.  All
operation and process  details are stored in various libraries (Design Profit® databases)
which are readily available for reuse in additional analyzes. For example drilled holes
are categorized in the Material Modification Library by depth of hole, as this is typically
the cycle time driver.
The actual  cycle time,  and other operation details, for items captured in the libraries are
based on a number of parameters depending on the actual process being analyzed. As an
example, the machining times are based on typical feeds and speeds associated with the
specific material being removed, and/or based on averages from available processing data
(machining bill of materials),  and/or  actual  listed equipment capabilities.  In  other
situations the process time may be calculated based on distance calculations i.e. applying
RTV is based on seconds per inch. Each of these processes is mapped within their own
string  of symbols and is assigned  burden rates dependent  on the actual equipment
required. See Figure 4-5 through 4-8 for snap shots of the actual libraries found within
the Design Profit® software.
                                      4-12

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  File   View   Project   Tools  Central Server   Window  Help
Sync
      Assemblies
      ^~] Basic Process Maps
      [nJ] Ford 3.SL Engine
      [r?j Fusion Gas Powered
      |2 Fusion Hybrid
      |Tj Mini Cooper 1.6L Turbo
      |TJ Saturn Vue Start Stop Technology
      [rj Toyota 6 Speed Transmission
      0 VW 6 Speed DSG
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                                                       J Fastening Libraries
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                                                       j Repeat Libtanes
                                                        ^3 Default Repeat Library
                   Name
18"Moue
Adjust Dump Valve Shaft
Adjust TRS Position
Align and install chain
Align Clamp
Align disks
Align Ribbon Wire to Terminals
Align to Bullet
Align Wire Leads
Anodize
-pnj Bf szinij M 'rn^!: jH'i
Apply Lubricant
Apply RTV
Apply Solder Flux
Applying Coat
Aqueous Clean
Auto Tool Change
Bake  4HR
Bake and Cure
Bunch Wire
CDI
 Estimated Time
2.0000 sec
5.0000 sec
3.0000 sec
10.0000 sec
3.0000 sec
5.0000 sec
3.0000 sec
4.0000 sec
5.0000 sec
5.0000 sec
j ni inn  -i
1.0000 sec
2.0000 sec
3.0000 sec
10.0000 sec
6.0000 sec
5.0000 sec
30.0000 sec
3,600.0000 sec
0.1000 sec
1.0000 sec
 Piece Cost
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
IHI nni i
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
                                               Figure  4-5:     Operations Library - Design Profit® Database
                                                                                      4-13

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 Assemblies
 ^j Basic Process Maps
 ^J Ford 3.5L Engine
 [g~j Fur ion C-ai Powered
 £2 Fusion Hybrid
 [rj Mini Cooper 1.6L Turbo
 ^T] Saturn Vue Start Stop Technology
 HJ Toyota 8 Speed Transmission
 |T] VW 6 Speed DSG
> Unattached Symbols
Q  y  | Default |  >C   Q,  J
 - £j| Part Libraries
    + JJ Default Part Library
 - ^ Tool Libraries
    +
 - j£j Operation Libraries
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 - ^ Fastening Libraries
    + tJ Default Fastening Librar>
 - |Q( Material Mod Libraries
    + ^ Machining Reference
 - ^^ Repeat Libraries
    + jj Default Repeat Lihrar\'
Q   >t  g, ,  Edit Default Symbol.,
                   Name

10 Spindle Nut Runner
10 Spindle Hut Runner
11 Spindle Hut Runner
12 Spindle Hut Runner
13 Spindle nut Runner
14 Spindle Hut Runner
16 Spindle Hut Runner
17 Spindle Hut Runner
18 Spindle Hut Runner
19 Spindle Hut Runner
2 Spindle Allen Screw Driver
20 Spindle Hut Runner
3 Spindle Hut Runner
4 Spindle Hut Runner
5 Spindle Hut Runner
6 Spindle Hut Runner
6 spindle nut runner - flywheel
7 Spindle Hut Runner
8 Spindle Hut Runner
9 Soindle Hut Runner
 Estimated Time
~ M! I! Ill  f
6.0000 sec
6.0000 sec
6.0000 sec
6.0000 sec
6.0000 sec
6.0000 sec
6.0000 sec
6.0000 sec
6.0000 sec
6.0000 sec
6.0000 sec
6.0000 sec
6.0000 sec
6.0000 sec
6.0000 sec
6.0000 sec
6.0000 sec
6.0000 sec
6.0000 sec
6.0000 sec
 Piece Cost
louin
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
                                               Figure  4-6:     Tool Library - Design Profit® Database
                                                                                   4-14

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:   File   View   Proiect  Tools   Central Server   Window   Help
           $ M      tt  is  y w
       Assemblies
         j Basic Process Maps
          Ford 3.5L Engine
          Fusion Gas Powered
          Fusion Hybrid
          Mini Cooper 1,6L Turbo
          Saturn Vue Start Stop Technology
          Toyota 6 Speed Transmission
          VW 6 Speed  DSG
       Unattached Symbols
  |  Default  |K  I ft
D  I X S I Edit Default Symbol
Part Libraries
   Default Part Library
Tool Libraries
   Default Tool Library
Operation Libraries
   Default Operation Library
Fastening Libraries
   Default Fastening Library
Material Mod Libraries
   Machining Reference
Repeat Libraries
 2 Default Repeat Library
                   Name
Debur Tumble
Drill S Chamfer Hole 100 150mm
Drill 8 Chamfer Hole 1 30mm
Drill S Chamfer Hole 30 60mm
Drill & Chamfer Hole 60 100mm
Drill and Tap Hole 1-30mm
Drill and Tap Hole 3060mm
Drill Balancing Holes
Drill Hole
Drill Hole
Drill Hole 100-150mm
Drill Hole 1 30mm
Drill Hole 30 - 60mm
Drill Hole 60-100mm
Drill Hole Medium
Drill Hole Small
End Mill
End Mill Slot cut
Flare Tube End
Flare Tube End - Double
Flow drill
                                           Estimated Time
                                           3.0000 sec
                                           4.0000 sec
                                           1.0000 sec
                                           2.0000 sec
                                           3.0000 sec
                                           5.0000 sec
                                           6.0000 sec
                                           1.0000 sec
                                           1.0000 sec
                                           1.0000 sec
                                           4.0000 sec
                                           1.0000 sec
                                           2.0000 sec
                                           3.0000 sec
                                           3.0000 sec
                                           2.0000 sec
                                           1.0000 sec
                                           1.0000 sec
                                           1.0000 sec
                                           2.0000 sec
                                           3.0000 sec
 Piece Cost
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
$0.000
                                         Figure 4-7:     Material Modification Library - Design Profit® Database
                                                                                             4-15

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'v.
   File  View  Project  Tools   Central Server   Window  Help
       Assemblies
       ^73 Basic Process Maps
       13 Ford 3.5L Engine
       ^T] Fusion Gas Powered
       ^7] Fusion Hybrid
       IU Mini Cooper 1 BL Turbo
       0 Saturn Vue Start Stop Technology
       ^J Toyota 6 Speed Transmission
       Q s -W 6 Speed DSG
      » Unattached Symbols
 D  y j| Default |  )<  13, -/
•-.  i£jj Part Libraries
j   +: S3 Defauft Part Library
"  £^ "*"o°' Libraries
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-  ^ Operation Libraries
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•-  ^ Fastening Libraries
i   t: *^ Default Fastening Library
-  ^J Material Mod Libraries
i   +  ^3 Machining Reference
-  ^ Repeat Libraries
i   +  iTJ Default Repeat Library
 D  . X  6 :  EC

Apply Brazing Compound
Apply Glue
APPLY GREASE
Apply Heat Locally
Apply Loctite
Apply Paste
Apply RTV
Arc Weld
Arc Wire Weld
Braze together
COMPRESS SPRINGS
CRIMP
Crimp tabs
Drop In Place
Engage Connector Can
Gross Deform
Gross Deform
Hand Staple
Install Rings
Laser Weld
Manual Screw
fiiV1ijl*
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Figure 4-9 is a sample  excerpt displaying the various steps associated with a vacuum
pump base component and how it was mapped using the Design Profit® software. The
vacuum pump is assumed to be purchased by the OEM and its' assembly to the vehicle is
represented on the top line of the map (Symbols 121 thru 127). The top line is assigned a
labor rate, based on OEM assembly, pulled from the labor database. The next line below
the OEM is the assembly  of the various parts at  the supplier level and is  assigned a
supplier general assembly labor  rate, also pulled in from  the labor database (11 of 30
symbols shown). The pump base  was identified as a die cast machined part based on part
attributes, and was  further analyzed with the third line representing the casting being
machined on a  CNC machine with the appropriate burden rate being selected from the
burden database. The machining  total time was estimated at 122 seconds based on all of
its discreet features  (7 of the 45 symbols shown). The last line of symbols represents the
casting as its primary manufacturing method. To establish the casting  cost a number of
inputs are required in the cost modeling tool. In the case of the pump  base the material
was  identified as Aluminum A3 80  with a raw material cost of $1.10 pulled from the
material  database. Additional  inputs required to  calculate the part cost included the
following for die casting: annual  volume  (450,000),  years  of production (5),  wall
thickness (0.25 inches),  part length (5.4 inches), part width (4.6 inches), part depth (1
inch), part projected area (24.84 square inches),  part weight  after machining (0.4733
pounds), number of planes with die lock features (2) and number of cavities in the tool
(4). These inputs are then utilized to establish the actual material required for the casting
accounting for  sprue and runner lengths associated with the process;  material  required
was  estimated to be 0.542 pounds for the raw casting. The tool calculates the press size
(tonnage) based on the number of parts and their total project area estimating the clamp
load required to prevent  die  separation (-173 ton  theoretical) This is then used to
establish the actual  equipment to determine the appropriate burden rate associated  with
the casting. The tool then calculates the cycle time for the machine establishing injection
time (2.4 sec) cooling time (60.36 sec) resetting time (5.4 sec) and die lubricating  time
(10.5 sec)  for a total cycle time of 78.6 seconds divided by the  number  of cavities
resulting in 19.7 seconds per  part.  The cycle time is input  into the Design Profit®
symbols actual time cell  and all others are zeroed out.
                                     4-17

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   OEM
Assembly
   Labor
Space for
 Printing
\£cuum Pump
 Assembly
                       Q-Ring -
                       pump to head
Push In Place  Bracket - Unused   Bolt - Vacuum
          on \-acuum Pump     Pump
                                                                              127
                                                                      Power Tool     Power Screw
                                                                                  Space for
                                                                                  Printing
                                                                      Space for
                                                                      Printing
Space for
 Printing
Space for
 Printing
Space for
 Printing
                 Supplier
                Assembly
                   Labor

                               Base \£c Pump   Fitting Clean
                                rotor support      Inlet


M

8
                                                                                                   relief     retain er/limiter -
                         Machining Process
                                                                                                                 pecial Tool    Press Together  Rotor Vac Pump
                                                           CMC Machine   Base Vac Pump
                                                                      rotor support Cas
                                                                                                          Clamp Part     Mil Flat Ivted
                                                                                                             Cover Bolts
                                                                                                               'tea
                                                                                                                                                         ap Hole
                                               Casting Process
                                                                                                      Base V&c Pump
                                                                                                     rotor support Cas
          Figure 4-9'     Example Illustrating the Various Levels Associated with Process Mapping a Vacuum Pump Base Support
                                                                                4-18

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5   Cost Model Overview

The cost parameters considered in determining the net incremental component/assembly
impact to the OEM for new technologies are discussed in detail below.

Unit Cost is the sum  of total manufacturing cost (TMC), mark-up costs and packaging
cost associated with producing a component/assembly. It is the net component/assembly
cost impact to the OEM (generally, the automobile manufacturer).  Figure 5-1 shows all
the factors contributing to unit cost for supplier manufactured components.  Additional
details on the subcategories are discussed in the sections that follow.
                                  Net Component/Assembly Cost
                                        Impact To OEM
                                             II
   Total Manufacturing
        Cost
Raw Material

In-process Scrap
Purchased Part -
Commodity Parts

Direct Labor

Maintenance,
Repair, Other


Indirect Labor

Fringe
Primary
Equipment

General Plant &
Office Equip.

Utilities





Process
Supporting Equip.

Facilities

Plant Salary
Mark-up Cost
Packaging Cost
Quality Defects
Shipping Damage
Destruct Tests

                                                        Corporate Overhead: personnel functions,
                                                          finance/accounting, systems data
                                                         processing, sales/marketing, purchasing,
                                                          public relations, legal staff, training,
                                                               warranty, etc
                                                         Supplier compensation for the assumption
                                                         of investment risk in supplying a part to a
                                                               customer.
         Figure 5-1:    Unit Cost Model - Costing Factors Included in Analysis

For OEM manufactured components/assemblies, the unit cost is calculated in the same
way, except that mark-up is addressed outside the scope of this study through application
of indirect cost (1C) multipliers.  The 1C multiplier assigned is based on the technology
complexity level and timeframe in the market place; see Section 6 for additional details.
                                        5-1

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The full report, "Automobile Industry Retail Price Equivalent and Indirect Cost
Multipliers" EPA report EPA-420-R-09-003, February 2009, can be downloaded from
http://www.epa.gov/OMSWWW/ld-hwv/420r09003.pdf.

Shipping  Costs are  those required to  transport a  component between  dispersed
manufacturing and assembly  locations,  including  any applicable  insurance, tax, or
surcharge  expenses. Shipping costs between T2/T3 and Tl suppliers are captured as part
of the mark-up  rate except where special handling measures are involved.  For Tl
supplier to OEM facilities, the shipping costs are captured using the 1C multiplier that
replaces mark-up as discussed above. Additional details on shipping costs are discussed
in Section 8.

Tooling Costs are the dedicated tool, gauge and fixture costs required to manufacture a
part.  Examples  of items covered by tooling costs are:  injection molds, casting molds,
stamping  dies, weld fixtures, assembly fixtures,  dedicated assembly and/or machining
pallets, and dedicated gauging.  For this analysis, all tooling is  assumed to be owned by
the OEM  and the differential cost impact is accounted for through the application of an
1C multiplier.

Investment Costs are the manufacturing facility costs, not covered as tooling, required to
manufacture  parts.   Investment  costs  include  manufacturing plants,  manufacturing
equipment (e.g.  injection mold machines, die cast machines, machining and turning
machines, welding  equipment, assembly lines), material  handling equipment (e.g. lift
forks, overhead cranes, loading dock lifts, conveyor systems), paint lines, plating lines,
and heat treat equipment. Investment costs are covered by manufacturing overhead rates
and thus are not summed up separately in the cost analysis.  Additional details on how
investments expenses are accounted for through manufacturing overhead can be found in
Section 7.4.

Product Development Costs  are the  ED&T costs incurred  for  development  of  a
component or system.  These costs can be associated with a vehicle specific application
and/or be  part of the normal research and development (R&D)  performed by companies
to remain  competitive.  In the cost analysis, the product development  costs for suppliers
are included in the mark-up rate as ED&T.  More details are provided in Section 7.5.  For
the OEM, the product development costs are captured in the 1C multipliers  that replace
mark-up, as discussed in the unit cost section above.

In summary, the two (2) main cost elements  (TMC and Mark-up), in the supplier  unit
cost  model defined in  Figure 5-1  includes considerations for shipping, investment and
product development costs. For  the OEM, investment costs are accounted for in the
OEM Unit cost model  via the  TMC. Shipping, tooling and product development costs
are accounted for as part of the 1C  multiplier addressed outside the scope of this study.
                                       5-2

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Lastly, the "Net Incremental Component /Assembly Cost Impact to OEM" is defined as
the summation of the supplier and OEM unit costs, for all the identified component and
assembly differences, between the new and base technology configurations.

A more detailed discussion on the elements which make-up the unit cost model follows.
                                      5-2

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6  Indirect OEM Costs

In addition to the direct manufacturing costs, a manufacturer also incurs certain indirect
costs.  These costs  may be related  to production, such as research and  development
(R&D); tooling; corporate operations, such as salaries, pensions, and health care costs for
corporate staff; or selling, such as transportation, dealer support, and marketing. Indirect
costs incurred by  a  supplier  of  a  component or vehicle system  constitute a direct
manufacturing cost to the OEM (the original equipment (vehicle) manufacturer), and thus
are included in this  study.  The OEM's indirect costs, however, are not included and must
be determined and applied separately to obtain total manufacturing costs.  These indirect
costs are beyond the scope of this  study and are applied separately by EPA staff in their
analysis. A brief discussion of this follows.

In February 2009, EPA issued a report, "Automobile Industry Retail Price Equivalent and
Indirect  Cost Multipliers,"  written  by  Alex Rogozhin and Michael  Gallaher of RTI
International  and Walter  McManus of the  University of  Michigan  Transportation
Research Institute.  The discussion in this section is taken from that report.

The RPE/IC report provides a new calculation of the retail price equivalent (RPE)
multiplier  commonly  used  to  estimate  the   indirect  costs  associated  with a new
technology.  The RPE is a ratio of total revenue to direct manufacturing cost; put another
way,  it is the ratio of indirect costs plus profit to direct manufacturing costs. It is an
average  over all the  activities of a  manufacturer.  However, a problem in using RPE
multipliers in regulatory analysis is that some of the indirect cost components of the RPE
multiplier, such as fixed  depreciation costs, health care costs for retired workers, or
pensions, may not be affected by all vehicle modifications resulting from regulation.  In
addition, RPEs assume that market prices  will increase by the full cost plus constant
profit of the  new  technology;  in fact,  other factors that influence price (especially
consumer demand and preferences)  will affect how much of those costs will be passed
along into market price.

The RPE/IC report develops a modified multiplier, referred to as an 1C multiplier, which
specifically evaluates the  components of indirect costs that are likely to be affected by
vehicle  modifications associated with  environmental regulation.  A  range  of  1C
multipliers are developed that 1) account for differences in the technical complexity of
required vehicle modifications  and 2)  adjust  over time as new  technologies become
assimilated into the automotive supply chain.

ICMs are calculated in the RPE/IC report to range from 1.05 to 1.45 in the short run and
from  1.02 to 1.26 in  the long run. The  differences between the short- and long-run 1C
multipliers are primarily due to  R&D and  warranty costs,  which are  projected to
decrease  over time. R&D expenditures also vary greatly over the level of technology
complexity, as does the need for dealer support.  To use the multipliers in the RPE/IC

                                      6-1

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report, analysts can start by assessing the degree of complexity of the new technology
under consideration. That identification process will lead to the short-run and long-run
multipliers for the new technology. If an analyst has  additional information about the
role of indirect cost contributors for the new technology,  that information can be used to
develop project-specific adjustment factor.
                                        6-2

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7   Costing Databases

7.1   Database Overview

The Unit Cost Model shown  in Figure 5-1 illustrates the three  (3) main cost element
categories, along with all the  core subcategories, which make up the unit costs  for all
components and assemblies in the analysis.

Every  cost  element used throughout the analysis is extracted  from one of the  core
databases.   There  are databases for material  prices ($/pound), labor rates ($/hour),
manufacturing  overhead rates ($/hour), mark-up rates (% of  TMC)  and  packaging
($/packaging option).  The databases provide the foundation of the cost analysis, since all
costs originate  from them, and they  are also used to document sources and  supporting
information for the  cost numbers. Excerpts from all five (5) databases may be found in
Appendix E. 1-E.6.

The model  allows  for updates to the cost elements which  automatically roll into the
individual component/assembly cost  models.   Since  all cost sheets and parameters are
directly linked to  the databases,  changing the  "Active  Rate" cost elements  in the
applicable  database  automatically  updates  the  Manufacturing  Assumption  Quote
Summary (MAQS) worksheets. Thus if a material doubles  in price,  one can easily assess
the impact on the technology configurations under study.

The model also includes a forecasting feature associated with each database to project
changes from the baseline cost data.  For each database there is a baseline data set based
on 2008 figures, and two (2) additional "projected cost" data sets which reference back to
this baseline dataset.  The projected cost data sets can be specified either manually or by
using the Annual Adjustment Factor (AAF)  feature. The AAF feature is  basically a
depreciation/interest calculator where the  user defines a period, and a  percent rate  of
growth or decline relative to the baseline.  To illustrate the AFF feature,  an exaggerated
gross  decline of 5% per year, from  2008 through to 2015,  was entered into the labor
database to create a mock 2015 forecasted  data set (see Figure 7-1).  Changing the active
rate value in the database from 2008 to 2015 loads the new dataset; all cost sheets are
automatically updated with the 2015 labor projections.

Additional details are provided for each database in the following sections.
                                      7-1

-------











sf
3


m

socs
Code
(BLS)


— \\/l
= \\ff
= w

Direct Labor Title
(BLS)


1. Motor Vehicle Parts Manufacturing - NAICS 336















1

4
~7~


10



15



17

51-2022

51-2092
51-4011


51-4031



51-4072



51-4122

Electrical and Electronic
Equipment Assemblers
Team Assemblers
Computer-Controlled Machine
Tool Operators (Metal &
Plastic)
Cutting, Punching, and Press
Machine Setters, Operators
and Tenders, Metal and
Plastic
Molding, Core making, and
Casting Machine Setters,
Operators, and Tenders,
Metal & Plastic
Welding, Soldering, and
Brazing Machine Setters,
Operators, and Tenders.



2008

Fringe
Allocation
"%"


52.00%
52%

52%
52%


52%



52%



52%

Fringe
Contribution
t.'llour


$14.18
$10.16

$12.15
$12.21


$14.43



$14.89



$15.38

Total Labor
Kate
{/Hour


$41.45
$29.69

$35.51
$35.70


$42.18



$43.52



$44.96


























I


Production Year Start 201 5
Adjustment Period, Years
Mean
Hourly
Baseline
2008

$16.42
$12.85

$13.66
$15.25


$16.04



$15.15



$18.72

Ave.
Annual
Adjust.
Factor 1
(AAF)

-5.00%
-5.00%

-5.00%
-5.00%


-5.00%



-5.00%



-5.00%

Mean Hourly
Wage


$11.47
8.97

9.54
10.65


11.20



10.58



13.07

7
Indirect
Labor
Rate
Ratio
"%"

49.42%
40%

52 It
42%


54%



66%



42%


Indirect Labor
Contribution
S.'Hour


$5.71
$3.59

$4.96
$4.47


$6.05



$6.98



$5.49

MRO
Labor
Rate
Ratio
Id

16.16%
12%

19%
12%


19%



23%



16%

MRO Labor
Contribution
t/llour


$1.86
$1.88

$1.81
$1.28


$2.13



$2.43



$2.09

Fringe
Allocation
"%"


52.00%
52*

52%
52%


52%



52%



52%

Fringe
Contribution
S.'Hour


$9.90
$7.89

$8.48
$8.53


$10.08



$10.40



$10.74

Total Labor
Rate
t/llour


$28.95
$20.73

$24.79
$24.93


$29.46



$30.39



$31.40

Figure 7-1:   Illustrates the change in Labor Rates between 2008 and 2015, Assuming a Negative 5% Annual Adjustment Factor
                                                    (AFF)
                                                    7-2

-------
7.2   Material Database

7.2.1   Overview

The Material Database houses specific material prices and related material information
required for component cost estimating analysis.   The information  related to each
material listed includes the material name, standard industry identification (e.g. AISI or
SAE  nomenclature), typical  automotive  applications,  pricing per  pound,  annual
consumption rates, and source references.  The prices recorded in the database are in US
dollars per pound.  The  database provides for input of forecasted future year prices; a
discussion of the forecasting methodology follows.  Figure  7-2  and Figure 7-3 provide
the price data for significant materials identified in the cost study analysis.
                                      7-2

-------
FEI
Cat.
A. CA








A6. C






A7. N


B. HI



Cl. 3










D. C/
Dl. IS




D2. ft*

D3. G
E. AL
El. Vi







E2. C





tern
rTT^™;i^7s™en i 	 s~^n^; — i rr TJ^=rn^n i — r^nnn^~~ir 	 	 ~ 	 u--^--^-^--- , r 	 	 — 	 ,, 	 ^;-"- 	 — L

Material Description
RBON & ALLOY STEELS (SAE1000-90E





A1.3 1


Low Carbon Steel
Med um Carbon Steel
Low Carbon, Hot Dip Galvanized
Steel.

Med um Carbon Steel
High Carbon Steel
Industry Specification
Carbon Ranges: Low 0.05-0.15%, Mid
Mn 1.00% Max
SAEJ403 1018
SAE J403 1008/1010

SAEJ403 1018
SAEJ403 1040
2XX Resulfurized and Rephosphorized
1215
Low Carbon Steel Tubing
HROMIUM-MOLYBDENUM (CHROMOLY
A6.1 41XX





41xx
Chrome-MolyVanadium Steel
4140RH
4130
4130 Tight Thickness Tolerance.
CKLE-CHROMIUM-MOLYBDENUM STEE
A7.1 43XX


300M
Ni-Chrome-Moly




00 Se
C1.13




Cl.1.1



Cl.1.2
ST IRC
odula




alleal

rey Ca
JMINU
rough
E1.2 3


E1.3 4



C70S6
36MnVS4
les - Austenltlc Chromium-Nick
>4 General Purpose
304
304/3 04L
304/3 04L
304
316
316
3 16/3 16 L
3 16/3 16 L
309/309S
310/310S
NS
/Ductile Cast Iron
Nodular/Ductile Iron (80-55-06)
Nodular/Ductile Iron (100-70-03)
Ni-resistcast iron, D5S
Silicon Molybdenum Cast Iron
le Cast Irons
Malleable Cast Iron
»t Iron
M ALLOYS
Alloys
(XX AI-Mn Alloys
3003, 3005, 3012
3003-H14 Uncladded
3003-H14 Uncladded
XX Al-Si Alloys
4032
3003-H14 Clad 4XXX
isting Alloys ( Hypoeutectic 8.5-10.5
3XX A -Si + Cu and/or Mg Alloys




319 T5
332/F132

A380.1
Replacement to 12L14
1215
STEELS
Cr 0.50% Or 0.80% or 0.95%, Mo 0.12% or 0.2

32CrMoV13
42CrMoS4
0.80/1.10, P&S 0.025 Max, Mo 0.15/0.25
C 0.28/0.33 Si 0.20/0.35, Mn 0.40/0.60, Cr
/ , *. /
LS
Ni 1.82%, Cr 0.50-0.80%, Mo 0.25%
SAE 4340Mod
SAE 4330/4340


VO.04%
Harden by cold working, can not be hardened b
usuallygood formability.







C reduced for weldability
C reduced for weldability
CR & Ni increased for high temperature.
Same as 309, only more so.
Typical Cast Irons are 95%wt. Iran, 2.1-
ASTM A53 6-80-5 5-06
ASTM A53 6-100-70-03
D5S, ASTM A-43 9-84
4%Si& l%Mo



SAE J431 Grade 3000 (3.1-3.4C, 1.9-2. 3Si,
Mn 0.60-0.90)



A uminum-Manganese Sheet
A uminum-Manganese Sheet

4032-T651
A uminum-Manganese Cladded Tube
Eutectic 11-12, 16-18 Hypereutectic Ma

AI-3.5Cu-6Si
8.5-lOSi, 2.0-4.0CU, NiO.10
7SI-0.3 Mg alloy
A-9Si-3Cu(Fe)
Supplemental
Specification
Information
0.16-0.29%, High 0.30-1
Coil
Coil
Coil

Bar
Bar (1-3")

Bar
Tube

0% or 0.25% or 0.30%
Bar
Bar
Bar

Coil, 0.05" to 0.08", Tight



Vacuum melted high
strength, super alloy.
Bar 1-7"

Steel
Bar
heat treating, Non Magnetic
Bar
Coil
Sheet or Cast
Tube

Bar
Coil
Cast/Sheet

%wt Carbon, and l-3%wt
$0.90-$1.2/lb finished
casting
$0.90-$1.2/lb finished
casting



$0.90-$1.2/lb finished
casting





3.15mm)
Thick. 0.003-0.009" (0.075-
0.22mm)

Bar 01. 0-2. 5"
Seamless welded tube -
thickness 0.012-0.02" (0.3-
terial )

Hypoeutectic/Perm.
grade, large recycled
composition (Die.)
Hypoeutectic (Perm.)
Hypoeutectic (Die.)
Application Examples
.10%, Ultra High 1-2%
Brackets, Spacers
Splash Pans, Dampers, Windage Tray
PCV Baffles




Bushings, Inserts, Couplings
Metal Tubing coolant lines, oil lines, etc.


Injector Body
Bearings, Crank shafts
Crankshafts, axle journals, gears, pushrods.




Drive shafts, Con. Rods
Planetary Gear Carrier, Shafts

Forged fractured split rods
Crankshafts, Cracked Forged Rods, Short and Long-shaft
Ball Points, threaded heavy duty anchor bolts.
n annealed condition. Excellent corrosion resistance and
Valves and Tubing
Exhaust Systems, Fuel tanks
Housings for Catalytic Converters and Turbochargers.
Fuel Rail

Valves and Tubing

Housings for Catalytic Converters and Turbochargers.

Internal Components for Turbochargers (e.g.. Rotors)
Silicon.
Crankshaft, blocks
High Strength Cam shafts i.e.., driving HP fuel pumps.
Housing -Turbo Exhaust
Housing-Block Center, Turbo Support

Crankshaft, camshafts, blocks

Engine Blocks
hardened.
Braze-clad welded radiator tubes, heatercores, radiator,
heater and evaporative fins, heater inlet and outlet tubes,
oil coolers, and air conditioner liquid lines, radiator heater
and evaporative parts, extruded condenser tubes.

Heat Exchangers


Heat Exchangers


Manifolds, cylinder heads, blocks, internal engine parts
Hypoeutectic
Engine blocks, flywheel, oil pan, pump bodies, cyl heads,
Blocks, transmission housings/parts, fuel metering
devices, oil pump cyl heads,

Material Class

LC-Steel-1000S, Coil
MC-Steel-lOOOS, Coil
LC-GStee 1-100 OS, Coil

MC-Steel-1018,Bar
HC-Steel-1040S, Bar

LC-Steel-1215, Bar
LC-Steel-1215, Tubing


A-Steel-41XXS, Bar
MA-Steel-CrMoV, Bar
A-Steel-4140, Bar
HC-Steel-4130, Coil
0.04"-0.125"
HC-Steel-4130, Coil
0.04"-0.08"


MA-Steel-300M, Bar
MA-Steel-43XXM, Bar

MA-Steel-C70S6, Bar
MA-Steel-MnVS, Bar

S-Steel-304, Bar
S-Steel-304, Coil
S-Steel-304, Cast
S-Steel-304, Tube

S-Steel-316, Bar
S-Steel-316, Coil


S-Steel-310,Cast
Nodular Iron, Cast
Nodular Iron,
GrlOO/70/03,Cast
NiResist Iron, D5S,
Cast
SiMo Ductile Iron, Cas

Malleable Cast Iron

Grey Iron, Cast
Aluminum-3000S, Co
Aluminum-3003, Coil
A
Aluminum-3003, Coil
B

Aluminum-4032,Bar
Cladded Aluminum-
3003, Tube


Aluminum-A319-T5,
Cast
Aluminum-332, Cast
Cast
Aluminum-A380,
Cast
Active Rate
2008

$ 0.45
$ 0.55
$ 0.48

$ 0.74
$ 0.80

$ 0.62
$ 0.62


$ 0.78
$ 0.98
$ 0.78
$ 1.18
$ 2.79


$ 0.89
$ 1.08

$ 0.70
$ 0.73

$ 1.65
$ 1.64
$ 1.39
$ 1.65

$ 2.44
$ 2.72
$ 2.82

$ 4.23
$ 0.35
$ 0.42
$ 3.50
$ 0.60

$ 0.41

$ 0.35
"$ 0.84
$ 1.41
$ 1.93

$ 1.44
$ 2.28


$ 1.15
$ 1.24
$ 1.20
$ 1.10
Figure 7-2:   Price Data for Significant Materials Identified in Case Study #0101
                     (Materials Database Excerpt #2A)
                                  7-4

-------
S^^ ^ ' — A~C~~ ~~ii — st — n ' 	 D"~C~ T'i 	 1 r 	 1 i 	 i f 	 ' i 	 1 1 	 ' f 	 '
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Cat.


H. TIT
HI. V
J. CO











K. NT
Kl. V
Q. TH
















R. TH





















Item


ANIUN
fro ugh
'PER
J6.3 Hi



J6.4 Al
Material Description
B330
384
B390.0
WROUGHT& CASTING ALLOYS
Alloys
Titanium
WROUGHT & CASTING ALLOYS (
*h Lead Tin Bronze & Lead Free Bron
C93200
CS9320
Oilite Bronze Bearing Alloy
jminum Bronze(LC-VH, T=VH, C/E=P
ASTMC63000.C63020
J6.12 Silicon Brasses (LC=? , T=? , C/E=? ,


J6.13 E

J6.14 C
KELV
/rough
Kl.l In
CS7500(500)
CDA673-Silicon Manganese
Brass
rass General
C36000
ooper General
Copper
BROUGHT & CASTING ALLOYS
Alloy*
cone ®
Inconel® 713 Coil
Nickel Alloy - Internal Turbo Parts Ge
jlnconel® 713 Coil
ERMOPLASTIC POLYMNERS
Ql. Po yamide (PA/Nylon)









Q3. Po

Q4. Po

Nylon 6
Nylon 6 (15% glass)
Nylon 6 (30 to 35%glass)
Nylon 66
Nylon 66 (30 to 35% glass)
Nylon 66 (50%glass)
Nylon 66, 40% Fibrous Mineral
Reinforced
Nylon 12
Nylon 12, 30% glass
yethylene
HOPE Copolymer - blowmolding
ybutylene Terephthalate (PBT)
Polybutylene Terephthalate
Q6. Poypropylene(PP)
[Random copolymer blow molding
[grade.
Q9. Po yviny chloride (PVC)
ERMOS
Rl Hyd




R3. Nit

R8. Flu
RIO. P
R12. P

R13.S

R14. M




Blended NBR-PVC
ET POLYMERS
Natural rubber/TSR20
Synthetic poly-isoprene rubber
Styrene butadiene rubber
Polubutadiene rubber -glass filled
Buty rubber
le
Nitrile butadiene rubber
Drocarbon
Fluoro elastomer
alyim de
Polyimide - Vespel SP-21
Polyimide - Vespel SP-21
ilyurethane
Polyurethane elastomer, ester-
based
cone
Silicone rubber
scellaneous
SBRTubing w. Fiber Reinforcement
SBRTubingw. Metal
Reinforcement
SBRTubing w. Fiber Reinforcement
and outer wrap.


Industry Specification
AI-9Si-3Cu(Fe)

Hypereutectic aluminum-silicon
(6ALV4)
IRONZE & BRASS)
ze (LC-M/H,T=H, C/E=G RS=G, H/W=H)
SAE 660 Bearing Bronze
Lead Free Replacement to C93200
SAES41
RS=M, H/W=VH)
Nickel Aluminum Bronze
RS=7, H/W=?)
Silicon Brass, S2-4Si-14Zn
C67300

CDA360

>99.0%Pure




PA6
PA6 GF15
PA6 GF30
PA66
PA66 GF30
PA66 GF50
PA66 FMR40%
PA12
PA12, GF30

HOPE

PBTGF20

PP


NR
IR
SBR
PBRGF20
1 R

NBR

FKM

P 30%Carbon filled
P 30%Glass filled

AU

MVQ

SBR Reinforced Tubing
SBR Reinforced Tubing
SBR Reinforced Tubing


Supplemental
Specification
Information
Hypoeutectic (Die)
Eutectic (Die)
Hypereutectic (Die.)
Bar


39%Cu, 6%Sn, and 5%Bi
1" Round Bar




Bar





Coil
Coil
'"'






GMNASpec PA66 060
































Application Examples
Blocks, transmission housings/parts, fuel metering
devices, oil pump cyl heads,
Pistons, automatic transmissions
transmission parts, Hypereutectic pistons, cylinder blocks
High Pressure Bellows Pump

bushings, pump fixtures, pump impellers, fuel pump
bushings, thrust washers, insert bearings, gears, valves
and valve components, etc.
Turbocharger Spindle Bushings (Floating Type)


Valve stems and trim, bearings and bushings, fasteners,
gears

Bearings, gears, impellers, rocker arms, valve stems, brush
holders, bearing races, small boat propellers.


Fluid connectors, threaded inserts for plastic parts, sensor
bodies, thermostat parts

VUre harnesses

Heat Shields, Turbo
Heat Shields, Turbo


Air cooler tube outlet
Vacuum reservoir, Intake manifold
Fuel injector connector, hose asm end - pump to turbo,
chain tension guides
Intake manifold, cylinder cover, cooler asm end caps
cooler asm end caps
Direct Injection Connectors
Reservior tube
PCV Hose Intake End

Rubberized blow molded air induction ducts and couplings.

Silencer Air by-pass

High strength blow molded air induction ducts.

Rubberized blow molded air induction ducts and couplings.
Hoses, O-rings, gaskets, tubes
Hoses, O-rings, gaskets, tubes
Hoses, O-rings, gaskets, tubes
Auxiliary water pump housing
Hoses, O-rings, gaskets, tubes

Hoses, O-rings, gaskets, tubes

ERG valve seals

thrust washers, bearings and seals — low-friction
properties, work with or without lubrication.


Hoses, O-rings, gaskets, tubes

Hoses, O-rings, gaskets, tubes







Material Class
Aluminum-B3SO,
Cast
Aluminum-334, Cast
Cast
Titanium-6AL4V, Bar

Bronze-932, Bar
Bronze-39320, Bar


Ni-AI-Bronze-630000,
Bar

Si-Brass-37500, Bar
Si-Brass-67300, Bar

Brass-36000, Bar

Copper-Pure, VUre

lnconel-713C, Coil
Nickel Alloy Gen, Cast
lnconel-713, Cast
Nylon 6, Inject.
Nylon 6-1 5 GF, Inject.
Nylon 6-3 OGF, Inject.
Nylon 66, Inject.
Nylon66-30GF, Inject.
Nylon66-50GF, Inject.
Nylon66-40FMR, Injec
Nylonl2, Inject.


HOPE BM Grade

PBT-GF20, Inject.

HD Polypro

NBR-PVC
Thermoset-NR
Thermoset-IR
Th e rm o set-S B R
Thermoset-PBR-G F2 0
Thermoset-IIR

Thermoset-NBR

Thermoset-FKM

Thermoset-Vespel
SP21CF30
Thermoset-Vespel
SP21GF30

Thermoset^U

Thermoset-MVQ

SBR-Fiber Rein.,
Extruded
SBR-Metal Rein.,
Extruded
SBR-Fiber Rein. W.
Outer Wrap, Extruded


Active Ftate
2008
$ 1.18
$ 1.14
$ 1.20
$ 34.37

$ 2.56
$ 2.56
$ 5.31

$ 2.44

$ 2.11
$ 3.71

$ 1.70

$ 2.45

$ 6.00
$ 5.00
$ 6.00
$ .65
$ .59
$ .76
$ .74
$ .54
$ .54
$ .54
$ 3.03
$ 3.41

$ 0.72

$ 1.46

$ 0.37

$ 1.27
$ 2.14

$ 1.32
$ 1.17
$ 1.37

$ 1.27

$ 12.50

$ 35.13
$ 24.36

$ 1.77

$ 4.50

$ 1.35
$ 2.24
$ 2.05


Figure 7-3:   Price Data for Significant Materials Identified in Case Study #0101
                      (Materials Database Excerpt #2B)
                                    7-5

-------
The applications identified for a material also help determine the annual consumption
rate which impacts whether high or low volume prices are used. The annual consumption
rate assigned to a particular material is determined by its weight, usage and uniqueness.
For example, a single polypropylene cover on an engine  assembly represents a very
minor  usage and  weight contribution to the engine.  Polypropylene, however, is a
common high usage resin.  Therefore, despite its limited use in this application a high
annual consumption rate pricing is applied.  This resin is readily available, and the part
can be  obtained from any number of competitive molding companies  that regularly
manufacture these  types of components.  A Viton® fluoroelastomer engine seal, on  the
other hand, is specified as a low annual consumption rate material.  This component also
represents a very minor usage and weight contribution to the engine, but, in addition, this
resin is a specialty material.  It is known for its excellent heat and chemical resistance,
and is used sparingly for certain engine end-use applications.  For case study #0101, only
material pricing corresponding to high annual volume consumption was considered.

7.2.2   Material Selection Process

The materials listed in the database are resins and ferrous and non-ferrous alloys used in
the products  and components selected for cost  analysis.  The materials  identification
process is based on visual part markings,  part appearance and part application.  Material
markings are the most  obvious method  of material identification.  Resin components
typically have  material markings  (for  example,  >PA66  30GF<)  which are easily
identified, recorded in the database and researched to establish price trends.

For components which  are not marked,  such as pistons and crankshafts,  the FEV and
Munro  cross  functional team members  are  consulted  to  help  in  the  materials
identification. For any materials still not identified, information published in print and on
the web is  researched, or primary manufacturers and experts within the Tier 1 supplier
community are contacted to establish credible material choices.

The specific application and the part  appearance play a role in materials identification.
Steels  commonly  referred  to as work-hardenable  steels with high manganese content
(13% Mn)  are readily made in a casting  and are not forgeable.  Therefore establishing
whether a component is  forged or cast can narrow the materials identification process.
Observing visual cues on components can be very informative. Complex part geometry
alone can rule out the possibility of forgings; however more subtle differences must be
considered.  For example, forged components typically have a smoother appearance to
the grain whereas  cast components have  a rougher finish, especially in the areas where
machining is absent. Castings also usually display evidence of casting flash.

The component application environment will also help determine material  choice. There
are, for example,  several  conventional  ductile  cast  iron  applications  found in base
gasoline engines that  are moving to Ductile High Silicon - Molybdenum  or Ductile Ni-

                                     7-6

-------
Resist cast irons in downsized turbocharged engines.  This is due to high temperature,
thermal cycling, and corrosion resistance demands associated with elevated exhaust gas
temperatures in turbocharged engines.  Therefore understanding the part application and
use environment can greatly assist in more accurate material determinations.

7.2.3  Pricing Sources and Considerations

The pricing data housed in the  database  is derived from various sources of publicly
available data from which historical trend data can be derived.  The objective is to find
historical pricing data  over  as many years  as possible to obtain the most accurate trend
response.   Ferrous  and non-ferrous alloy pricing involves internet searches of several
sources, including the U.S. Geological Survey (USGS), MEPS (previously Management
Engineering & Production Services), Metalprices, estainlesssteel and Longbow.  Figure
7-4 is a snap shot of historical  steel prices for US stainless steel grade 304 sheet compiled
from estainlesssteel and purchasing.com.

•u
c
o
a.
Q.
JS
"o
D
$3.00

$2.50
$2.00
$1.50
$1.00 .
$0.50
^
                   o
                   o
o
o
•H
O
r-l  fN
O  O
>  C
O  D
rn
o
                                   c
                                   ra
rn
o
                       o
                       -e
                       o
in
o
in
o
LD
O
                                                          o
                                                          -ii
                                    o
                                    Q.
CO
o
CO
o

O
                  Figure 7-4:   Historical 304 Stainless Steel Prices

Resin pricing is also obtained from sources such as Plastics News, Plastics Technology
Online, Rubber and Plastics News and IDES (Integrated Design Engineering Systems).
Several other sources are used in this research as outlined in the database.

Though material prices are often published for standard materials, prices for specialized
material formulations and/or those having a nonstandard geometric configuration (e.g.
length, width, thickness, cross-section), are not typically available.  Where pricing is not
available for a  given material with a known composition, two  (2) approaches are used:
industry consultation  and composition analysis.  In cases such  as Ni-Resist cast iron,
which  has several different  possible pre-processed heat treatments, consultation with
manufacturers of the component or similar components is required.
                                        7-7

-------
Obtaining prices for unknown proprietary material compositions, such as powder metals,
necessitated a standardized industry approach.  In these cases manufacturers and industry
market  research firms  are  consulted to provide  generic  pricing formulas and pricing
trends.  Their price formulas are balanced  against published market trends of similar
materials to establish new pricing trends.  In terms of ferrous alloys, the  database must
also take into account unique or non-standard material thicknesses.  Any  specified non-
standard sheet or plate thickness requires  additional  mill runs and must be  priced
accordingly.    In  this case,  price  estimations  from  consultations  with  industry
manufacturers in conjunction with similar material pricing trend data are utilized.

Resin formulations are  also available with a variety of fillers and filler content.   Some
pricing  data is available for specific formulations; however pricing is not published for
every variation.  This variation is  significant since many manufactures can easily tailor
resin filler type and content to serve the specific application. Consequently, the database
has been structured  to  group resins with a common filler, into ranges of filler content.
For example, glass filled Nylon 6 is grouped into three (3) categories; 0 to 15 percent
glass filled, 30 to 35 percent glass filled and 50 percent glass filled, each with their own
price point.  These groupings provide a single price point as the price differential within a
group (0 to 15 percent glass filled) is not statistically significant

7.2.4  Material Price Forecasting, Accuracy and Variation

Though it is very difficult to accurately predict future material prices, there are statistical
methods, such as regression analysis, to help predict expected pricing outcomes based on
past trends.  Price movements  can be  greatly affected over a short period of time by
unpredictable global economic movements  and  policies  such  as the price  of oil  or
embargos.  In order to  mitigate sporadic anomalies, these extreme peaks  and valleys in
the data set, which normalize within short periods of time, are disregarded.

Figure 7-5 illustrates the power curve trend  line applied to historical 304 stainless steel
prices.  Other trend line plotting options (exponential, linear, etc.) are available; however,
the power trend line  obtains what is felt to be a realistic upward trend line response in this
case.   Each  material  data history  is  evaluated to  establish the  best fit  line and
corresponding projection.  However, it should be noted that, for the case study presented
in this report, a  sensitivity analysis  has been  performed  in lieu of calculating future
technology cost impacts based on these data-based material-by-material price projections.
Subsequent case analyses are expected to make use of these projections.
                                        7-8

-------
      $3.00   r	

  TJ  52 50   1	

  §    "    I                        /\
  O  $2.00   I-	    /   v(
  Q.         |                      A   - t
                                   /      \ -. :.»xi-^*^
  01  $1.50   '                      , ^
  &                         __-^r'Jt"^"    "                            _p0,,yer

  5  S1"°°   ;-     .'-"•"^
  ^           !-fC,",   ,-/v
  S  $0.50   .-'  '.-,.,,.>
                                             .
            OOOOOOOoOO     —
                Figure 7-5:    Projected Pricing for 304 Stainless Steel
7.2.5  In-process Scrap

In-process scrap is  defined  as the  raw material mass, beyond the final part  weight,
required to manufacture a component.  For example in an injection molded part, the in-
process scrap is typically created from the delivery system of the molten plastic  into the
part cavity (e.g. sprue, runners and  part gate).  This additional material is trimmed off
following part  injection from the mold. In some cases, dependent on the material and
application, a portion of this material  can be ground up and returned into the virgin
material mix.

In the case of screw machine parts, the in-process scrap is defined as the  amount of
material removed from the raw bar stock  in the process  of creating the  part features.
Generally, material  removed during the various machining processes is  sold  at  scrap
value.  Within this  cost analysis study, no considerations  were made to account for
recovering scrap costs.

A second scrap parameter accounted for in the cost analysis is end-item scrap. End-item
scrap is captured as  a cost element within mark-up and will be discussed in more  detail
within the mark-up database section (Section 6.5).  Although it is worth reiterating here
that in-process scrap only covers  the additional  raw  material mass   required  for
manufacturing  a part.  It does not include an allowance for quality defects, rework costs
and/or destructive test parts; these costs  are covered by the end-item scrap allowance.
                                        7-9

-------
7.2.6  Purchase Part - Commodity Parts

In the quote assumption section of the CBOM, parts are identified as either "make" or
"buy". The "make" classification indicates a detailed quote is required for the applicable
part, and "buy" indicates an established price based on historical data is used in place of a
full quote work-up.  Parts identified as a "buy" are treated as a purchased part.  For the
first case study, no attempt was made to split purchased part costs into material, labor,
and burden components. In this case purchased part costs are binned solely as material
costs.

Many of the parts considered to be purchased are simple standard fasteners (nuts, bolts,
screws, washers, clips, hose clamps) and seals (gaskets, o-rings).  However,  in certain
cases more value-added components  are considered purchased when sufficient  data
existed supporting their cost as a commodity, that is, where  competitive or other forces
drive these costs to levels on the order of those expected had these parts been analyzed as
"make" parts.

Purchased part costs are obtained from a variety  of sources.  These include FEV and
Munro team members'  cost knowledge, surrogate component  costing databases, Tier 1
supplier networks, published information, and service part cost information. Although an
important component of the overall costing  methodology, purchase part costs are used
judiciously and conservatively, primarily for mature commodity parts.
                                       7-10

-------
7.3  Labor Database

7.3.1   Overview

The Labor Database contains all the standard occupations and associated labor rates
required  to manufacture  automotive parts  and vehicles. All labor  rates referenced
throughout the cost analysis are referenced from the established Labor Database.

The labor classification format of the database is created using the same methodology as
the Bureau of Labor Statistics (BLS). Further, the core labor wage data used throughout
the study, with exception of fringe and wage projection parameters, is acquired from the
BLS.

The Labor Database is broken into (2) two primary industry sections, Motor Vehicle
Parts Manufacturing (supplier base) and Motor Vehicle Manufacturing (OEMs). These
(2) two industry sections correspond to the BLS, North American Industry Classification
System (NAICS) 336300 and 336100 respectively.  Within each industry section of the
database, there is a list of standard production occupations taken from the BLS Standard
Occupation Classification  (SOC)  system.  For reference,  the  base  SOC  code  for
production occupations within  the  Motor  Vehicle  Parts Manufacturing  and Motor
Vehicle Manufacturing is  51-0000.    Every production occupation  listed in the Labor
Database has a calculated labor rate, as discussed in more detail below.

Labor rates for 2008 establish the reference baseline from which projected labor rates can
be developed.  An "Annual  Adjustment Factor"  is used to account  for  labor rate
projections. The labor rates can be modified for  each production occupation, or for the
industry as a whole.
7.3.2   Direct Versus Total Labor, Wage Versus Rate

Each  standard production occupation found in the  Labor Database has  an SOC
identification number, title, labor description and mean hourly wage taken directly from
the BLS. Figure 7-6 is an excerpt from the Labor Database.
                                     7-11

-------


1. Mo




-------
7.3.3  Contributors to Labor Rate and Labor Rate Equation

Summarized below are the four (4) contributors to labor costs used in this study:

Direct Labor (DIR) is the mean  manufacturing labor wage  directly associated with
fabricating,  finishing and/or assembling a physical component or assembly. Examples
falling into this labor classification would include injection mold press operators, die cast
press operators, heat treat equipment operators, team/general  assemblers,  computer
numerical controlled (CNC)  machine  operators, and  stamping press operators.  The
median labor wage for each direct labor title is also included in the database; these values
are treated as reference only.

Indirect Labor (IND) is the  manufacturing labor indirectly associated with making a
physical  component or assembly. Examples  include material  handling personnel,
shipping and receiving personnel, quality control technicians, first-line supervisors, and
manufacturing/process engineers.  For  a selected industry  sector  (such  as  injection
molding, permanent casting, or  metal stamping),  an average ratio of indirect to direct
labor costs can be  derived from  which the contribution of indirect labor ($/hour) can be
calculated.

This ratio is calculated as follows:
          1.  An industry sector is chosen from the BLS, NAIC System, e.g., Plastics
             Product Manufacturing NAICS 326100.
          2.  Within the selected industry sector, occupations are sorted (using SOC
             codes)  into one (1)  of the four (4) categories, Direct Labor, Indirect Labor,
             MRO Labor, or Other.
          3.  For each category (excluding "Other") a total cost/hour is calculated by
             summing up the population weighted cost per hour rates, for the SOC codes
             within  each labor category.
          4.  Dividing the total indirect labor costs by total direct labor costs, the
             industry sector ratio is calculated.
          5.  When multiple industries employ the same  type direct laborer, as defined
             by NAICS, a weighted average of indirect to direct is calculated using the
             top three (3) industries.

Maintenance Repair and Other (MRO) is the labor  required to repair and maintain
manufacturing equipment  and tools  directly associated with manufacturing  a given
component  or assembly.   Examples  falling  into  this  labor  classification  include
electricians, pipe fitters, millwrights, and on-site tool  and die tradesmen.  Similar to
indirect labor, an average ratio of MRO to direct labor costs can be derived from which
the contribution of MRO labor  ($/hour)  can be calculated. The  same process used to
calculate the indirect labor ratio is also used for the MRO ratio.
                                       7-13

-------
Fringe (FR) is all the additional expenses a company must pay for an employee above
and beyond their base wage.  Examples of expenses captured as part of fringe include
company  medical  and  insurance  benefits,  pension/retirement  benefits,  government
directed benefits, vacation and holiday benefits, shift premiums, training, etc.

Fringe applies to all manufacturing employees. Therefore the contribution of fringe to
the overall labor rate is based on a percentage of direct, indirect and MRO labor. Two (2)
fringe  rates  are used:  52% for  supplier  manufacturing,  and  160%  for OEM
manufacturing. The supplier manufacturing fringe rate is based on data aquired from the
BLS; Employer Costs for Employee  Compensation Historical  Listings, March 2004 -
2009. Using the average 2007/2008  manufacturing sector numbers, an average fringe
rate  of 52% was calculated ([[$31.86-$20.95]/$20.95]*100), where average  employee
total compensation = $31.86/hour and wages and salaries = $20.95/hour).

The  OEM fringe rate was calculated the  same way as the supplier fringe rate above.
Taking the 2006/2007 average North American UAW OEM hourly wage  and total
compensation rate of $28.18 and $73.21 respectively, a rate of  160% was calculated.
Additional details on these calculations can be found in the labor database.

Taking the four (4) contributors of labor  cost, the following labor rate equation for a
manufacturing operation can be written:

Labor Rate ($/Hour) = DIR+ IND + MRO + FR

Where,

IND = DIR * ILRR, where ILRR = Ratio of Indirect to Direct Overall Labor Costs

MRO = DIR * MLRR, where MLRR = Ratio of MRO to Direct Overall Labor Costs

FR = {DIR + IND + MRO}*%FR, where %FR is the  fringe rate

For example, to  determine the applicable labor rate for a supplier injection molding
facility:

DIR= $15.15/hr (SOC 51-4072)

ILRR = 66%

MLRR = 23%

%FR = 52%

First indirect and MRO labor contributions are calculated:
                                      7-14

-------
IND = $15.15 * 0.66 = $10.00/hr

MRO = $15.15 * 0.23 = $3.48/hr

Next Fringe is calculated as a percent of direct, indirect and MRO labor:

Fringe = ($15.15 + $10.00 + $3.48) * 0.52 = $14.88/hr

Lastly,  the  labor rate for injection molding is  calculated by  summing the four  (4)
contributors.

Labor Rate = $15.15/hr + $10.00/hr + $3.48/hr + $14.88/hr = $43.52/hr
In Figure 7-7, some additional examples of production occupations and corresponding
total labor  rates are  shown.   Similar  calculations are made  for  every production
occupation classification found in the Labor Database.
                                       7-15

-------
F&





—









&

2
3
4~
8~~

10
12
13
14
15
IS

3
5
socs
Code
(BLS)

51-2O23
51-2O31
51-2092
51-4021

51-4031
51-4O33
5 1 -4O34
51 -4O35
51-4072
51-4191

5 I -2092
51-4011
?=•! //
^W
Direct Labor Title
(BLS)

Electromechanical Equipment
Assemblers
Engine and Other Machine
Team Assemblers
Plastic)
Machine setters. Operators.

Metal and Plastic
Machine Setters, Operators
Plastic
Grinding. Lapping. Polishing .
Tenders. Metal and Plastics
Tool Setters. Operators, and
Tenders. Metal and Plastic
Milling and Planing Machine
Tenders, Metal and Plastic.
Operators, and Tenders.
Metal SL Plastic
Heat Treat Equipment
Tenders. Metal and Plastic


Tool Operators (Metal Si
Plastic)

Direct Labor Description (BLS)

=^~^^=1^S Z^-h "
*°^^p^^"^^-:°°z^,~s'
Work as part of a team having responsibility for assembling an entire
through all or most of them rather than being assigned
Set up. operate . or tend machines to extrude or draw thermoplastic or

m*t»l or plastic parts
crimp, notch, bend, or straighten metal or plastic material.
Set up. operate, or tend grinding and related tools that remove excess

thread, form, or face metal or plastic materials, such as wire. rod. or
bar stock.
Set up. operate, or tend milling or planing machines to mill, plane.

products

plastic objects.

Work as part of a team having responsibility for assembling an entire
through all or most of them rather than being assigned



Labor Classification

Electromechanical Assembly
Complex Assembly
General Assembly
Extruding/Drawing Operator

Cut/Punch/Forming Operator
Grinding/Polishing Operator

Milling/Planing Operator

Heat Treat Operator


General Assembly-OEM













Production Year Start (Baseline) 2OO8
Median
Hourly
(REF)

$15.13
$15.34
$13-38
$17.23

$14-14
$16 27
$15-67
$15 02

$15 15

$21 .35

Mean Hourly
Wage

$16.06
$17.64
$13.66
$18.92

$16.04
$17.63
$16.49
$15.41

$16.28

$20.23
$17.00
Indirect
Labor
Rale
Ratio
"%"

40%
43%
52%
42%
67%
54%
54%
5O%
38%
40%
66%
69%

44%
42%
Indirect Labor
Contribution
i,.1lnur

$6.42
$7.59
$7.10
$6.41
$12.68
$7.91
$8.66
$8.82
$6.27
$6.16
S10.OO
$11.23

$8.92
$7.14
MRO
Labor
Rate
Ratio
%

13%
T7%
19%
22%
19%
19%
16%
12%
11%

19%

14%
12%
MRO Labor
Contribution
i Ulnur

$2 .09
$3 .DO
$2.60
$4.16
$2.78
$3.05
$2.82
$1.98
$1.7O

$3.09

$2.84
$2.04
Fringe
"%"

52%
52%
52%
5214

52%
52%
52%

52%

160%
160%
Fringe
Contribution
$SHour

$12.78
$14.68
$12.15
$18.59

$14.43
$15.22
$12.10

$15.92

$51.27
$41.89
Total Labor
Rate
$SHour

$37.35
$42 .90
$35.51
$54.35

$42.18
$44.48
$37.68
$35.37

$46.52

$83.31
$68 .07
Figure 7-7:   Labor Database Excerpt Showing Contributors to Total Labor Rate for Various Direct Labor Occupations




                                                  7-16

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7.4  Manufacturing Overhead Database

7.4.1   Overview

The Manufacturing Overhead Database  contains several manufacturing overhead rates
(also sometimes referred to as burden rates, or simply burden) associated to various types
of manufacturing equipment, that are required to manufacture  automotive  parts and
vehicles. With material and labor costs,  it forms the total manufacturing cost (TMC) to
manufacture a component or assembly, accounting for workers, supervisors, managers,
raw materials, purchased parts, production  facilities, fabrication equipment,  finishing
equipment, assembly  equipment,  utilities, measurement and test equipment,  handling
equipment, office  equipment, etc.  Manufacturing equipment is typically one  of the
largest contributors to manufacturing overhead, and so manufacturing overhead rates are
categorized according to primary manufacturing processes and the associated equipment
as follows:
   1.  The first tier of the Manufacturing  Overhead Database is arranged by the primary
      manufacturing process groups (e.g., thermoplastic molding, thermoset molding,
      castings, forgings, stamping and forming, powder metal, machining, turning, etc.)
   2.  The second tier subdivides the primary manufacturing process groups into primary
      processing equipment groups. For example the 'turning group' consists of several
      subgroups including some of the following: (1) CNC turning, auto bar fed, dual
      axis machining, (2) CNC turning, auto  bar fed, quad axis machining,  (3) double
      sided part, CNC turning, auto bar fed, dual axis machining, and (4) double sided
      part, CNC turning, auto bar fed, quad axis machining.
   3.  The third and final tier of the database,  increases the resolution of the primary
      processing equipment groups, and  defines the applicable manufacturing overhead
      rates. The added resolution is typically based on part size and complexity and the
      need for particular models/versions of primary and secondary processing
      equipment. An excerpt from the Manufacturing Overhead Database is shown in
      Figure 7-8. In this example, the levels  of complexity in CNC equipment are
      described and assigned an 'Active  Rate', which is the burden cost-per-hour for the
      equipment.
                                     7-17

-------
f
Cat.
H.CN










Item
CTu
H1.
H1.1
H1.2
H1.3
H1.4
H3.
H3.1
H3.2
H3.3
H3.4
E\\//
j^ Vu/

Burden Title
ning
CNC Turning, Auto Bar Feed (BF),
CNC Turning, Bar Fed, Machining in
"C" and "Z1 Axis Only, Medium-Large
Size Parts
CNC Turning, Bar Fed, Machining in
"C" and "Z1 Axis Only, Medium Size
Parts
CNC Turning, Bar Fed, Machining in
"C" and "Z1 Axis Only, Small-Medium
Size Parts
CNC Turning, Bar Fed, Machining in
"C" and "Z1 Axis Only, Small Size
Parts




A. Thermoplastic | | D. Forging jj G. Machining |j

K.
L.
Balancing | N. Washing ||^ £."", || U. ~\\ X. ~[
Heat Treat \\P . T1/T2/T3 Ass'y[j 8. V. [| Y. M iscellaneous |
	 — ^"][i— :"-:..l L.t.=™' II 	 _^=Hl 	 4~, 	 II 	 _ 	 i_J[ 	 _i.._.l 	 _i...._j
Primary Processing Equipment

lual Axis (DA) Machining ( "C" And "Z1 Axis), Genera

2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
SL^OBB, BarCapacity=0178mm
Max Cutting Diameter = 0648mm, Max Cutting
Length =1118 mm
12 Station Turret, Bolt on Tooling
Automatic Bar Feeder


SL-30BB, BarCapacity=0102mm
Max Cutting Diameter = 0432mm, Max Cutting
Length =864mm
12 Station Turret, Bolt on Tooling
Automatic Bar Feeder


SL-20BB, BarCapacity=064mm
Max Cutting Diameter = 0262mm, Max Cutting
Length =508mm
12 Station Turret, Bolt on Tooling
Automatic Bar Feeder


SL-10BB, BarCapacity=051mm
Max Cutting Diameter = 0279mm, Max Cutting
Length =356mm
12 Station Turret, Bolt on Tooling
Automatic Bar Feeder



,£

2
3
4
b
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
b
6
Secondary Process Equipment

tation Based with multiplier for added complexity
Lathe Work Gauging Probe
Parts Catcher System
Tool Presetter System
Chip Auger with Mobile Chip Lift
High-Pressure Coolant, 300 psi (21 bar)
Auxiliary Coolant Filter System, 25-micron filter
Lathe Work Gauging Probe
Parts Catcher System
Tool Presetter System
Chip Auger with Mobile Chip Lift
High-Pressure Coolant, 300 psi (21 bar)
Auxiliary Coolant Filter System, 25-micron filter
Lathe Work Gauging Probe
Parts Catcher System
Tool Presetter System
Chip Auger with Mobile Chip Lift
High-Pressure Coolant, 300 psi (21 bar)
Auxiliary Coolant Filter System, 25-micron filter
Lathe Work Gauging Probe
Parts Catcher System
Tool Presetter System
Chip Auger with Mobile Chip Lift
High-Pressure Coolant, 300 psi (21 bar)
Auxiliary Coolant Filter System, 25-micron filter
Burden
Classification

over base assumptions.
CNC Turning, MLS, BF, DA




CNC Turning, MS, BF, DA




CNC Turning, SMS, BF, DA





CNC Turning, SS, BF, DA








Active Rate
2008


$32.88





$27.08




$22.72





$20.48





Double Sided (DS) Part, CNC Turning, Auto Bar Feed (BF), Dual Axis (DA) Machining ( "C" And "Z" Axis), General, Station Based with multiplier for added complexity over base
assumptions.
Double Sided Part, CNC Turning, Bar
Fed, Machining in "C" and "Z1 Axis
Only, Medium-Large Size Parts
Double Sided Part, CNC Turning, Bar
Fed, Machining in "C" and "Z1 Axis
Only, Medium Size Parts
Double Sided Part, CNC Turning, Bar
Fed, Machining in "C" and "Z1 Axis
Only, Small-Medium Size Parts
Double Sided Part, CNC Turning, Bar
Fed, Machining in "C" and "Z1 Axis
Only, Small Size Parts
1
2
3
4
5
6
2
3
4
5
6
2
3
4
5
6
2
3
4
5
6
THEO-TL-35BB, Bar Capacity=0178mm
Max Cutting Diameter = 0648mm, Max Cutting
Length =11 18 mm
12 Station Turret, Bolt on Tooling
Automatic Bar Feeder


TL-25 BB, BarCapacity=0102mm
Max Cutting Diameter = 0406mm, Max Cutting
Length =864mm
12 Station Turret, Bolt on Tooling
Automatic Bar Feeder


TL-15BB, BarCapacity=064mm
Max Cutting Diameter = 0208mm, Max Cutting
Length =445mm
12 Station Turret, Bolt on Tooling
Automatic Bar Feeder


THEO-TL-05BB, Bar Capacity=051mm
Max Cutting Diameter = 0279mm, Max Cutting
Length =356mm
12 Station Turret, Bolt on Tooling
Automatic Bar Feeder


1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6

2
3
4
5
6
Lathe Work Gauging Probe
Parts Catcher System
Tool Presetter System
Chip Auger with Mobile Chip Lift
High-Pressure Coolant, 300 psi (21 bar)
Auxiliary Coolant Filter System, 25-micron filter
Lathe Work Gauging Probe
Parts Catcher System
Tool Presetter System
Chip Auger with Mobile Chip Lift
High-Pressure Coolant, 300 psi (21 bar)
Auxiliary Coolant Filter System, 25-micron filter
Lathe Work Gauging Probe
Parts Catcher System
Tool Presetter System
Chip Auger with Mobile Chip Lift
High-Pressure Coolant, 300 psi (21 bar)
Auxiliary Coolant Filter System, 25-micron filter
Lathe Work Gauging Probe
Parts Catcher System
Tool Presetter System
Chip Auger with Mobile Chip Lift
High-Pressure Coolant, 300 psi (21 bar)
Auxiliary Coolant Filter System, 25-micron filter
DS-CNC Turning, MLS, BF,
DA





DS-CNC Turning, MS, BF,





DS-CNC Turning, SMS, BF,
DA





DS-CNC Turning, SS, BF,





$37.49





$31 .69





$27.76





$25.52




Figure 7-8:  Manufacturing  Overhead  Database  Excerpt Showing  Standard
           Overhead   Rates for CNC Turning
                            7-18

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Manufacturing overhead rates for 2008 establish the baseline from which projected rates
can be  developed.  A single  Average Annual Adjustment Factor is used to for this
purpose.

7.4.2   Manufacturing Overhead Rate Contributors and Calculations

In this analysis burden is defined in terms of an "inclusion/exclusion" list as follows:

Burden costs do not include:
   •  manufacturing material costs
   •  manufacturing labor costs
          o direct labor
          o indirect labor
          o maintenance repair and other (MRO) labor
   •  mark-up
          o end-item scrap
          o corporate SG&A expenses
          o profit
          o ED&T/ R&D costs expenses
   •  tooling (e.g. mold, dies,  gauges, fixtures, dedicated pallets )
   •  packaging costs
   •  shipping and handling costs

Burden costs do include:
   •  rented and leased equipment
   •  primary and process support manufacturing equipment depreciation
   •  plant office equipment depreciation
   •  utilities expense
   •  insurance (fire and general)
   •  municipal taxes
   •  plant floor space (equipment and plant offices)
   •  maintenance of manufacturing equipment - non-labor
   •  maintenance of manufacturing building - general, internal and external, parts, and
      labor
   •  operating supplies
   •  perishable and supplier-owned tooling
   •  all other plant wages (excluding direct, indirect and MRO labor)
   •  returnable dunnage maintenance
   •  intra-company shipping  costs
                                     7-19

-------
As  can be  seen in the lists  above, burden  includes both  fixed  and variable  costs.
Generally,  the largest  contribution to the  fixed  burden costs are  the  investments
associated with primary and process support equipment. The single largest contributor to
the variable burden rate is typically utility usage.

In general the average burden rate for a production facility is  calculated by  summing up
the total burden costs for the facility for a pre-defined period. This value is  then divided
by either the total direct labor cost,  the total direct labor hours, or  the total machining
hours.

Since this cost analysis assumes that all production is in North America and at relatively
high volumes, the standard quote assumption is that higher labor  costs are offset by
automation.  With this assumption, there are considerably fewer direct labor  hours versus
machine  hours, making a machine-based burden  rate more applicable for this cost
analysis.  Thus all burden rates contained in the Manufacturing Overhead Database are
considered machine based burden rates.

Depending on the mix of equipment, processes, and  product variation at a  given
manufacturing facility, a corporation may choose to apply either a flat rate approach or an
activity based approach to burden rates. The flat rate approach assumes one burden rate
for the entire manufacturing facility, regardless of the types of manufacturing processes
employed. (For example, stamping,  welding,  and general assembly would all share  a
common burden rate).  The activity based approach applies a unique burden rate to each
core manufacturing activity or process which exists  within  the facility. For example,
stamping welding, and general assembly would each be assigned a unique burden rate.

For this cost analysis the majority of the costing is done using activity based burden rates.
However, for a few components where there  are some minor secondary operations
performed, the flat rate approach is used for simplification.
7.4.3  Acquiring Manufacturing Overhead Data

Because there is very limited publicly available data on manufacturing overhead rates for
the industry sectors included in this analysis, overhead rates have been developed from a
combination of internal knowledge at FEV and Munro, supplier networks, miscellaneous
publications, reverse  costing  exercises  and  "ground-up"  manufacturing  overhead
calculations.

For ground-up  calculations, a generic  "Manufacturing Overhead Calculator Template"
was  created. The template consists of eight (8) sections:  A. General Manufacturing
Overhead Information, B. Primary Process Equipment, C. Process Support Equipment,
D. General Plant & Office Hardware/Equipment, E. Facilities Cost, F. Utilities, G. Plant

                                       7-20

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Salaries, and H. Calculated Hourly Burden Rate.  An example of the template can be
found in Appendix E.4 illustrating the hourly burden rate calculation for a 500 ton (T)
injection mold machine.  To assist in the discussion of the various sections of the costing
template,  input  and calculated values for this  same example  are captured below in
parentheses.

The  General Manufacturing Overhead Information  section, in  addition to defining the
burden  title  (Injection  Molding, Medium  Size  and/or Moderate  Complexity)  and
description (Injection Molding Station, SOOT Press), also  defines the equipment life
expectancy  (12  years), yearly operating  capacity  (4700 hours),  operation  efficiency
(85%), equipment utilization (81.99%) and borrowing cost of money (8%).  These input
variables support many of the calculations made throughout the costing template.

The  Primary Process Equipment  section (SOOT Horizontal  Injection Molding Machine)
calculates the annual expense ($53,139) associated with equipment  depreciation over the
defined life expectancy. A straight-line-depreciation method, with zero end of life value,
is  assumed for all equipment. Included in the cost  of the base equipment  are  several
factors including sales tax, freight, installation, insurance, maintenance-parts, etc.

The  Process Support Equipment section  (e.g. Chiller,  Dryer, Thermal Control Unit-
Mold), similar to the primary process equipment section, calculates the annual expense
($6,121) associated with process support equipment depreciation.

The  General Plant  and  Office  Hardware/Equipment  section  assigns  an  annual
contribution  directed towards covering a  portion of the miscellaneous plant & office
hardware/equipment costs  (e.g.  millwright,  electrician,   and plumbing  tool  crib,
production/quality communication, data tracking and storage, general material handling
equipment,  storage, shipping and receiving  equipment, general quality lab  equipment,
office equipment).  The contribution expense ($2,607) is calculated as a percent of the
annual primary and process support equipment depreciation costs.

The  Facilities Cost section assigns a cost based on square footage utilization for the
primary equipment ($4,807), process support equipment ($3,692), and general plant and
office hardware/equipment ($6,374).  The general plant and office hardware/equipment
floor space allocation is a calculated percentage (default 75%) of the derived primary and
process support equipment floor space. The expense per square foot is $11.50 and covers
several  cost  categories  including facility depreciation  costs, property taxes, property
insurance, general facility maintenance, general utilities, etc.

The  Utilities section calculates a utility expense per hour  for both primary equipment
($9.29/hour)  and process support equipment ($3.5I/hour) based on  equipment utility
usage specifications.   Some of  the utility  categories covered in  this section include:
electricity  at  $0.10/Kw-hr.,  natural gas   at  $0.00664/cubic  foot,  and  water at
                                       7-21

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$0.00 I/gallon.  General plant and office hardware/equipment utility expenses are covered
as part of the facility cost addressed above (i.e., $11.50/square foot).

The Plant Salary section estimates the contribution of manufacturing salaries (e.g. plant
manager,  production manager,  quality  assurance manager) assigned to the indirect
participation of primary and process  support equipment.   An estimate is made  on the
average size of the manufacturing facility for this type of primary process equipment.
There  are  six  (6)  established manufacturing facility sizes and corresponding  salary
payrolls to choose  from;  each has a calculated salary cost/square  foot.  Based  on the
combined square footage  utilization of the primary, process support, and general plant
and office equipment, an annual salary contribution cost is calculated ($6,625).

The final section, Calculated Hourly  Burden Rate, takes the calculated values  from the
previous sections and calculates the  hourly burden rate in three (3) steps:  (1) 100%
efficiency and utilization ($30.54/hour), (2) user-defined efficiency with 100% utilization
($35.12/hour), and (3) both user-defined efficiency and utilization ( $38.79/hour).

The majority of primary process  equipment groups (e.g. injection molding, aluminum die
casting, forging,  stamping and  forming) in  the  manufacturing overhead database are
broken into five (5) to ten (10) burden rate subcategories based on processing complexity
and/or size, as discussed in the manufacturing overhead review.  For any given category,
there will often be a range of equipment sizes  and associated burden rates which are
averaged into a final burden rate.  The goal of this averaging method is to  keep the
database compact while maintaining high costing resolution.

In the example of the 500T injection molding  press burden rate, the calculated rate
($38.79) was averaged with three (3) other calculated rates  (for 390T, 610T and 720T
injection mold presses) into a final burden rate called "Injection Molding, Medium Size
and/or Moderate Complexity". The final calculated burden rate of $50.58/hour is used in
applications requiring injection molding presses in the range of 400-800 tons.

As discussed, multiple methods of arriving at  burden rates are used within  the cost
analysis. Every attempt is made  to acquire multiple data points for a given burden rate as
a means of validating the rate.  In some cases the validation is accomplished at the final
rate level and in other cases multiple pieces of input data, used in the calculation  of a rate,
are acquired as a means of validation.
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7.5  Mark-up (Scrap, SG&A, Profit, ED&T)

7.5.1   Overview

All mark-up rates referenced throughout the cost analysis, for Tier 1  and Tier 2/3
automotive suppliers, can be found in the Mark-up Database, except in those cases where
unique component tolerances, performance requirements, or some other unique feature
dictates a special rate.  In cases where a  mark-up rate is "flagged" within the  costing
worksheet, a note is included which describes the assumption differences  justifying the
modified rate.

For this cost analysis  study, four (4) mark-up sub-categories are used in determining an
overall mark-up rate: (1) end-item scrap allowance, (2) SG&A expenses, (3) profit, and
(4) ED&T/ R&D expenses. Additional details for each subcategory are discussed below.

The layout of the Mark-up Database is similar to the Manufacturing Overhead Database
in that the first tier of the Mark-up Database is  arranged by the primary manufacturing
process groups (e.g., thermoplastic processing, thermoset processing, casting, etc.).  The
second tier subdivides the primary manufacturing process groups into primary processing
equipment groups (e.g., thermoplastic processing is subdivided  into injection molding,
blow or rotational molding, and pressure or vacuum form molding).  The third and final
tier of the database, increases the resolution of the primary processing equipment groups,
and defines  the applicable  mark-up rates.  Similar to the overhead manufacturing rates,
size  and  complexity   of the  parts  being  manufactured will  direct the  process  and
equipment requirements,  as  well  as investments,  which  in turn,  will have  a direct
correlation to mark-up rates.

For example, a small, low  complexity Tier  2/Tier 3  injection molding facility will
generally  have less in-process scrap (as a result of defective parts and/or destructive
testing),  less corporate overhead, less investment risk,  and less engineering, design and
testing support than a large, high complexity Tier 2/Tier 3 injection molding facility, as
illustrated in Figure 7-9.
                                       7-23

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j
Cat.


Item

a
Iff
*lr w/
It Vu
Supplier/OEM Classification
(Based On Manufacturing
Overhead Categories)


Y


A. T2fT3 THERMOPLASTIC PROCESSING



A1.1
A1.2
A1.3
Injection Molding
Injection Molding
Injection Molding
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5

| A. T2/T3 ThermoPlast.


D. T2/T3 Forging
B. T2fT3 Thermoset I E. T2fT3 Stamp-Form
C. T2.'T3 Casting

F. T2fT3 Powder Metal |
Primary Processing Equipment


Large Size, High Complexity







Medium Size, Moderate Complexity




Small Size, Low Complexity










1
2
3
4
5
1
2
3
4
5
1
2
3
4
5

G. T2/T3 Machining J. T2.T3Assembly
H. T2fT3 Heat Treat K. T2/T3 Misc.
1. T2fT3 Platijg J.J L.
OEM or Supplier
Classification


T2/T3 Inject. Mold, LSHC




T2/T3 Inject. Mold, MSMC



T2/T3 Inject. Mold, SSLC



End Item
Scrap,
Active Rate
2008


0.70%




0.50%



0.30%




h



M. [ P. OEM Assembly
H. T1 Assembly Q- |
O. Z. MISC
SG&A,
Active Rate
2008


7.00%






6.50%




6.00%



Profit,
Active Rate
2008


8.00%




6.00%




4.00%



ED&T/R&D,
Active Rate
2008


2.00%




1.00%




0.00%




Figure 7-9:    Mark-up Database Excerpt Highlighting the Rate Differences ( End Item Scrap, SG&A, Profit, and ED&T), for Three (3) Levels of
                                         Injection Molding, Based on Part Size and Complexity
                                                              7-24

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As  shown in the Figure 7-9, the Mark-up Database has a column for each category of
mark-up, making it possible to modify each category independently or as a group.  In
addition, the mark-up rates for a particular supplier/OEM classification and/or primary
processing equipment category can be modified independently.

Mark-up rates for 2008 establish the reference baseline from which projected rates can be
developed.  A single average Annual Adjustment Factor is used to for this purpose.

7.5.2   Mark-up Rate Contributors and Calculations

Mark-up, in general, is an added allowance to the Total Manufacturing Cost to cover end-
item scrap, SG&A, profit and ED&T expenses.  Below are  some additional details on
what is included in each mark-up category.

End-Item Scrap Mark-up: is an added allowance to cover the projected manufacturing
fall-out  and/or rework  costs  associated with  producing  a particular  component or
assembly.  In addition, any  costs associated with in-process  destructive testing of a
component or  assembly would also be covered by this allowance.  As a  starting  point,
scrap allowances were estimated to be between 0.3%  and 0.7% of the TMC within each
primary manufacturing processing group  The actual assigned value, for each category, is
an estimate based on size and complexity of the primary processing equipment as shown
in Table 7-2.

When published industry data or consultation with an industry  expert produces more
reliable  estimates for scrap allowance associated with a generic manufacturing process
(e.g. 5% for  sand casting,  investment casting),  the Mark-up  Database  is  updated
accordingly.  In cases where the manufacturing process is considered generic, but the
component performance requirements drive a higher fall-out rate (e.g. 25% combined
process  fallout on turbocharger turbine wheels), then the scrap mark-up rate would only
be adjusted in the Manufacturing Assumption Quote Summary (MAQS) worksheet.

Selling.  General and Administrative (SG&A) Mark-up: is  also referred to as  corporate
overhead or non-manufacturing  overhead costs, and some of the more  common cost
elements of SG&A are as follows:
   •  Non-manufacturing, corporate facilities (building, office equipment,  utilities,
      maintenance expenses, etc.)
   •  Corporate salaries (President, Chief Executive Officers, Chief Financial Officers,
      Vice Presidents, Directors,  Corporate Manufacturing, Logistics, Purchasing,
      Accounting, Quality, Sales, etc.)
   •  Insurance on non-manufacturing buildings and equipment
   •  Legal and public relation expenses
   •  Recall insurance and warranty expenses
                                     7-25

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   •  Patent fees
   •  Marketing and advertising expenses
   •  Corporate travel expenses
SG&A, like all mark-up rates, is  an applied percentage to the Total Manufacturing Cost.
The  default rates for  this cost analysis range between 6% to 7% within each of the
primary processing groups.  The actual values, as with the end-item scrap allowances,
vary within these ranges based on the size and complexity of the part, which in turn is
reflected in the size and complexity of the processing equipment as shown in Table 7-2.
To  support the  estimated SG&A rates (which are  based on generalized  OEM data),
SG&A values are extracted from  publicly traded automotive supplier 10-K reports (Table
7-1).

Profit Mark-up: is the supplier's or OEM's reward for the investment risk associated with
taking on a project.  On average, the  higher the investment risk, the larger the profit
mark-up that is sought by a manufacturer.

As  part  of the  assumptions list made for this  cost  analysis, it is  assumed that the
technology being studied is mature  from the  development and competition standpoint.
These assumptions are reflected in the conservative profit mark-up rates which range
from 4% to 8% of the Total Manufacturing Cost.  The profit mark-up ranges selected
from this cost analysis are based on generalized historical data from OEMs and suppliers.

As detailed with the preceding mark-up rates, the actual assigned percentage is based on
the supplier processing equipment size and complexity capabilities (Table 7-2).

ED&T Mark-up:  the ED&T used for this cost analysis is  a combination of "Traditional
ED&T" plus R&D mark-up.

Traditional ED&T may be  defined  as the  engineering,  design and  testing activities
required  to take an "implementation ready" technology and  integrate  it into a  specific
vehicle application.  The ED&T calculation is typically more straight-forward because
the  tasks are predefined.  R&D, defined as the cost of the  research and development
activities  required  to   create  a new  (or enhance  an  existing)  component/system
technology, is often independent  of a specific vehicle application. In contrast to ED&T,
pure R&D costs are very difficult  to  predict and are very risky  from an OEM  and
suppliers perspective, in that these costs may or may not result in a profitable outcome.

For many automotive  suppliers and OEMs, traditional ED&T and R&D are combined
into one (1) cost center.  For this cost analysis, the same methodology has been adopted,
creating  a  combined traditional  ED&T and R&D mark-up rate simply referred to as
ED&T.
                                      7-26

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Based on the assumption stated above for this cost analysis (technology is mature from
the product development and competition point-of-view), a  ED&T  mark-up range
between 0% to 6% has been selected.  The selected range is based on a combination of
publications examining ED&T mark-up rates in the automotive industry, available 10K
reports, and EPA's Indirect Cost Multiplier report. Table 7-1 provides some examples of
Tier 1  automotive supplier SG&A and ED&T/R&D rates.  These  rates  are based  on
world wide operations including automotive and non-automotive components.

    Table 7-1:    Tier 1 Published SG&A and ED&T/R&D Rates for 2007 and 2008
Corporation
Dana Holding Corp
Wescast Industries Inc.
Honeywell Internationational Inc
Delphi Corp
Federal Mogul Corp
American Axle and Manufacturing
SG&A
2008
4.2%
6.5%
13.8%
10.5%
8.8%
4.8%
2007
4.2%
7.2%
13.2%
9.0%
9.4%
3.8%
ED&T/R&D
2008
2.4%
2.4%
4.2%
8.1%
2.5%
4.0%
2007
2.2%
2.0%
4.2%
7.2%
2.6%
2.5%
Source: 2008 Company Annual Financial Reports
Royalty fees, as the result of employing intellectual property, are also captured in the
ED&T mark-up section.  When  such  cases exist, separate lines in the Manufacturing
Assumption &  Quote Summary  (MAQS)  worksheet are  used to capture these  costs.
These costs are in addition to the standard  ED&T rates. The calculation of the royalty
fees are on a case by case basis and information regarding the calculation of each fee can
be found in the individual MAQS  worksheets where applicable.

As part of the costing assumptions, intellectual property is  always treated as though it is
purchased from a second entity.

See Table 7-2 for applicable mark-up rates based on the supplier processing equipment
size and complexity capabilities.
                                      7-27

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Table 7-2:    Standard Mark-up Rates Applied to Tier 1 and Tier 2/3 Suppliers Based on
                           Size and Complexity Ratings
Primary Manufacturing Equipment Group

Tier 2 /3 - Large Size, High Complexity,
Tier 2 /3 - Medium Size, Moderate
Complexity,
Tier 2 /3 - Small Size, Low Complexity

Tier 1 Complete System/Subsystem Supplier
(System/Subsystem Integrator)
Tl High Complexity Component Supplier
Tl Moderate Complexity Component
Supplier
Tl Low Complexity Component Supplier
End Item
Scrap
Mark-up

0.7%
0.5%
0.3%

0.7%
0.7%
0.5%
0.3%
SG&A
Mark-up

7.0%
6.5%
6.0%

7.0%
7.0%
6.5%
6.0%
Profit
Mark-up

8.0%
6.0%
4.0%

8.0%
8.0%
6.0%
4.0%
ED&T
Mark-up

2.0%
1.0%
0.0%

6.0%
4.0%
2.5%
1.0%
Total
Mark-up

17.7%
14.0%
10.3%

21.7%
19.7%
15.5%
11.3%
The following additional points should be noted:

For Tier 2/Tier 3 (T2/T3) suppliers, the same level of mark-up is applied regardless of the
primary manufacturing  process  group and  primary manufacturing equipment group
involved.  For example a T2/T3,  large, high complexity thermoplastic injection molding
process will have the same mark-up rates as a T2/T3, large, high complexity, stamping
and forming fine blanking process; it is size and complexity capabilities which produce
the different mark-up rates  within the T2/T3 supplier's classifications.
    •   In reference to the item above, these are standard or base rates.  If one of the
       primary manufacturing process groups and/or equipment groups requires a higher
       scrap, SG&A, profit and/or ED&T rate, the Mark-up Database is adjusted
       accordingly.
    •   The Tier 1 (Tl) mark-up classification system is based on a component,
       assembly, or system complexity ranking. For example a supplier who is
       manufacturing complete transmissions for an OEM would charge a total mark-up
       rate of'21.7% on the Total Manufacturing Costs versus the Supplier who provides
       an oil pan directly to the OEM would only receive 11.3% in mark-up.
                                      7-28

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       All value-added operations, in addition to final assembly performed by a Tl
       supplier (injection molding, casting, stamping, etc.), receive the mark-up rate
       defined by their complexity rating.
7.5.3   Assigning Mark-up Rates

The three (3) primary steps to matching mark-up rates to a given component/assembly
are as follows:

      Step 1. Primary manufacturing process and equipment groupings are pre-selected
      as part of the process to identify the manufacturing overhead rate.

      Step 2.   Manufacturing facilities are identified as OEM, Tl  or T2/T3  (this
      identification process is discussed in more detail in the Manufacturing Assumption
      & Quote Summary worksheet section).

      Step 3.  The best-fit mark-up rate is selected based on the size and complexity of
      the part, which in turn is reflected in the  size and complexity of the processing
      equipment.  Note  that  size  and  complexity  are  considered  as  independent
      parameters when reviewing a component and the equipment capabilities (with
      priority typically given to 'complexity')

Table 7-3 is an example of mark-up rate classifications based on size and complexity
combinations for some typical stampings, castings,  and  injection  molded  parts.   In
addition, other attributes which are not included  in  the naming convention (such as
component function and performance) are also considered when assigning mark-up rates.
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   Table 7-3:    Generic Mark-Up Rate Classification Based on Component Size and
                                   Complexity
Size
Attribute
Large
Medium
Small
Large
Medium
Small
Large
Medium
Small
Complexity Attribute
High
High
High
Moderate
Moderate
Moderate
Low
Low
Low
Mark-Up Rate Classification
Large Size, High Complexity
Large Size, High Complexity
Large Size, High Complexity
Large Size, High Complexity
Medium Size, Moderate Complexity
Medium Size, Moderate Complexity
Medium Size, Moderate Complexity
Small Size, Low Complexity
Small Size, Low Complexity
7.6  Packaging Database

7.6.1  Overview

The  Packaging Database  contains  standardized  packaging  options  available for
developing packaging costs  for components and assemblies.  In the cost analysis only
packaging costs required to  transport a component/assembly from a Tier 1  to an OEM
facility (or one facility to another at the same OEM) are calculated in detail. For Tier 2/3
suppliers of high-  and low-impact components, as well as purchased parts, the Tier 1
mark-up is estimated to cover the packaging as well as shipping expenses. Tier 1 mark-
up on incoming Tier 2/3 parts and purchase parts are discussed in more detail in Section
8.

All core packaging items (containers,  pallets, totes, etc.) referenced in the database are
considered returnable dunnage.  Internal packaging (tier pads, dividers, formed trays,
etc.) are also considered returnable with the exception of a few items that are expendable.
The  cost to clean  and maintain returnable dunnage is assumed to be covered by the
manufacturing overhead rate.
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7.6.2 Types of Packaging and Selection Process

Packaging  options in the database are limited to  a few standard types and  sizes to
minimize complexity.  In general, everything is tailored towards fitting onto a standard
automotive pallet (as specified by the Automotive  Industry Action Group), which has
exterior dimensions  of 48 by 45 inches and a base height assumption of 34 inches
(although other standard sizes exist in 25, 33 39, 42, 48, and 50 inches in height).  A
standard transport trailer height  of 106" is used as the guideline for overall packaging
height.

When initially trying to package a component, three (3) typical packaging options are
considered:
         •   standard 48 by 45 by 34-inch palletized container (with tier pads and
             dividers)
         •   48 by 45-inch base pallet with stacked 21.5 by 15 by 12.5-inch totes (48
             totes max - and note that totes can have specialized tier pads, dividers, etc.)
         •   48 by 45-inch base pallet with vacuum formed dividers strapped together

Considering component attributes such as weight, size, shape, fragility, and cleanliness,
one  (1) of the  packaging options above are selected, along with an  internal dunnage
scheme.  If it is  deemed impractical  to package the component within  one  (1) of the
primary options, a new package style is created and added to the Packaging Database.

Once the primary packaging type and associated internal dunnage  are selected for a
component, the assumptions along with the costs  are  entered into  a  Manufacturing
Assumption Quote Summary (MAQS) worksheet.  In the MAQS worksheet, packaging
costs along with volume assumptions,  pack densities, stock turn-over times, program life,
packaging life, and interest expenses are used to calculate a cost-per-part for packaging.
Section 9 provides more details on the calculation of packaging costs.

7.6.3 Support for Costs in Packaging Database

Primary pallet and container costs are acquired from either Tier 1 automotive suppliers or
from container vendors.  In some cases, scaling within container groups is performed to
quantify the pricing for slightly larger or smaller containers within the same family.

Internal dunnage costs are acquired from either Tier 1 automotive suppliers or calculated
based on standard material and processing estimates.  When tooling costs are required for
packaging,  the value of that tooling is added to the  total pallet container piece cost, as
calculated in the  MAQS worksheets.   The total value is then amortized to calculate a
cost-per-part for packaging.
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8    Shipping Costs

In the cost analysis, shipping  costs are accounted for by one  of three factors: Indirect
Cost multiplier, total mark-up  allowance, or manufacturing overhead.  Further shipping
costs, with the exception of inner company transportation,  are always considered freight
on  board (FOB) the  shipper's dock.   Below  are the  four (4)  shipping  scenarios
encountered in the cost analysis and how each case is handled.

The first two (2) cases, OEM and supplier inner company transportation, shipping costs
are accounted for as part of the manufacturing overhead rate. It is assumed that the OEM
or supplier would either have their own transportation equipment and/or subcontract this
service out.  In either case the expense is binned to manufacturing overhead.

The third case is Tier 1 shipments to an OEM facility. As stated above  the shipments are
FOB the shipper's dock and thus the OEM is responsible for the shipping expense. In this
case the Indirect Cost multiplier is assumed to cover the OEM's expense to have all parts
delivered to the applicable OEM manufacturing facilities.

The final case is Tier 2/3 shipments to the Tier 1 facility.  Generally, the Tier 1 supplier is
allowed a mark-up on  incoming purchased parts from Tier 2/3 suppliers.  The mark-up
covers many costs including the shipping expenses to have the part delivered onto  the
Tier 1  supplier's dock.  Further, the mark-up can either be a  separate mark-up only
applied  to incoming purchased parts, or accounted for  by the mark-up applied to  the
TMCs.  In the former, the purchase part content would not be included  in the final mark-
up calculation (i.e., Mark-up =  (TMC -Purchase Parts cost) x Applicable Mark-up Rate).

For this cost analysis, the latter case is chosen using the same mark-up  rate for all Tier  1
value-added manufacturing as well as all incoming purchase parts.
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9   Manufacturing Assumption and Quote Summary Worksheet

9.1   Overview

The  Manufacturing  Assumption  and Quote  Summary (MAQS) worksheet  is  the
document used in the cost analysis process to compile all the known cost data, add any
remaining cost parameters, and calculate a final unit cost.  All key manufacturing cost
information can be viewed in the MAQS worksheet for any component or assembly.
Additional details on the information which flows into, and out of the MAQS worksheet
are  discussed in more detail below.  Section 11 discusses how MAQS worksheets are
uploaded  into  subsystem  and  system  summary templates  to  calculate the  net
component/assembly cost impact to the OEM.

The fundamental objective of the MAQS worksheet is similar  to  a standard quoting
template  used by the automotive industry.   However the format has been revised to
capture additional quote details and manufacturing assumptions, improve on transparency
by breaking out all major cost elements, and accommodate variable data inputs  for the
purpose of sensitivity  assessments.  These features are discussed in more detail below.

For a given case study, all Tier  1  or OEM assemblies, identified in  the  CBOM  as
requiring cost analysis, will have a link to a MAQS worksheet. In some cases where high
value final assembly Tier 2/3 parts are shipped to a Tier 1 supplier, a separate MAQS
worksheet is created for greater transparency. These T2/3 MAQS worksheets are linked
to T I/OEM MAQS worksheets, which in turn are referenced back to the CBOM.

9.2   Main Sections of Manufacturing Assumption and Quote Summary
     Worksheet

At the top of every  MAQS worksheet is  an information header  (Section A) which
captures the basic project details along with the primary  quote assumptions.  The project
detail section references the MAQS worksheet back to the applicable  CBOM.  The
primary quote assumption section provides the basic information needed to put together a
quote for a  component/assembly.   Some  of the parameters in  the quote  assumption
section are automatically referenced/linked throughout  the MAQS  worksheet such  as
capacity planning volumes, product life span,  and OEM/T1 classification.  The remaining
parameters  in this section  including  facility locations, shipping methods, packing
specifications, and  component  quote  level  are  manually considered  for  certain
calculations.  Included in Appendix F.I is a sample MAQS worksheet identifying all the
major sections.

Two (2) parameters above whose functions perhaps are not so evident from their names
are the "OEM/T1 classification" and "component quote level".
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The  "OEM/T1   classification"  parameter  addresses  who  is  taking  the  lead  on
manufacturing the end-item component,  the OEM or Tier 1 supplier.  In addition, the
OEM or Tier 1 level, defined by size, complexity, and expertise level is  also captured.
The value entered into the cell is linked to the Mark-up Database, which will up-load the
corresponding mark-up values  from the database  into the  MAQS worksheet.   For
example if "T1 High Assembly  Complexity" is typed  into the input cell,  the following
values for mark-up are pulled into the worksheet:  Scrap = 0.70%, SG&A = 7%, Profit =
8.0% and ED&T = 4%.  These rates are then multiplied by the TMC at the bottom of the
MAQS worksheet to calculate the applied mark-up as shown in Figure 9-1.

The process for selecting the classification of the lead  manufacturing site  (OEM or Tl)
and corresponding complexity (e.g. High Assembly Complexity, Moderate Assembly
Complexity, Low Assembly Complexity) is  based on the team's knowledge of existing
value chains for same or similar type components.
OEM Operating Pattern (Weeks/Year):
      Annual Engine Volume (CPV):
         Components per Engine:
       Annual Component Volume:
       Weekly Component Volume:
          Estimated Product Life:
                              +5Q,ooo
                                              OEM Plant Location: Horth America
                                            Si                   ^piQn^s
                                *
                              1,300,000

                               3s,29s
                                10
Packaging Specification: Returnable Container *    Dunnage
                                                                    TMC

T1 or OE



',( Total Manufacturing Cost
T1 or OEM MartUJp Rates:
m or OEM MarMJp Values:
Base Cost Impact to Vehicle:




Material
$2.16
0.00
$2.16
Labor
$1+7

$1+7
Burden
$6.++

$6.+4
TMC
$10.07

$10.07
Scrap
,s*~
0.70%
' &!»_-
$0.11
SGSA

7.00%
...JOJ7
$1.18
Profit
tf ti J*rs
8.00%
$O.SG
$1.26
ED&T
.S1.J06
4.00%
n*'~-
$0.iO
Total
Mark-
up
$0.89
"tfl6
$3.0J



u
kP



Packaging Cost
Net Cost Impact to Vehicle:
- ;
$10.91
$10.91
$13.11
$0.01
$13.13
Figure 9-1:   Excerpt Illustrating Automated Link between OEM/T1 Classification Input
  in MAQS Worksheet and the Corresponding Mark-up Percentages Uploaded from the
                                 Mark-up Database

The "component quote level" identifies what level of detail is captured in the MAQS
worksheet  for  a particular component/assembly,  full quote, modification quote, or
differential  quote.   When the  "full  quote" box is checked off, it  indicates  all
manufacturing costs are captured for the component/assembly.  When the "modification
quote"  box  is  checked  off,  it   indicates  only  the  changed   portion  of  the
component/assembly, has been quoted.  A differential quote is similar to a modification
quote  with  the  exception that  information from  both technology  configurations, is
                                        9-2

-------
brought into the same MAQS worksheet, and a differential analysis is conducted on the
input cost attributes versus the output cost attributes.  For example, if two (2)  engine
cylinder heads are being compared for cost, each head can have its' differences quoted in
a separate MAQS worksheet (modification quote) and the total cost outputs for each can
be subtracted to acquire the differential cost.  Alternatively in a single MAQS worksheet
the cost driving attributes for the differences between the head's (e.g., weight, material
type, machining time, heat treat processes, etc.) can be offset, and the differential cost
calculated in a single worksheet. The differential quote method is typically employed
with those components with low differential cost impact to help minimize the number of
MAQS worksheets being generated.

From left to right, the MAQS worksheet is broken into two (2) main sections as the name
suggests, a quote summary (Section B) and manufacturing assumption section (Section
D).  The manufacturing assumption section, positioned to the right of the quote summary
section, is where the additional assumptions  and calculations are made to convert the
serial processing operations  from  Lean Design® into mass production  operations.
Calculations  made  in this section are automatically  loaded into  the quote summary
section. The quote summary section, utilizes this data, along with other costing database
data, to calculate the total cost for each defined operation in the MAQS worksheet.

Note "defined operations"  are all  the  value-added  operations  required  to make a
component or assembly. For example, a high pressure fuel injector may have twenty (20)
base level components which all need to be assembled together.  To manufacture one (1)
of the base level components there may be as many as two  (2) or three (3) value-added
process operations (e.g., cast, heat treat, machine). In the MAQS worksheet each of these
process operations has an individual line summarizing the manufacturing assumptions
and costs for the defined operation.  For a case with two (2) defined operations per base
level component, plus two (2) subassembly and final assembly operations, there could be
as many as forty (40) defined operations detailed out in the MAQS worksheet. For ease
of viewing all the costs associated with a part, with multiple value-added operations, the
operations are grouped together in the MAQS worksheet.

Commodity based purchased parts are also included as  a separate line code in the MAQS
worksheet.   Although  there  are no  supporting  manufacturing  assumptions  and/or
calculations required since the costs are provided as total costs.

From top to bottom, the MAQS worksheet is divided into four (4) quoting levels in which
both the value-added operations and  commodity based purchase parts are grouped:  (1)
Tier 1 Supplier or  OEM Processing and Assembly, (2) Purchase  Part - High Impact
Items, (3) Purchase  Part - Low Impact Items, and (4) Purchase Part - Commodity. Each
quoting level has different rules relative to what cost elements are applicable, how cost
elements are binned, and how they are calculated.
                                       9-2

-------
Items listed in the Tier 1 Supplier or OEM Processing and Assembly section are all the
assembly  and subassembly manufacturing  operations assumed to be performed at the
main OEM or Tl manufacturing facility.  Included in manufacturing operations, would
be any on-line attribute and/or variable product engineering characteristic checks.  For
this quote level full detailed cost analysis is performed, with the exception of mark-up
which is applied to the TMC at the bottom of the worksheet.

Purchase Part — High Impact Items include all the operations assumed to be performed
at Tier 2/3 (T2/3) supplier facilities and/or Tl internal supporting  facilities.  For this
quote level, detailed cost analysis is performed including mark-up calculations for those
components/operations  considered  to  be  supplied  by T2/3 facilities.   Tl  internal
supporting facilities included in this category do not include  mark-up calculations.  As
mentioned above, the Tl mark-up (for main and supporting facilities), is applied to the
TMC at the bottom of the worksheet.

Purchase Part — Low Impact Items are for higher priced commodity based items which
need to have  their manufacturing cost elements broken out and presented in the MAQS
sheet similar to high impact purchase parts. If not,  the material cost group in the MAQS
worksheet may become distorted since commodity based purchase part costs are binned
to material costs.  The cost estimating methodology  used is basically a reverse costing
process, where the total cost is known and estimates are required to divide the costs into
material, labor, burden and mark-up. This level of quoting was not frequently used in the
first case study (#0101).

Purchase Part — Commodity parts  are represented in the MAQS worksheet  as  a single
cost and are binned to material costs.

At the bottom of the MAQS worksheet (Section F),  all the value-added operations and
commodity based purchase  part costs, recorded in  the  four  (4) quote levels,  are
automatically added together to obtain the TMC. The applicable mark-up rates based on
the Tl or OEM classification recorded in the MAQS header  are then multiplied by the
TMC to obtain the mark-up contribution.   Adding the TMC and mark-up contribution
together a subtotal unit cost is calculated.

Important to  note is  that throughout the MAQS worksheet, all seven (7) cost  element
categories (material, labor, burden,  scrap, SG&A, profit, and ED&T) are maintained in
the analysis.  Section C, MAQS breakout  calculator, which resides between the quote
summary and manufacturing assumption sections, exists primarily for this function.

The last major section of the MAQS worksheet is the packaging calculation,  Section E.
In this section of the MAQS  worksheet a packaging cost contribution is calculated for
each part  based on packaging requirements, pack densities, volume assumptions, stock
and transit lead times, etc.
                                       9-4

-------
The  sample packaging calculation (Figure 9-2) is taken from the high pressure fuel
injector MAQS worksheet, Case Study #N0101.  In this example, six (6) weeks (which is
the default value) of packaging is required to support inventory and transit lead times.
This equates to packaging for 229,787 parts, over the six (6) weeks, based off the weekly
capacity planning rates. There are 9,072 pieces per pallet at a packaging hardware cost of
$4180 per pallet (container and internal dunnage costs are from the Packaging Database).
From the above information, twenty (26) pallet sets are required @ $4180/set equaling a
total of $108,680 in packaging costs.  Packaging is estimated to last sixty (60) months.
Thus applying the amortization formula based on sixty (60) months, 5% interest, and 9M
parts/ 60 months yields $0.014/part.  This cost is added to the subtotal unit cost (TMC +
mark-up) to obtain the Total Unit Cost.
Note in this  case both the container  and dunnage are assumed returnable.
bottom section of the packaging calculator is not used.
Thus the
PACKAGING CALCULATIONS:
Packaging Type: Opfen #} Tote, 42 Totes/Pallet
Part Size : 90x55x25 mm
Parts/Layer per tote:3x$
Number of Layers per tote: 9


RacUPallet Investment Amortization:




Expendable Packaging in Piece Cost
Packaging Cost Total:

Cost
pei
Piece
jo.c-14

Cost per


$aoo









Total
Amoun
I
$103,680

Tit, Pad
Price
Per

$0.00

Lump
Sum
Pagme
nt(X)
0.00%

Pads


0

Total •
of
Pieces*
Amortiz
ation
Period
9,000,000

Divider
Pads.
Price Per

JO .00

Number of
Service
Months
60

Dirider
Pads
PalletlRack

0

Inteies
t Rate
5.00%
Otter
*1
Packagi
•g Price
Per
58.00



Oiler
•1
Pads
Palletl
Rack
0

Cost pei Pallet
(Rack
$4,180
Oiler
Packagi
•9
Per
$0.00

otal Number of
Pallets! Racks
Required
26
Oiler
»2
Pads
Palletl
Rack
0
X
e
mber of Parts per
Palletl Rack
3072
Oiler
Packagi
•9.
Per
$0.00
IB
pplier. Customer
and In-transit
Inventor!
6
Oiler
•3
Pads
Palletl
Rack
0
in
pplier. Customer
and In-transit
Inventory
2297ST





$0.014
 Figure 9-2:   Example of Packaging Cost Calculation for a High Pressure Fuel Injector

9.3   Manufacturing Assumption and Quote Summary Detail Review

Although simple in function, the MAQS worksheet appears rather complex due to the
amount of information imported, referenced, analyzed, and exported. To help describe
this information flow into and out of the MAQS worksheet, as well as the internal
interactions taking place, a detailed reference table has been created.

In Appendix F.I, the main tasks for each section of the MAQS worksheet have been
listed, along with the input sources, reference sources and output sources of information
and data  exchange associated with each task. In addition, key sources of interaction and
data exchanges have been identified with special text formatting to help highlight these
key interaction sources.  For example two (2) of the major sources of data into the  MAQS
worksheet come from  Lean Design® process maps/exports and databases  (five (5)
databases in total).  Thus, both these sources are highlighted through the table. Lastly, in
the task description column, the word "Enter" or "Automatically" have been highlighted
                                       9-5

-------
to give the reader a sense of how much data is manually entered versus automatically
loaded for each MAQS worksheet.

Note, revisions were made to the MAQS worksheet template as the cost study analysis
progressed.  As such, the information shown in Appendix F.I, MAQS Worksheet Task
Reference Guide and accompanying MAQS worksheet template, will exist at a higher
revision level than a few of the case study MAQS worksheets found in Appendix G.I.
Only components which required the latest revision level MAQS template features were
updated during the first cost analysis.
                                      9-6

-------
10 Marketplace Validation

Marketplace  validation is the process by which  individual parts, components and/or
assemblies are cross-checked with costing data developed by entities and processes
external to the team responsible for the cost analysis. This process occurs at all stages of
the cost  analysis;  special emphasis is placed on  cross-checking in-process costs (e.g.
material costs, material selection, labor costs, manufacturing overhead costs, scrap rates,
and individual component costs within an assembly).

In-process cost validation occurs when  a preliminary  cost has been developed for a
particular part within  an assembly, and  the  cost is significantly higher or lower than
expected  based on the team's  technical  knowledge,  or  on pricing  from  similar
components.  In this circumstance the cost analysis team would first revisit the costs,
drawing  in part/process-specific  internal  expertise and checking  surrogate parts from
previously costed bills  of materials where available. If the discrepancy is still unresolved,
the team would rely on automotive supplier networks, industry experts, and/or publicly
available publications to validate the cost assumptions, making changes where warranted.

Cross-checking on final assembly costs (e.g. turbochargers, direct injectors, high pressure
fuel pumps) also occurs within the scope  of the cost analysis, mainly as a "big picture"
check. In general  cross-checking final assembly  costs are  typically achieved through
solicitation of  industry  experts.  The depth  of cross-checking  ranges from simple
comparison of cost data on surrogate assemblies to full Manufacturing Assumption and
Quote Summary (MAQS) worksheet reviews.
                                      10-1

-------
11  Cost Model Analysis Templates

11.1 Subsystem Cost Model Analysis Templates

The Subsystem Cost Model Analysis Template (CMAT) is the document used to display
and roll-up  all the  costs associated  with a subsystem (fuel induction, air induction,
exhaust,  etc.)  as defined by the  CBOM.  All  parts identified, within the applicable
subsystem of the CBOM, as requiring cost analysis, are entered into the CMAT.  Also
both the  base  and new technology configurations are included in the same CMAT to
facilitate  the differential cost analysis.

The cost inputs for the Subsystem CMAT are  the MAQS  worksheets.  As discussed
previously,  generally every component  and assembly  identified  in the  CBOM, as
requiring cost analysis will have  a MAQS  worksheet.  However,  there are a few key
exceptions to this rule, listed below, worth pointing out.
    1.  Because the basis of the analysis is a differential analysis, the base technology
      configuration is assumed "Zero Cost" and everything is quoted as a differential to
      this zero baseline.  Thus in many case studies there are very few MAQS
      worksheets for the baseline configuration.  Note that in the CMAT, "$  0" or "$ -"
      indicates that no MAQS worksheets exists.
    2.  In those cases where the baseline configuration has identified differences requiring
      costing, two (2) potential paths  are possible.
            a. A Full or Modified Quote level MAQS worksheet (pending  situation) is
               created for both the new and base technology components and/or
               assemblies, and the totals are subtracted out in the CMAT.
            b. A Differential Quote level MAQS worksheet is created where both the
               baseline and new  technology components or assemblies are pulled into
               the same MAQS worksheet for differential cost analysis. In this case
               the costs are binned to either the base or new technology configuration
               (case dependent) and the technology configuration showing  zero costs is
               highlighted yellow (i.e., "$ 0" or "$ - ")  in the CMAT.
The MAQS worksheets are automatically linked  to the CMAT templates  to  facilitate
automatic updating  for assumption changes and/or sensitivity  studies.   This includes
uploading all eight (8) unit cost elements including packaging.  Figure 11-1 and Figure
11-2 are  samples excerpts of the CMAT taken from the Fuel Induction Subsystem, Case
Study #0101 (Base 2.4L 14, Naturally Aspirated,  Port Fuel Injected (PFI) downsized to a
new 1.6L, 14 Turbo, Direct Injection (DI). Included in Figure 11-1, is an overlay of the
Unit Cost Summary section, taken from the MAQS worksheet for the high pressure fuel
Pump, highlighting the link between the documents.  For this particular Fuel Induction
Subsystem example, the Net Component Assembly Cost Impact to the OEM is $148.18,
for  the new technology configuration, and $40.84 for the base technology configuration.

                                     11-1

-------
Thus $107.34 ($148.18440.84) is the pre-estimated cost impact to add DI over PFI.  Pre-
estimated indicating that there  are other potentially cost factors for adding DI which are
not included in the Fuel Induction Subsystem  classification.  For example additional
machining  of the cylinder head for mounting  the  injectors  would be an  added cost
addressed in the Head Subsystem.
                                      11-2

-------
                             Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
                               Vehicle Class: Compact/Economy 2-4 Passenger
                               Study CaseS: N0101 & B0101 (N=New, B=Base, j 01=Technology Package, 01=Vehide Class


£

























E
S f 2
I 1 1


1

•E
E
GENERAL PART INFORMATION

Name/Description
11 Fuel Induction Systems

01 Fuel Rails
A FuplPiiht
«l Fuel Pill
•C SKI
04 Fuel
A Fuel
07 Fuel
High
Pre^utHUHNaor «= emblj
Hiijh Prn-sure
or FUH! HiL|h Prp -urn
Injectors
nieetor As=
embl jolenoid ~" HN!P
Injection Pumps
A Fuel Pump
70 Pipe
Hig
PtebbUtn w /ol intrul ^ dbn iDriven Oft IntdS-e * -it
s, Hoses: Low Pressure, High Pressure
A FI|IH k,v
A Bolt
B

C

D
E
F
Bolt-

hleta

\\j\i
Fuel High Prns ure Pump to Pail
FuHlF-iil
Fuel Pump

ner -


uel Injector

Was ier, Re ainer - Fuel Injector


Spacer - Re ainer, Fuel Injector
85 Sealing Elements

A
100 Engine As

A
Sea

semlily
Fuel
nduction impact to engine assembly


Part Number



11
11
11

11

11

11
11
11

11

11
11
11

11






01
01
01

04

07

70
:0
BO

dU

BO
RO
BO

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N0101
N0101
N0101

N0101

110101

N0101
N0101
N0101

\IU1U1

N0101
N0101
N0101

NQ101































01
02
03

11

01

01
01
02

Jj

04
15
06

11




QTY/
P.T



1
1
1

4

1

1
4
3

4

4
4
4

1




Notes




PIA Fuel Pail A^emblv
PIA Fuel Pall A==«nblv






PIA Engine A cernblj
PIA Engine AEeernblj

PIAInjerloi

PIA Injertoi
PIA Injectoi
PIA Injector






s


























Addition or
Modification



Mod



Mod

Add

Add
Mod
Add

Mod

Mod
Mod
Mod



Mod

NEW TECHNOLOGY PACKAGE: 1.6L 14, 16V DOHC, Dl, Turbo, w. dWT (Study
Case#N0101)
Manufactur ng
Material



J 11.09



%r,\^

W.fl

ting
Labor



I iai



11 J
--
1824

to:4
Burden



J 5"0



125 '4
'
i;r -
-™
51 nt
Total
Cost
(Component/
Assembly)



$ 18.S9



$ 40.26
- - --
$ 53.55
'-"
$ 1SII
Miterial Labor Burden IMC

$1699 $&24 »32 $)!«


U , I


W6« IS.24 $28.32 $J3.M
Markup
End Item
Scrap



t 0.06



$ LJ4j

5 rr-
.
$ 0.01
Strap

$133

0,70%
$M1
$0.73
S6SA



J 1.12



( 4.72

I rx
— ,
Front



J 0.74



I 5U]

t 640
-
t 011 t 007
SGSA

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7.00%
$4.06
».36
Profit

$1.76

8,0011
$4.61
$6.40
EDSJ-
R&D



I on



t JUI

( 24F
_ .
t oo;
loss

$ai4

4.00%
$232
$2.48
Total Markup
Cost
(Component/
Assembly)



$




2.10



$ 12.19
"
m *
J 15.96

$
Total
Mark-
up
$4.»2

19,70%
f1144
$1196
_.
0.20
Total
Cost
(Component/
Assembly)



t oo:



$ ODS
™*
J 011
-
f 0.00
Net
Assembly
Cost Impact to
OEM



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$ 52.50

$ 6961

t 2.00
E J1S06

	 »0 $s&06





Example showing Section F of the MAQS worksheet, *«*>&* Cos
for the high pressure fuel pump, uploading the "«< Cost Impart to Miicl
subsystem CM AT.
I 	 	

J 0.15
(3725

J 1.13
$1741

5 204
J6207



< 3.33
J 117.53



t -
t 1.23



J -
$1230



I -
J1225



J -
( 4.67




'
$ 30.44



$
$ 0.20
$easo
t $0.11
t: $»61




$ 3.33
$ 148.18
Figure 11-1:  Excerpt from Subsystem Cost Model Analysis Template Illustrating Subsystem Cost Roll Up for the Fuel Induction
                                 Subsystem - New Technology Configuration - Case Study #N0101
                                                             11-3

-------
                                   Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
                                     Vehicle Class: Compact/Economy 2-4 Passenger
                                     Study CaseS: N0101 8.B0101 (N=New, B=Base,) 01 technology Package, 01 =Vehicle Class

e














1 1 |
S at 1
3 $ a
01

|
1

Component
GENERAL PART INFORMATION
Name/Description
11 Fuel Induction Systems
01 Fuel Rails
A Fuel Rail w. High Pressure Sensor Assembly
A1 Fuel Rail - High Pressure
A2 Sensor- Fuel, H gh Pressure
04 Fuel Injectois
A Fuel injector Assembly - Solenoid, 7 Hole
07 Fuel Injection Pumps
A Fuel Pump - High Pressure w. Vol Cotrol Valve (Driven-Off Intake Car
70 Pines, Hoses: Low Pressure, High Pressure
A Pipe Assembly - Fuel, High Pressure, Pump to Rail
00 Bolting
A Bolt -
B
C
D
E
F
Bolt-
Fuei
Rail
Fuel Pump
Reta ner- Fuel Injector
Washer, Retainer- Fuel Injector
0-rJng Reta ner, Fuel Injector
Spacer- Retainer. Fuei Injector
05 Sealing Elements
A Sea - High Pressure Fuel Pump to Cylinder Head
100 Engine As
A
sembly
Fuel Induction impact to engine assembly

Part Number

11
11
11
11
11
11
11
11
11
11
11
11
11



01
01
01
04
07
70
80
00
80
80
00
80
85



N0101-
N0101-
N0101-
N0101 -
N0101-
N0101-
N0101 -
N0101-
N0101-
N0101-
N0101-
N0101-
N0101-



01
02
03
01
01
01
01
02
03
04
05
06
01


QTY/
P.T

1
1
1
4
1
1
4
3
4
4
4
4
1


Notes

PIA Fuel Rail Assembly
PIA Fuel Rail Assembly



PIA Engine Assembly
PIA Engine Assembly
PIA Injector
PIA Injector
PIA Injector
PIA Injector
PIA Fuel Pump


1














Addition or
Modification

Mod
Mod
Add
Add
Mod
Add
Mod
Mod
Mod
Mod
Add
Mod

















BASE TECHNOLOGY PACKAGE: 2.4L 14, 16V DOHC, NA w. dWT (Study Case*
B0101)
Manufacturing
Material

1 1 3B
$ 4.13
1 -
S -







S -
$ 549
Labor

1 1 46
t 4.15
( -
1 -







( -
J 561
Burden

$ 2.35
$19.46
J -
( -







( -
(21 81
Total
Manufacturing
Cost
(Component/
Assembly)

$ 5.10
$ 27.74
$
S







S
$ 32.91
Markup
End Item
Scrap

J 0.02
$ 0.26
$ -
$ -







$ -
J 0.27
SGSA

( 0.31
t 2.79
J -
$ -







$ -
( 3.10
Profit

( 0.21
t 2.98
$ -
$ -







$ -
( 3.19
EDST-
R&D

( O.D5
t 1.26
$ -
$ -







$ -
.( 	 1.31_.
Total Markup
Cost
(Component^
Assembly)

f 0.50
$ 7.2B
$
$







$
1 7.87
Total
Packaging
Cost
(Component/
Assembly)

$ 0.03
$ 0.02
1
t







t
$ 0.06
Net
Component/
Assembly
Cost Impact to
OEM

$ 5.79
$ 35.0S
$
J







f
$ 40.84
            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
Figure  11-2:     Excerpt from Subsystem Cost Model Analysis Template Illustrating Subsystem Cost Roll Up for the Fuel Induction
                                          Subsystem - Base Technology Package - Case Study #B0101
                                                                        11-4

-------
11.2 System Cost Model Analysis Template

The System CMAT, similar in function to the Subsystem CMAT, is the document used to
display and roll-up all the subsystem costs associated within a system, as defined by the
Comparison Bill of Materials. Within the scope of this cost analysis, the System CMAT
provides the bottom line unit cost, between the base and new technology configurations
under evaluation.

As evident in Figure  11-3, the  same level  of cost detail is maintained throughout all
documents providing  optimal transparency  up to the concluding  cost worksheet.  In
addition, all Subsystem CMAT totals are linked directly to the System CMAT supporting
automatic  updates due to assumption changes and/or sensitivity studies.
                                     11-5

-------
'(



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03
04
05
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07
08
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16
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e Frames


t
, • v Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
- 41 Vehicle Class: Compact/Economy 2-4 Passenger
; -»' Study CaseS: NOIGI &B0101 (N=New, B-Base, ) 01 ^Technology Package, 01 =Vehcle Class
GENERAL PART INFORMATION
Name/Description
Mountings £ Brackets
Cratik Drives
Counter B
Cylinder E
alanc
locks
Cylinder Heads
e Systems


Subsystem
Valve Tra ns
Timing Drives
Accessory Drives
ntake Systems
:uel Induction Systems
Exhaust Systems
.utirication Systems, Oil Pans/Sumps
Cooling Systems
miuction Air Chargi
zxhasistGas Re
g Systems
-Circu atioiss
Breather Systems
Engine Management Systems, Engine Electronic Systems, Electrical S
Acce
ssori
s (Starter Engines, Generators, Power Steering Pumps, etc


Part Number
















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ems











































QTY/
PT




















Notes
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Required
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Mod
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Mod.
Mod
Mod
NA
NA
Add & Mod
Mod
Add i Mod
Add
Add
Ir
Mod
Mod
Add


INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE: 1.6L M, 16V DOHC, Dl, Turbo w. dWT (Study Case* N0101)
BASE TECHNOLOGY PACKAGE: 2.4L 14, 16V DOHC, NA w. dWT (Study Case* B0101)
Manufacturing
Material




! S57
i 840
I 160


t 3176
t 2724
i 1263
I 17.24
$ 9016

J 135
t 52.1!
J 344

1218.82
Labor

J 033

J 136
I 081
J -
t -


i 1180
1 Oil
J 530
I 6.14
$ 4838

S 037
J 160
j 255

$ 72.58
Burden

t 415

I 5.78
i 604
J -
J -


J 41.05
J 309
J 11 74
J 12.02
$ 6866

S 1 49
J 288
J 790

J 154.24
Total
Manufacturing
Cost
(Component/
Assembly)

5 0.46
.,„
-- ,„„„
i 13.32
5 0.40
S 1.60

, ,,u b,
t 84.62
f 30.44
t 29.67
t 35.40
1 207.21

! 3.21
t 56.61
$ 13.00

I 445.64
Markup
End Item
Scrap

1 028


$ 1 80
$ 005
t -


1 0.95
t 297
1 014
1 0.20
$ 661

$ 003
1 -
1 009

J 1172
SOSA



1 083
$ 065
$ 059
i -


i 920
$ 197
1 2.13
i 239
$ 1868

1 042
i -
) 141

J 33.96
Profit



I 056
i 071
1 068
I -


I 906
$ 179
, ,70
J 2.45
$ 1860

i 039
1 -
I 115

1 33.12
ED6T-
R&D

J 014

I -
S 004
S 034
t -


J 3.36
1 071
J 051
J 1.03
I 698

J 012
t -
J 032

$ 12.36
Total Markup
Cost
(Component/
Assembly)

, 01 „„

i 0.86
i 3.20
$ 1.65
$

, „..,
S 22.50
S 7.44
S 4.55
* 6.06
1 50.97

$ 0.96
S
S 2.96

1 91.16
Total
Packajini
Cost
(Component.'
Assembly)

J

I 0.04
S 003
J
f


J 0.13

J 024
J 010
I 071

J
t
J 009

I 0.30
Net
Component,'
«ssemlily
Cost Impact to
OEM

1 0.00

S 0.44
1 16,55
f 10.06
S 1,60


S 107,32
t 37,77
( 34.46
( 41.56
S 250.00

S 4.17
i 56,61
1 16,95

t 537,70
System
EOSTMD
1X1000)

1
J
J
J
J
t

J
J
$
i
1
J

J
J
t

t -


i
$
t
1
i
1

i
1
1
i
1
i

1
1
i

t -


1
$
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J
$
1

$
1
t
i
S
t

$
1
t

t -
Figure 11-3:      Excerpt from System Cost Model Analysis Template Illustrating the Incrmental Subystem Cost Roll Up for
            Case Study #0101 - 2.4L 14, 16 Valve, DOHC, NA, PFI downsized to 1.6L 14, DOHC, Turbo GDI
                                                  11-6

-------
12 Operating and End-of-Life Costs

Some of the technologies being analyzed may involve additional maintenance or a
change in existing maintenance.  Some may  also involve additional vehicle scrappage
costs or salvage value.  These incremental costs and savings are evaluated and presented
separately from the new vehicle unit costs.

The maintenance and end-of-life cost calculations are performed on a  case basis, using
methodologies developed and documented specifically for the relevant technology case.
The general methodology for maintenance calculations is the following:

    1.  Identify a new or altered maintenance practice based on owner's manuals, service
       instructions, and the team's engineering knowledge of how the technology affects
       vehicle operation.

    2.  Calculate the differential cost of the identified maintenance practice.

    3.  Calculate the number of corresponding maintenance  cycles over the expected
       service life of the vehicle.

    4. Calculate  an  incremental cost (or savings) per year and a net present value of the
       cumulative costs.

A similar approach is  used for the differential salvage value and disposal  costs.  The
#0101  case  study  documented in this report  has identified no new or modified
maintenance or end-of-life costs.
                                     12-1

-------
13  Results for Case Study #0101

Using the established study methodology detailed in the previous sections, the first cost
study analysis  was conducted: stoichiometric, gasoline  direct injection (GDI) with
turbocharging on a downsized 14 engine,  compared to an equivalent conventional 14
engine. The hardware chosen to represent the new technology configuration was the 2007
Mini Cooper S,  1.6L 14, four (4) valve, dual overhead cam, turbocharged, direct injection
engine (172 hp).  The engine selected to represent the baseline configuration was the
2007 Chrysler GEMA 2.4L 14,  four (4) valve, dual overhead cam, naturally aspirated,
port fuel injected engine (173 hp).

Figure 13-1 is an excerpt from the System  CMAT showing the incremental cost impact
for each subsystem for Case Study #0101.  For Case Study #0101, condensed versions of
all  supporting MAQS worksheets  can be found in Appendix G.I.   In addition the
Subsystem CMATs and the System CMAT  may be found in Appendix H.I  and H.2
respectively.  Table 13-1, captures some of the basic cost analysis assumptions made for
this first case study (#0101).

Because many of the documents referenced  within this report are too large to be shown in
their entirety  (e.g.   MAQS worksheets, CMATs, Costing  Databases),  electronic  copies
can be accessed at http;//www.epa.gov/otaq/.
                                     13-1

-------
£_/.-|,/

ENGINE SUBSYSTEMS
02 Engine Frames, Mountings & Brackets
03 Crank Drives
04 Counter Balance Systems
05 Cylinder Blocks
06 Cylinder Heads - Subsystem
07 	 Valve Trains 	
08 Timing Drives
09 Accessory Drives
10 Intake Systems
11 Fuel Induction Systems
12 Exhaust Systems
13 Lubrication Systems, Oil Pans/Sumps
14 Cooling Systems
15 Induction Air Charging Systems
16 Exhaust Gas Re Circulations
17 Breather Systems
Engine Management Systems, Engine
Electronic Systems, Electrical Systems
Accessories (Starter Engines,
70 Generators, Power Steering Pumps,
etc)
TOTAL UNIT COST




















INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE: 1.6L 14, 16V DOHC, Dl, Turbo w. dWT
(Study Case* NG1 01)
BASE TECHNOLOGY PACKAGE: 2.4L I4, 16V DOHC, NA w. dWT
(Study Case* BG1 01)
Manufacturing
Material
NA



$ 5.57
I 40
$ 1.60
NA

$ 31.76
$ 27.24
$ 12.63
$ 17.24
$ 90.16
NA
$ 1.35
?. . 5.2-.1?
$ 3.44
.1.218.82...
Labor
NA
I n 9

! 1 j6
1 U 31
I
!
NA

$ 11.80
$ 0.11
$ 5.30
$ 6.14
$ 48.38
NA
$ 0.37
$ 1.60
$ 2.55
1 72.58
Burden
NA
J 4.15

$ 5."8
$ 6.94
I
I
NA

$ 41.05
$ 3.09
$ 11.74
$ 12.02
$ 68.66
NA
I 1.49
I 2.88
$ 7.90
1 ...1.5.4.24
Total
Manufacturing
Cost
(Component/
Assembly)
NA
$ 0.46
-
.i
$ 13.32
$ 8.40
$ 1.60
NA

$ 84.62
$ 30.44
$ 29.67
$ 35.40
$ 207.21
NA
$ 3.21
$ 56.61
$ 13.89
J 1.45.64
Markup
End Item
Scrap
NA
r II ^r


( 1.80
t 0.05
$
ri«

t 0.95
t 2.97
t 0.14
I 0.20
t 6.61
NA
1 0.03
.1 	 -
t 0.09
.!... 1 1 72
SG&A
NA


t 0.83
J 065
t 0.59
1
ri«

J 920
( 1 97
t 2.13
t 239
t 1868
NA
t 0.42
t :
J 1 .41
' 33.96
Profit
NA


$ 0.56
$ 0.71
$ 0.68
$
NA

$ 9.06
$ 1.79
$ 1.78
J 2.45
$ 18.69
NA
J 0.39
*.... .:.
$ 1.15
J 33.12
ED&T-R&D
NA
( 0.14

I
} 0.04
I 034
%
N«

$ 3.36
$ 071
$ 0.51
$ 1.03
$ 6.98
NA
$ 0.12
$ :
$ 0.32
J 12.36
Total Markup
Cost
(Component/
Assembly)
NA

-
t 0.86
$ 3.20
$ 1.65
t
NA

$ 22.58
$ 7.44
J 4.55
J 6.06
t 50.97
NA
1 0.96
| 	 - 	
$ 2.96
J 91.16
Total
Packaging
Cost
(Component/
Assembly)
NA
*

J 0.04
1 0.03
t :
% :
M»

t 0.13
t
t 0.24
J 0.10
J 0.71
NA
J :
J 	 : 	
t 0.09
J 0.90
Net
Component/
Assembly
Cost Impact to
OEM
NA
t 0.00

$ 0.44
$ 16.55
$ 10.06
$ 1.60
NA

t 107.32
t 37.77
t 34.46
$ 41.56
$ 258.89
NA
$ 4.17
t 56.61
$ 16.95
J 537.70.
Figure 13-1:  System Cost Model Analysis Template Illustrating the Incremental
  Subsytem Costs Roll Up for 14, Turbo, GDI Downsizing, Case Study #0101
                                  13-2

-------
Table 13-1:   Summary of Cost Analysis Assumptions for Case Study #0101
Description
Annual Volume
Supplier Manufacturing Locations
OEM Manufacturing Locations
Manufacturing Cost Structure:
(e.g. Material Costs, Labor Rates,
Manufacturing Overhead Rates)
Supplier Mark-up Rate Structure:
Manufacturing Process and Operation
Considerations
Intellectual Property Cost
Considerations
Cost analysis identified and assigned
costs to neighboring systems as a
result of new technology adaptation.
Operating and End-of Life Costs
Material Cost Reductions (MCRs) on
analyzed hardware.
New Technology Advances (NTAs) on
analyzed hardware
Costs elements not handle within the
scope of this cost analysis.
Case Study Assumption
450,000 units
North America
North America
2008 production year rates
2008 production year rates,
based on mature technology assumptions
Based on standard/mainstream industrial practices
No special cases of intellectual property were identified
and costed within the analysis.
No neighboring system (e.g. Engine Mounting, NVH
Packages) upgrades were considered in analysis.
Assumed that the engine mounts and NVH packages were
of reasonable quality for the PFI engine. As such, no
changes would be required for the adaptation of turbo DI
No new, or modified, maintenance or end-of-life costs,
were identified in this analysis.
Potential MCRs were identified and evaluated, but not
found to be of great significance to the incremental cost.
As representative hardware is acquired, the potential exists
to create MCR costing scenarios based on the initial cost
analysis work.
Potential NTAs were identified and evaluated, but not
found to be of great significance to the incremental cost.
As representative hardware is acquired, the potential exists
to create NTA costing scenarios based on the initial cost
analysis work.
Several cost elements (e.g. OEM mark-up, vehicle and
system engineering, design and testing costs, dedicated
production tooling costs) are handled through the
application of an Indirect Cost Multiplier. See EPA report
EPA-420-R-09-003, February 2009, "Automobile Industry
Retail Price Equivalent and Indirect Cost Multipliers" for
additional details.
                            13-3

-------
14 Sensitivity Analysis

For this case study, it was necessary to understand how sensitive the incremental unit cost
impact ($537.70) was  to any future changes in the cost of materials, labor, burden or
mark-up.  The following scenarios were modeled relative to 2008 dollars: supplier and
OEM labor cost -20%; OEM labor rate fringe contribution  reduced from 160% to 52%
(matching  supplier rate); burden cost -20%; material cost +/- 20%; mark-up +/- 20%.
Given the clear trends  in North American manufacturing, only declines were considered
for the labor and burden rates within this sensitivity analysis. The percent change in cost
for each of these categories was modeled independently, and the results for each scenario
are shown in Table 14-1.

                  Table 14-1:   Cost Model Sensitivity Study Results
Model Description
Baseline, Case Study #0101
20% average decrease in labor rates
OEM fringe reduced from 160% to 52%
20% average decrease in burden rates
20% average decrease in raw material costs(1)
20% average increase in raw material costs0 }
20% average decrease in mark-up rates
20% average increase in mark-up rates
Net Component /Assembly
Cost Impact to OEM
$537.70
$520. 16 (-3%)
$530.28 (-1%)
$498.59 (-7%)
$493. 94 (-8%)
$58 1.46 (+8%)
$5 19.47 (-3%)
555.93 (+3%)
        Both raw material and commodity purchased components are grouped together in the above sensitivity
      analysis. Total Incremental Material Costs = $218.82 of which $160.37 are commodity purchased parts and
      $58.45 are raw material costs including in-process scrap.

As  discussed  in  Section  5.0, material  costs include a  combination of raw materials,
material processing scrap, and commodity purchased parts.  The value of commodity
purchase parts, if excessive, can prove misleading relative to the contribution of each cost
element within the cost model.  In case studies which follow, greater efforts are being
employed on binning unit costs, for those higher price  commodities, into defined cost
element categories.   This is accomplished  by using surrogate costing data for like
components and developing standardized cost models (e.g., the Total Manufacturing Cost
for  a electromechanical device type "X" would have the predefined cost model - 35%
material, 15% labor and 50% burden). Because surrogate costing data for the commodity
                                      14-1

-------
purchase parts were not used in this case study, there will be a modest effect on the above
sensitivity results (i.e., somewhat lower labor, burden, and somewhat higher material).
                                       14-2

-------
15 GLOSSARY OF TERMS

Assembly: generally refers to a group of interdependent components joined together to
perform  a defined function (e.g. turbocharger assembly, high  pressure  fuel  pump
assembly, high pressure fuel injector assembly).

Buy:  is the terminology used to identify those components or assemblies as ones in
which a manufacturer would purchase versus manufacture.  All parts designated as a
"buy" part, within the analysis, only have a net component cost presented.  Typically
these types of parts are considered commodity purchase parts having industry established
pricing.

CBOM (Comparison Bill of Materials): is a system bill of materials, identifying all the
subsystems, assemblies and components associated  with the technology configurations
under evaluation.   The CBOM records  all the high level details of the  technology
configurations under study, identifies those items which have cost implication as a result
of the new versus base technology differences, documents the study assumptions, and is
the primary document for capturing input from the cross functional team.

Component: is the lowest level part within the  cost analysis.  An  assembly is typically
made  up of several components  acting together to perform a function (e.g. the turbine
wheel  in  a turbocharger  assembly). However,  in  some  cases a  component can act
independently performing a function within a sub-subsystem or subsystem (e.g. exhaust
manifold within the exhaust subsystem).

Cost  Estimating Models: are  cost estimating tools, external to  the Design Profit®
software, used to calculate  operation and process parameters for primary manufacturing
processes  (e.g.  injection molding, die  casting, metal  stamping, forging).     Key
information calculated from the costing estimating tools  (e.g. cycle times, raw material
usage, equipment size) is inputted into the Lean Design®  process maps supporting the
cost analysis.  The Excel base cost estimating models are developed and validated  by
Munro & Associates.

Costing Databases: refer to the five (5) core databases which contain all the cost rates
for the analysis.  The material database lists out all the materials used throughout the
analysis along with the estimated price/pound  for  each. The  labor database captures
various automotive, direct labor, manufacturing jobs  (supplier and OEM), along with the
associated mean hourly labor rates. The manufacturing overhead rate database contains
the cost/hour for the various pieces of manufacturing equipment assumed in the analysis.
A mark-up database assigns a percentage of mark-up for each of the four (4) main mark-
up categories (i.e. end-item scrap, SG&A, profit, and ED&T), based on the industry,
supplier size, and complexity classification.  The fifth database, the packaging database,
contains packaging options and costs for each case.

                                     15-1

-------
Lean Design® (a module  within the Design  Profit® software): is used to create
detailed process flow charts/process maps. Lean Design® uses a series of standardized
symbols, each base symbol  representing  a group of similar manufacturing  procedures
(e.g. fastening, material modifications, inspection).  For  each group, a Lean Design®
library/database exists  containing  standardized operations  along with the associated
manufacturing information and specifications for each operation.  The information and
specifications are used to generate a net operation cycle time.  Each operation on a
process flow chart is represented by a base symbol, operation description, and operation
time, all linked to  a Lean Design® library/database.

Make: is the terminology used to  identify those components or assemblies as ones in
which a manufacturer would produce internally versus purchase.  All parts  designated as
a "make" part, within the analysis, are costed in full detail.

MAQS (Manufacturing Assumption and  Quote  Summary)  worksheet:  is  the
standardized  template  used  in  the  analysis  to  calculate  the mass  production
manufacturing cost,  including  supplier  mark-up,  for  each system,  subsystem and
assembly quoted in the analysis.  Every component and assembly costed in the analysis
will have a MAQS  worksheet.   The worksheet is based  on a standard OEM (original
equipment manufacturer) quote sheet modified for improved costing transparency and
flexibility in sensitivity studies.  The main feeder documents to  the MAQS  worksheets
are process maps and the costing databases.

MCRs  (Material Cost Reductions):  is  a process  employed to  identify and capture
potential design  and/or  manufacturing optimization ideas with  the  hardware under
evaluation.  These savings could potentially reduce  or  increase the differential costs
between the new  and  base technology configurations, depending on whether an MCR
idea is for the new or the base technology.

Net Component/Assembly Cost Impact to OEM: is defined as the net manufacturing
cost impact per unit, to  the OEM, for a defined component, assembly,  subsystem or
system.  For components produced by the  supplier base,  the net manufacturing cost
impact  to  the   OEM  includes  total manufacturing   costs  (material,  labor,  and
manufacturing  overhead),   mark-up  (end-item   scrap   costs,  selling,  general  and
administrative costs, profit,  and engineering design  and testing costs) and packaging
costs. For OEM internally manufactured components, the net manufacturing cost impact
to the OEM includes total manufacturing costs and packaging costs; mark-up costs are
addressed through the application of an indirect cost multiplier.

NTAs  (New  Technology Advances):  is a process employed to  identify and capture
alternative advance  technology ideas which could be  substituted  in for  some of the
existing hardware under  evaluation.  These  advanced technologies, through improved
                                      15-2

-------
function and performance, and/or cost reductions, could help increase the overall value of
the technology configuration.

Powertrain Package Proforma: is a summary worksheet comparing the key physical
and performance attributes of the technology under study with those of the corresponding
base configuration.

Process Maps:  are  detailed process  flow  charts used to capture the operations and
processes,  and  associated  key manufacturing  variables,  involved in  manufacturing
products at any level (e.g. vehicle, system, subsystem, assembly, component).

P-VCSM  (Powertrain-Vehicle Class Summary Matrix): records the technologies
being evaluated, the applicable vehicle classes for each technology, and key parameters
for vehicles or vehicle systems that have been selected to represent the new technology
and baseline configurations in each vehicle class to be costed.

Quote:  refers to the analytical process of establishing a  cost for a  component  or
assembly.

Sub-subsystem: refers to a group of interdependent assemblies and/or components,
required to create a functioning sub-subsystem. For example, the air induction subsystem
contains several sub-subsystems including the following: turbocharging, heat exchangers,
and pipes, hoses and ducting.

Subsystem: refers to a  group of interdependent sub-subsystems,  assemblies  and/or
components, required to create a functioning subsystem. For example, the engine system
contains several subsystems including the following:  crank drive subsystem, cylinder
block subsystem, cylinder head subsystem, fuel induction subsystem, and air induction
subsystem.

Subsystem CMAT (Cost Model Analysis Templates): is the document used to display
and roll up all the sub-subsystem, assembly and  component incremental costs associated
with  a  subsystem (e.g.  fuel  induction,  air  induction, exhaust),  as  defined by  the
Comparison Bill of Material (CBOM).

Surrogate part: refers to a part similar in fit, form and function as the part required for
the cost analysis. Surrogate parts are sometimes used in the cost analysis when actual
parts are unavailable.  The cost of a surrogate part is considered equivalent to the cost of
the actual part.

System: refers to a  group  of interdependent subsystems, sub-subsystems,  assemblies
and/or components, working together  to create  a vehicle primary function (e.g. engine
system, transmission  system, brake system, fuel system, suspension system).
                                      15-3

-------
System CMAT (Cost Model Analysis Template): is the document used to display and
roll up all the subsystem  incremental costs associated with a  system (e.g. engine,
transmission, steering), as defined by the CBOMs.
                                      15-4

-------
                          APPENDIX A.I Powertrain-Vehicle Class Summary Matrix Excerpt - Case Study #0101
                 TRUCKS  	
                 SPORTS UTILITY VEHCILES
                 CROSSOVER VEHICLES
                 PASSENGER CAR
                                                                                                                                       SMALL
                                                                                                           SMALL
                                                                                                                MIDSIZE
                                              COMPACT
                                          BUDGET/ECONOMY
                                                 MIDSIZE
                                        LARGE
                              Vehicle Classification

                    Generic Vehicle Size
                                       jescnp
 Case
 Study
                      Typical Displaceme its  "liters
                          Typical Hcreep
Technology
   Level
                        Technology Defin
                                              ion
                                 wer "hp"
tion
          New
           Downsized, turbocharged, (asoline
           direct injection (GDI) Engin
                                                               PASSENGER (24)
                                                        LENGEND
                                                     172
                                                     1.6
                                                    10.5
                                                    29/36
                                                     NA
                                                    FBM
                                                    PTS
                                                     DA
                          45QK
                                                                Sibcompact or compact car/typically
                                                                powered by an inline 4 cylinder engine.
                                                                               1.5-2.5
                                              125-175
Technology Specification:
Downsized 14
Twin Scroll Turbo Charger
Solenoid Dl, Side Mount
dWT

Study Model:
2007 Mini Copper S, 1.GL-I4,16V, DOHC,
GDI, Turbo, iWT
                                                                                                             General Information Legend A
                                                                                                             Performance Attributes
                                                                      <1>HP = Horse Power
                                                                      <2>DIS=Displacement "Liters"
                                                                      <3>CR=Compression Ratio (X:l)
                                                                      <4>MPG=Miles per Gallon (City/Highway)
                                                                      <5>%MPG = Estimated improvement in MPG with New Technology
                                                                      Technology Package Availability
<1>TPR5 = Technology Package Reference Source
  -FBM (Existing Production Program, Technology >1 Year in Market)
  -FNB (fJew Production Program, Technology < 1 Year In Market)
  -FCP (FEV Concept Proposal, No Production Technology Available)
<2>CIT = Component Information Type
  -PTS (Majority Parts)
  -PAD (Combination of Parts and Drawings)
  -DWG (Majority Drawing)
  -CPK (Concept Package made from surrogate parts, concept drawings a CAD,
specs, etc)
<3> CAM = Cost Analysis Metiiod
  - DA (Differential Analysis between New and Baseline)
  - SA (Scaled Analysis using cost analysis from other vehicle class(s))
OTHER:
                                                                                                             <1> VOL = Volume used for case study,
                                                        LENGEND
          Base
           Port-fuel injected, 4-valve, naturally
           aspirated gasoline engine
                                                     173
                                                     2.4
                                                    10.5
                                                    21/30
                                                     NA
                                                    FBM
                                                    PTS
                                                     DA
                          450K
Technology Specification:
14
Naturally aspirated
Sequential Multi Point Injection
dWT
                                                                      Study Model:
                                                                      2007 Chrysler Sebring/Dodge Avenger 2.4L,
                                                                      14,16V DOHC, d-WT (GEMAAVorld Engine)
                                                                                                          LENGEND
 221  FNB 750K
                                                                                      Technology Specification:
                                                                                      V6
                                                                      DI = Direct Injection
                                                                      VVT = Variable Valve Timing
                                                                      iWT = Intake Variable Valve Timing
                                                                      d-VVT = Dual Variable Valve Timing (Intake a Exhaust)
                                                                      MDS = Multi Displacement System
EPA Contract: EP-C-07-069 WA1-3
                                                                           A-l, Pagelof 1

-------
                               APPENDIX B.I Powertrain Package Proforma  - Case Study #0101
          CASE STUDY:  01O1
          TECHNOLOGY:
          Downsized, turbocharged, gasoline direct
          injection (GDI) Engine versus Port-fuel
          injected, 4-valve, naturally aspirated gasoline
          engine.
          VEH CLE CLASS:
          Compact/Budget/Economy,
          Passenger Seating: 2-4
          Displacement: 1.5-2.4L
          Horsepower: 125-175
    Item
                          C h aracte ri sti c s
                                                                   Baseline Technology Package
                                                                                                               New Technology Package
 1
...._....
""3""
""•*""
ZC"
...........

""§""
""g""
"IP"
11
1?"
II
"li"
 l¥
 16"
                  .
         Engine Type
                                                  GEMA2.4L
                                                  2"4L"T	
                                                  2360"
                                                               16V
Prince/N14B16
l''lL"DOHC"i47'l6y	
'1598	
Turbgchnrnnd (Twin Scroli, Wastegatej
Aspiration
Compression Natio
  ..........
Variable Valve Timing
Multi Displacement System
ya..rla.^!^..!f1ls'::.e..Ms.n.!fpl^
Bore (mm)
Stroke (mm)
                                                           Naturaliy Aspirated
                                                           M5iTI.ZZ.ZZZZ

                                                           Intake and Exhaust
                                                           No	
                                                           No	
                                                           No	
                                                                                                    .
                                                                                                    Intake Only
                                                                                                    No
                                                                                                    No	
                                                                                                    No	
                                                                                                             77
                                                                                                             M^ZZZZZZZZZZZZZZZZZZZZZ"
                                                                                                             Direct Injection, Side Mounted Solenoid 17 Hole)
                                                                                                             Aluminum
         Block Material
         Cyjinder Head Material
         Cylinder Liner Material
         Connecting Rod Material
                                                  97
                                                  Sequential Electronic Port Fuel Injection
                                                  Aluminum
                                                  Aluminum
                                                  Cast iron
                                                  Forged Steel
                                                                                                    Aluminum
                                                                                                    Cast |run
    IF'
      '"
Intake Manifold Material
Horse Power @ RPM
lorcjue i;ib.ftj gj rpm (n°rm.a!i!
To rq u e (\ b. ft) @. rp rn (ove r b o o st)
                                                  Composite
                                                  f?l HP @ 6000 rpm
                                                  1B6']!b"-ft. @'44Gig"_r^m .......
                                                  N/AZZZZ...ZZZZZZZZ
                                                  4 Speed Autorn^tic (Siebring)
                                                  33l'b""i:s"ebr|nq" L;< -2068)
                                                                                                         Composite
                                                                                                         172 hp @ 5500 rpm
                                                                                                         1^7 !^--fl- & i^yy-Di-iuLi IPITI
     20
     21'"
     22
     23-
     24'
     "25"
     26
     "27"
     ._..
Curb Weight
Fuel E c o n o rn y (C 11 y/H i g h wa y)
                                                                                                              .
                                                                                                    b Sipeed Auto or Manua|
                                                                                                        "
                                                  p'ziv
                                                                                                    29736 (Manual)
                                                                                                    tier'27 §in"5"/"LEV-2 ........
    Fuel Octane
    Appiication(s)

    Manufacturer
    Pjant Locations
    Engine V9|ume
                                                  87
                                                                                                    87/91
                                                                                                    Mini Cooper S, Hard Top
     29
     30"
                                                  Chrysler Sebring, Dodge Avenger, Caliber R/T & Journey,
                                                        .               .
                                                  x2 Dundee Michigan, [x2 South Korea, 1 Shiga Japan)
                                                  Chrysler Projections: 840K
                                                                                                    PSA Peugeot - Citroen
                                                                                                    Warwickshlre","UK	
                                                                                                    20K	
EPA Contract: EP-C-07-069 WAI-3
                                                                 B-l, Pagelof 1

-------
                                APPENDIX C.I Comparison Bill of Materials Excerpt - Case Study #0101,
                                             2007 Mini Cooper 1.6L 14, Turbo, Direct Injection
 APPENDIX C.1,
   Printed:12/8/2009
II
FE¥
H
m
S





























ASY LVL 1


X



























SUBSYSTEM

02

X

X

X

X



03




X









SUB-SUBSYSTEM

ASSEMBLY

SUBASSEMBLY

COMPONENT

GENERAL PART
INFORMATION Technology Level:
NAME/DECRIPTION
n
ra
m
3

Indicates cost analysis potentially required, additional details
required.
technology package, no cost analysis required.
Same as above, however with potential MCR or Technology
Advance Considerations




02

10
A
75

SO



Crai

01


02
A

03





04



Engine Mountings

A Bracket - Engine Mount, Front
Hanging-up Eye
Bracket - Engine Lift

Engine Brackets

Bolti



ikDt

Cran


A Bracket- W re/Belt Guide (Front of Crank Damper )
ngs
A
B
C
wes

kSha
A.


Bolt- Brack
Bolt-
Bolt-

et, Engine Mount, Front
Bracket, Engine Mount, Front of Crank Damper
Lift Eye


tt
Shaft




- Crank

Flywheels
Flywheel Assembly - Engine

Conne
A





ct Rods Assemblies
Connecting Rod, Connecting Rod Cap)
Rod Subassembly - Connecting
A1
A2
B

Bushing - Connecting Rod
Rod-
Connecting
Cap- Connecting Rod

Pistons (Assemblies
Including Pistons, Ring Packs, Piston Pins, Circlips)
new




X

X

X

X
X
X






X








2007 Mini Cooper, 1.6LI4, 16VDOHC, Dl, Turbo, iVVT, 173hp
Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine Vehicle Class: Compact/Economy 2-4 Passenger
N0101 (N = New, 01 = Technology Package, 01 = Vehic e Class )
PART NUMBER





02

02

02

02
02
02



03


03


03
03
03
03






01

10

75

80
80
80



01


02


03
03
03
03


































N0101

N0101

N0101

N0101
N0101
N0101



N0101


N0101


N0101
N0101
N0101
N0101


































01

01

01

01
02
03



01


01


01
02
03
04


QTY/
P.T.





1

1

1

4
1
2



1


1


4
4
4
4


|





Ml

MT

MT

Ml
MT
MT



1


2



MP-3
MP-3
4


CHECK OFF ATTRIBUTES
WHICH ARE DIFFERENT
BETWEEN COMPARISON
TECHNOLOGY PACKAGES
•o
S
m
X
1























X




Material/Finishts)




























Weight/ Size
















X







X
X


Function




























Performance
















X






X
X
X


QTY/P.T.




























33
*




























BRIEF EXPLANATION OF DIFFERENCES
 - Item cost impact assumed
unaffected or negligibly affected by
technology differences


be required for Turbo Dl


NR

NR

NR

NR
NR
NR



Assumption both shafts are made from Micro-Alloyed
Steel such as C38N2 or C38Mod(+Vanadium) Due to
reduced stroke and overall crankshaft length expect cost
reduction


Single Mode Fly Wheel on Mini Cooper Potentially
tuning Would not be able to tune out any degradation due
to bending vibration



rs^±™daehi9herloadin9atpinto
Assumption both have forged connecting rods made from
either C70 or 36MnVS4 Micro Alloy Steel or equivalent
packages, however Turbo Dl rods have thicker cross
section to handle higher loads
Assumption both have forged connecting rods made from
Jther C70 or 36MnVS4 Micro Alloy Steel


Notes: Addititional Items Requiring
Investigation.
















Need to ensure additional features are equal between
New and Base such as Rolled Fillets


May not need to consider for smaller displacements,
but will be mandatory with higher displacement Turbo
Dl Engines








Design modifications for Material
Cost Reductions (MCR's).
















Potential for Base Engine Crank Shaft to be made
from Nodular Cast Iron as cost save


Dual Mass Fly Wheel Required for Dl Engine? Track
as cost Risk?




the rod length to crank radius (UK) ratio should be
3 6 The Chrysler GEMA engine is designed to use i
same platform Thus the 17 R ratios are as follows
2 4L = 2 964, 2 OL = 3 471 and 1 8L is 3 968
Cooper I7R ratio



Additional Technology Advances
or Performance Upgrades
















NA


NA



Connecting rod bushing typical may be replaced
with phosphate coated road end which is a newer
process which offers less design margin What
is cost delta???




File:Appendix C.1 Final Report120809.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                 C.I, Page 1 of 18
  Author: Greg Kolwich
(248) 373-6000 Ext.2411

-------
                                APPENDIX C.I Comparison Bill of Materials Excerpt - Case Study #0101,
                                             2007 Mini Cooper 1.6L 14, Turbo, Direct Injection
 APPENDIX C.1,
   Printed:12/8/2009
II
1 // GENERAL PART
If— fc Hff INFORMATION Technology Level:
it m^~ tSf Study Case*:
H
m
S
































ASY LVL 1

























X







SUBSYSTEM








X





X



X





04



X

X
SUB-SUBSYSTEM








80





85

90

99
A
B
C


Cou

01

02

03
ASSEMBLY





F


Bolt





Seali

SUBASSEMBLY
A
B
C
D
E
OilR
F1
F2
ngs:(
A
B
C
D

COMPONENT
NAME/DECRIPTION
n
m
m
3
Indicates cost analysis potentially required, additional details
required.
technology package, no cost analysis required.
Same as above, however with potential MCR or Technology
Advance Considerations
Piston - Engine, Machined
Ring/Clip -
Pin- Piston
Piston Pin Retainer

Compression Ring - Piston, Top
Compression Ring - Piston, 2nd
ng Subassembly
Spac
sr/Expander/Coil Spring - Oil Ring, Piston
Rail(s) - Oil Ring, Piston
Connecting-Rod Bolts
Bolt -Connector Rod Cap to Connecting Rod
Screw - Sensor Crankshaft to Block
Bolt -Flywh
Dowel/Pin
eel to Crankshaft
Flywheel to Crankshaft

ng Elements

Bearing Elements: Connecting Rod Bearing Shells, Connecting Rod

A
Bearing - Connecting Rod to Crank Shaft
Miscellaneous
Sensor - Crankshaft

Encoder Wheel Assembly - Crankshaft Sensor
Cover - Sensor Crankshaft


nter

Move









ce Systems


d Parts







Static Parts

Drives
„,„









X
X
X
X


X



X
X
X







X

2007 Mini Cooper, 1.6LI4, 16VDOHC, Dl, Turbo, iVVT, 173hp
Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine Vehicle Class: Compact/Economy 2-4 Passenger
N0101 (N = New, 01 = Technology Package, 01 = Vehic e Class )
PART NUMBER

03
03
03
03
03

03
03

03
03
03
03




03

03
03
03









04
04
04
04
04

04
04

80
80
80
80




90

99
99
99








































N0101
N0101
N0101
N0101
N0101

N0101
N0101

N0101
N0101
N0101
N0101




N0101

N0101
N0101
N0101








































01
02
03
04
05

07
08

01
02
03
04




01

01
02
03









QTY/
P.T.

4
8
4
4
4

4
4

8
1
6
1




8

1
1
1









|

5
6
7
8
9

10
11

12
13
14





17

19
20
MP-2(









CHECK OFF ATTRIBUTES
WHICH ARE DIFFERENT
BETWEEN COMPARISON
TECHNOLOGY PACKAGES
•o
S
m
X
1

X





























Material/Finishts)
X






























Weight/ Size
X

X




























Function































Performance
X

X
X
X

X
X









X













QTY/P.T.































33
S
•a































BRIEF EXPLANATION OF DIFFERENCES
 - Item cost impact assumed
unaffected or negligibly affected by
technology differences
Les!™s, addition, machining a, pis,onoro» end ,„
durability and reduction in the potential of micro welding
the top compression ring in the groove Assume same
Clips required for dual bearing slip fit design of pin to
connecting rod 8 piston
Assume same material, Chromium Steel SAE 5115
(1 6MnCr5) Quote mass difference only
Assume that the Turbo Dl will use a more durable, low
friction ring pack versus base For Example, top
Steel or Chrome Versus Cast or Nodular Iron Coating
may be Metallized Molybdenum versus a standard
Manganese Phosphate
Similar to Top Compression Ring

on Turbo Dl versus NA PFI
on Turbo Dl versus NA PFI

NR
NR
NR
NR




For Turbo Dl, Rod Bearings would be upgraded from
AISn20Mn (Federal Mogul A-370) to a AlSnl ONi (Federal
Mogul A-273)

NR
NR
NR





Balancer shafts are not required on Turbo Dl due to
Base NA PFI Engine In this application, the balance
shafts are integrated into the oil pump



Notes: Addititional Items Requiring
Investigation.



Second and Oil Ring) Confirm with Tech Specialist























Oil pump integration isn't typical, may need access
cost risk



Design modifications for Material
Cost Reductions (MCR's).




















Manufacturing process differences between Turbo D
and NA PFI Engines Encoder design has no
association with technology upgrade, purely a MCR
idea regardless of technology










Additional Technology Advances
or Performance Upgrades
Neither design has piston cooling channels
Benchmarking is split, for example BMW 3 OL Dl
Ecotec does not On a current Turbo Dl project,
FEV is evaluating if there is notable spark timing
advantage with the addition of piston cooling
channels






























File:Appendix C.1 Final Report120809.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                 C.I, Page 2 of 18
  Author: Greg Kolwich
(248) 373-6000 Ext.2411

-------
                                APPENDIX C.I Comparison Bill of Materials Excerpt - Case Study #0101,
                                             2007 Mini Cooper 1.6L 14, Turbo, Direct Injection
 APPENDIX C.1,
   Printed:12/8/2009






FE¥
H
m
S































ASY LVL |
































SUBSYSTEM

X

X

X

X

X

X

X

X














SUB-SUBSYSTEM

65

70

75

80

85

90

95

99



01
A




02

03
A

ASSEMBLY

Adap

Pipe

Brae

Conn

Seal!

Bear

Tool

Misc



CO
^
en

ters

, Ho

 - Item cost impact assumed
unaffected or negligibly affected by
technology differences




















Cost drivers between Turbo Dl and NA PFI Engines
and made from Diecast Hypereutectic Aluminum (B390)
2 Turbo block smaller overall due to smaller bore size
Base NA PFI (Base Bore 88, Turbo GDI Bore 77), would
yield aweight savings of approx 3 5kg Will confirm with
3 Added diecast complexity and machining to incorporate
features such as inter -bore cooling. Turbo cooling 8 oil
supply and return lines, piston cooling jets, etc
Reference Cylinder Block Assembly
Reference Cylinder Block Assembly
Both Engines have Cast cylinder liners Calculate cost
differential as a result of smaller liners for Turbo Dl


Captured below in Bed Plate Assembly

Both Engines Can operate using either a bedplate, cross-
bolted mains (rare on in-line engines), ladder caps, and
two-bolted main bearing caps The NVH characteristics
degrade in the same order as above For a clean sheet 14,
bedplate construction would likely be the best option for
will assume both engines have bed plate design and thus
only compare size/weight difference Material Diecast
Hyper eutec tic Aluminum (B390)
Reference Bed Plate Assembly
Notes: Addititional Items Requiring
Investigation.




















sand cast blocks to diecast block Initially higher
pays for itself
Need to verify material of block


Assume Nodular Cast Iron for both Engines, Spec?




Need to verify material spec of bedplate and caps

Design modifications for Material
Cost Reductions (MCR's).






























Additional Technology Advances
or Performance Upgrades






























File:Appendix C.1 Final Report120809.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                 C.I, Page 3 of 18
  Author: Greg Kolwich
(248) 373-6000 Ext.2411

-------
                                APPENDIX C.I Comparison Bill of Materials Excerpt - Case Study #0101,
                                             2007 Mini Cooper 1.6L 14, Turbo, Direct Injection
 APPENDIX C.1,
   Printed:12/8/2009
II
1 // GENERAL PART
If— fc Hff INFORMATION Technology Level:
it m^~ tSf Study Case*:
H
m
S








































ASY LVL |









































| SUBSYSTEM






X



















X








X



1 SUB-SUBSYSTEM



04


80



















85




90



99



1 ASSEMBLY
A1.1
I SUBASSEMBLY
I COMPONENT
NAME/DECRIPTION
n
m
m
"71
AJ
Indicates cost analysis potentially required, additional details
required.
technology package, no cost analysis required.
Same as above, however with potential MCR or Technology
Advance Considerations
Bed Plate Subassembly - Cast
A1.1.1

Pisto



n Co
A
B
Bearing - Bolt Through - Insert, Steel

>lmg


Squirter-Oil, Piston Cooler
Bolt-
Piston Cooler Valve/Retainer (Check Valve?)
Boltings/Dowel Pins/Plugs/Studs Etc








A
B
C
D
b


Screw - Windage Tray to Bed Plate
Bolt-
Bolt-
Bolt-
Bed Plate to Block, Main (Crank Bearings Approx 3.5")
Bed Plate to Block (Perimeter Approx. 1 .5")
Bed Plate to Block ( Perimeter Approx 2.5")
Screw - Sensor, Knock






Dowel Pins/Plugs/Studs - Cylinder Block





A
B
C
D

Plugs
- Oil Galley
Pin/Dowel - Locator Cylinder Block to Head
Pin/Dowel
Pin/Dowel
Locator Cylinder Block to Bedplate
Block & Bed Plate (Flywheel Side), Accessory

Dowel Pins/Plugs/Studs - Bed Plate




Seali




Bear



Misc
A
B

A
B
C

ngbl
A
B
C

ng b
A
B
C
Plug
Stud
Non
Turbo Oil Indicator, Bedplate
*1 - Accessory, Bed Plate (CC. Cat. Conv. Mnt)
Stud #2 - Accessory, Bed Plate

sments
Seal
Seal
Crankshaft Front
Crankshaft Rear
Gasket/Seal - Block to Bed Plate (Deposit)

ements: Crankshaft bearing shells
Bearing - Crankshaft, Block 1/2 Bearing (Topw. Lub. Pass.)
Bearing/Shim - Crankshaft Thrust
Bearing - Crankshaft, Block 1/2 Bearing (Bottom)
3llaneous


Windage Tray - Bed Plate
Sensor - Knock
C Cap-
Bed Plate Rear Main Bolts
„,„








X
X
X
X
X
X


X
X
X
X


X
X
X


X
X
X






X
X
X
2007 Mini Cooper, 1.6LI4, 16VDOHC, Dl, Turbo, iVVT, 173hp
Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine Vehicle Class: Compact/Economy 2-4 Passenger
N0101 (N = New, 01 = Technology Package, 01 = Vehic e Class )
PART NUMBER

05
05


05
05


05
05
05
05
05



05
05
05
05


05
05
05


05
05
05


05
05
05

05
05
05
03
03


04
04


80
80
80
80
80



80
80
80
80


80
80
80


85
85
85


90
90
90

99
99
99







































N0101
N0101


N0101
N0101


N0101
N0101
N0101
N0101
N0101



N0101
N0101
N0101
N0101


N0101
N0101
N0101


N0101
N0101
N0101


N0101
N0101
N0101

N0101
N0101
N0101







































02
03


01
02


01
02
03
04
05



10
11
12
13


20
21
22


01
02
03


01
02
03

01
02
04
QTY;
P.T.

1
5


4
4


4
10
16
2
1



2
2
2
2


1
2
2


1
1
1


5
2
5

1
1
1
|





3
4


5
6
7
8
9














10
11



13
14
13

15
16
MP-16
CHECK OFF ATTRIBUTES
WHICH ARE DIFFERENT
BETWEEN COMPARISON
TECHNOLOGY PACKAGES
•o
S
m
X
1




X
X

































Material/Finish(s)







































Weight/ Size

X





































Function




X
X

































Performance |







































QTY/P.T. |







































33
•3







































BRIEF EXPLANATION OF DIFFERENCES
 - Item cost impact assumed
unaffected or negligibly affected by
technology differences
Reference Bed Plate Assembly
Assume same material only, size /weight difference only


Required for Turbo Dl
Required for Turbo Dl


NR
Assuming both engines would have Bed Plate design with
same amount of main bear cap thru bolts
Assuming both engines would have Bed Plate design will
required Any difference would have negligible cost
impact
Assuming both engines would have Bed Plate design will
required Any difference would have negligible cost
impact
NR



NR
NR
NR
NR


Clean sheet design could eliminate
NR
NR


NR
NR
NR


For Turbo Dl, main bearings would be upgraded from
AISn20Mn (Federal Mogul A-370) to aAISn6Si4 (Federal
Mogul A-590)
Material Upgrade -TBD
For Turbo Dl, main bearings would be upgraded from
AISn20Mn (Federal Mogul A-370) to aAISn6Si4 (Federal
Mogul A-590)

NR
NR
NR
Notes: Addititional Items Requiring
Investigation.

Need material spec of inserted bearing caps







Check to see if size and grade are compatible between
two engines
Reasoning larger perimeter on base versus urbo Dl,
however greater loading on Turbo Dl versus ase,
equivalent
Reasoning larger perimeter on base versus urbo Dl,
however greater loading on Turbo Dl versus ase,
equivalent





















Talk to Steve on possible material options





Design modifications for Material
Cost Reductions (MCR's).







































Additional Technology Advances
or Performance Upgrades







































File:Appendix C.1 Final Report120809.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                 C.I, Page 4 of 18
  Author: Greg Kolwich
(248) 373-6000 Ext.2411

-------
                                APPENDIX C.I Comparison Bill of Materials Excerpt - Case Study #0101,
                                             2007 Mini Cooper 1.6L 14, Turbo, Direct Injection
 APPENDIX C.1,
   Printed:12/8/2009
II
\\// GENERAL PART ~-|" W«»-
If— fc Hff INFORMATION Technology Level:
If *^~ tSf Study Case*:
H
m
S
























ASY LVL I
























NAME/DECRIPTION
| SUBSYSTEM


06












X






X
I SUB-SUBSYSTEM


Cvli

01
A



02





03

06




07
I ASSEMBLY


1 SUBASSEMBLY


U
Ira
im
8 •


Indicates cost analysis potentially required, additional details
required.
technology package, no cost analysis required.
Same as above, however with potential MCR or Technology
Advance Considerations


ider Heads - Subsystem

Cylinder Head
Cylinder Head Assembly - Machined w. Studs, Valves, etc.



Valve





Guid

A1
A1.1

Guic
A
B
C
D

Cylinder Head - Machined w/o. Studs, Valves, etc.
Cylinder Head Subassembly - Cast


es. Va ve Seats
Guide - Intake Valve
Guide - Exhaust Valve
Seat - ntake Valve
Seat - Exhaust Valve


es for Valve Train

Camshaft Bear ng Housing




A
B
C

Cap-Bearing Camshaft, Intake, Phaser Type
Cap-Bearing Camshaft, Intake Standard
Cap, Head (Fuel Pump & Vacum Mount)


Cam Shaft Speed Sensor
„,„
X









X
X




X

X
X



2007 Mini Cooper, 1.6LI4, 16VDOHC, Dl, Turbo, IWT, 173hp
Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine Vehicle Class: Compact/Economy 2-4 Passenger
N0101 (N = New, 01 = Technology Package, 01 = Vehic e Class )
PART NUMBER






06
06
06


06
06
06
06




06
06
06







01
01
01


02
02
02
02




06
06
06






























N0101
N0101
N0101


N0101
N0101
N0101
N0101




N0101
N0101
N0101






























01
02
03


01
02
03
04




01
02
03


QTY/
P.T.






1
1
1


8
8
8
8




1
9
1


1
tt






1




MT
MT
MT
MT




2
3
4


CHECK OFF ATTRIBUTES
WHICH ARE DIFFERENT
BETWEEN COMPARISON
TECHNOLOGY PACKAGES
•o
S
m
X
1




















X


Material/Finishts)


















X
X



Weight/ Size





X












X
X



Function





X

















Performance |





X

















QTY/P.T. |























33
5
•3























BRIEF EXPLANATION OF DIFFERENCES
 - Item cost impact assumed
unaffected or negligibly affected by
technology differences





Cost drivers between Turbo Dl and NA PFI Engines
1 Assume material for Turbo head A356 T6 versus Base
A31 9 T7 A356 is required for high temperature strength
and heat conductivity (better spark timing)
2 Turbo head smaller overall due to smaller bore size
Approx 46 mm shorter in length
3 Added diecast complexity and machining to incorporate
HP fuel rail and fuel pump mounting etc
Reference Cylinder Head Assembly
Reference Cylinder Head Assembly


NR
NR
ntake Seats would need to be upgraded - typical upgrade
would be from Brico 31 0 to Corno! 207
zxhaust seats would need to be upgraded - typical
upgrade would be from MS25Cu to AR20




Cost drivers between Turbo Dl and NA PFI Engines
1 Assume both Base and Turbo are made from same
material, either Diecast Aluminum or Power Metal
3 Machining considered equivalent, assumption both
engines have dWT
Cost drivers between Turbo Dl and NA PFI Engines
1 Assume both Base and Turbo are made from same
material, either Diecast Aluminum or Power Metal
2 Compare mass difference between both sets of caps
Cap unique to Turbo Dl, required for HP fuel pump and


Notes: Addititional Items Requiring
Investigation.


















Negligible Weight Difference
Negligible Weight Difference
Same as above


Design modifications for Material
Cost Reductions (MCR's).























Additional Technology Advances
or Performance Upgrades























File:Appendix C.1 Final Report120809.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                 C.I, Page 5 of 18
  Author: Greg Kolwich
(248) 373-6000 Ext.2411

-------
                                APPENDIX C.I Comparison Bill of Materials Excerpt - Case Study #0101,
                                             2007 Mini Cooper 1.6L 14, Turbo, Direct Injection
 APPENDIX C.1,
   Printed:12/8/2009
M
IFE¥
H
m
S



































ASY LVL I




































SUBSYSTEM





























07




SUB-SUBSYSTEM
A
20
A




SO

















85



Valv

01


ASSEMBLY
SUBASSEMBLY
COMPONENT
GENERAL PART
INFORMATION Technology Level:
NAME/DECRIPTION
•T-l Indicates cost analysis potentially required, additional details
_J required.
^LJ technology package, no cost analysis required.
Same as above, however with potential MCR or Technology
"TT1 Advance Considerations
AiJ
Sensor - Cam Shaft, Speed
Cylinder Head Covers
Cover Assembly-
A1



PCV Subas
A2
A3
A4
Cap -
nser
nser
Cylinder Head Assembly
sembly (Built into cover)
Oil Fill
- Fastener, Torque Loss
- Threaded, Brass
Boltings: Cylinder Head, Cylinder Head Cover, Manifold
Boltings & Screws General






Dow









Seall





Inlet


A
B
C
D
E


B
C
D
b
F
G
H
I

igEle
A
B
C
Bolt-
Cap Bearing, Camshaft
Bolt & Washer Assembly - Cylinder Head to Block M1 0X1 50
Bolt & Washer Assembly - Cylinder Head to Block M8x96
Bolt & Washer Assembly - Cylinder Head to Block M8x35
Bolt-
Cam Sensor


Bolt-
s/Studs - Cylinder Head
Manifold, Intake
Pipe Plug -
Core Plug - Press Fit (01 8.5 Top)
Core Plug -Torx (15)
Cup Plug - Press Fit (040)
Core Plug - Press Fit (036 Top)
Core Plug - Ball, Adjuster
Dowel - Cap, Bearing Camshaft

merits
Cylinder Head, Cylinder Head Cover, ....
Gasket - Cylinder Head to Block
Seal
Sea
Cover to Cylinder Head, Perimeter
Cover to Cylinder Head, Inner


Valves
A

Valve
- Intake

„,„
X

X

X
X
X



X
X
X
X


X
X
X
X
X
X
X
X



X
X





2007 Mini Cooper, 1.6LI4, 16VDOHC, Dl, Turbo, iVVT, 173hp
Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine Vehicle Class: Compact/Economy 2-4 Passenger
N0101 (N = New, 01 = Technology Package, 01 = Vehic e Class )
PART NUMBER

06

06
06
06
06
06


06
06
06
06
06


06
06
06
06
06
06
06
06


06
06
06



07

07

20
20
20
20
20


80
80
80
80
80


80
80
80
80
80
80
80
80


85
85
85



01



































N0101

N0101
N0101
N0101
N0101
N0101


N0101
N0101
N0101
N0101
N0101


N0101
N0101
N0101
N0101
N0101
N0101
N0101
N0101


N0101
N0101
N0101



N0101



































01

01
02
03
04
05


01
02
03
04
05


11
12
13
14
15
16
17
18


01
02
03



01

QTY;
P.T.

1

1
1
1
13
3


23
10
2
1
1


5






'?


1
1
1



8

|

5

6






7
8
9
10
11












12
13
14



1

CHECK OFF ATTRIBUTES
WHICH ARE DIFFERENT
BETWEEN COMPARISON
TECHNOLOGY PACKAGES
•o
S
m
X
1


































Material/Finish(s)
































X

Weight/ Size


























X







Function


































Performance


























X





X

QTY/P.T.


































33
•3


































BRIEF EXPLANATION OF DIFFERENCES
 - Item cost impact assumed
unaffected or negligibly affected by
technology differences
NR


Crankcase vent system for Dl engine is more difficult and
requires better oil separation The cost associated with
upgraded PCV system is addressed in section 1 7 below





4 Extra Required for Extra Cap
NR Same QTY, Size and Property Class used in both
Engine Designs
NR - Design choice based on integrating timing cover into
block and head versus stand alone cover
block and head versus stand alone cover
NR


NR
NR
NR
NR
NR
NR
NR
NR


Base Engine 2 layer MLS gasket for standard engine
Turbo Dl would require 3 layer MLS gasket
NR
NR



Intake valves would need to be upgraded - typical
upgrade would be from nitrided JIS SUH11 (Fe-1 5Si,
85Cr, 0 5C) toSilichrome

Notes: Addititional Items Requiring
Investigation.


































Design modifications for Material
Cost Reductions (MCR's).


































Additional Technology Advances
or Performance Upgrades


































File:Appendix C.1 Final Report120809.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                 C.I, Page 6 of 18
  Author: Greg Kolwich
(248) 373-6000 Ext.2411

-------
                                APPENDIX C.I Comparison Bill of Materials Excerpt - Case Study #0101,
                                             2007 Mini Cooper 1.6L 14, Turbo, Direct Injection
 APPENDIX C.1,
   Printed:12/8/2009









n
1 // GENERAL PART
If— fc Hff INFORMATION Technology Level:
it m^~ tSf Study Case*:
H
m
S


























ASY LVL |



























SUBSYSTEM



X


X




X











X

SUB-SUBSYSTEM
02


03


04


C

05
A
B

06
A


B



08
A
ASSEMBLY
Oil tit


Valve


Sprh


SUBASSEMBLY
tVah
A

Spri
A

g He
A
B
COMPONENT
es
Valvs

ngs
NAME/DECRIPTION
n
m
m
3
ndicates cost analysis potentially required, additional details
required.
technology package, no cost analysis required.
Same as above, however with potential MCR or Technology
Advance Considerations

- Exhaust




Spring - Va ve

ainer
Seat

s, Co

tiers, Spring Seats
Spring Upper
Retainer - Valve Spring
Seal-Seat Subassembly - Spring Lower (Seat, Seal and Coil Spring)



Valve Actuation
Lash Adjusters,


Elements: Rockers, Finger Followers, Hydraulic
Adjuster - Hydraul c,

Follower- Roller Finger



Camshafts




Camshaft Assembly - Intake Machined


A1
A2
Camshaft -
Intake Machined
Encoder Wheel - Intake
Camshaft Assembly - Exhaust Machined



B1
B2

Camshaft -
Exhaust Machine
Encoder Wheel - Exhaust



Camshaft Phaser and/or Cam Sprockets
Cam Phaser Assembly- Intake
„,„




X


X
X
X


X
X




X


X


X


















2007 Mini Cooper, 1.6LI4, 16VDOHC, Dl, Turbo, iVVT, 173hp
Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine Vehicle Class: Compact/Economy 2-4 Passenger
N0101 (N = New, 01 = Technology Package, 01 = Vehic e Class )
PART NUMBER


07


07


07
07
07


07
07


07
07
07
07
07
07


07

02


03


04
04
04


05
06


06
06
06
06
06
06


08


























N0101


N0101


N0101
N0101
N0101


N0101
N0101


N0101
N0101
N0101
N0101
N0101
N0101


N0101


























01


01


01
02
03


01
02


01
02
03
10
11
12


01
QTY;
P.T.


8


16


16
32
16


16
16


1
1
1
1
1
1


1
|


2


3


4
5
6


7
8


9


10




11
CHECK OFF ATTRIBUTES
WHICH ARE DIFFERENT
BETWEEN COMPARISON
TECHNOLOGY PACKAGES
•o
S
m
X
1

























Material/Finish(s)

X























Weight/ Size
















X


X





Function
















X


X





Performance

X























QTY/P.T.

























33
•3

























BRIEF EXPLANATION OF DIFFERENCES
 - Item cost impact assumed
unaffected or negligibly affected by
technology differences

Exhaust valves would need to be upgraded - typical
upgrade would be from nitrided JIS SUM 35 (Fe, 9Mn,
21O4NI, 05C and 04N) to Inconel head and Silichrome
stem Exhaust valves on Mini Cooper Turbo Dl are
Sodium filled as well This design approach is not
considered preferred and thus will note be included in cost
analysis


NR


NR
NR
NR


NR
NR


1 Length of Camshaft reduced, mass reduction
3 Material Assumption, both Base and Turbo Dl made
from Nodular Cast Iron, Chilled
Reference Camshaft Assembly- In take
NR
1 Length of Camshaft reduced, mass reduction
2 Feature required to drive high pressure fuel pump for Dl
3 Material Assumption, both Base and Turbo Dl made
from Nodular Cast Iron, Chilled
Reference Camshaft Assembly-Exhaust
NR


Assumption Base and New Technology Packages have
Dual WT
Notes: Addititional Items Requiring
Investigation.

























Design modifications for Material
Cost Reductions (MCR's).

























Additional Technology Advances
or Performance Upgrades

























File:Appendix C.1 Final Report120809.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                 C.I, Page 7 of 18
  Author: Greg Kolwich
(248) 373-6000 Ext.2411

-------
                                APPENDIX C.I Comparison Bill of Materials Excerpt - Case Study #0101,
                                             2007 Mini Cooper 1.6L 14, Turbo, Direct Injection
 APPENDIX C.1,
   Printed:12/8/2009







FE¥
H
m
S





































ASY LVL |












X

























SUBSYSTEM

X





X









X


X







X


X

X

X
SUB-SUBSYSTEM
B
80





99
A
B

ASSEMBLY
SUBASSEMBLY
COMPONENT
Sprocket - Cam
Analysis)


II
GENERAL PART
INFORMATION Technology Level:
NAME/DECRIPTION
n
ra
m
3

Indicates cost analysis potentially required, additional details
required.
technology package, no cost analysis required.
Same as above, however with potential MCR or Technology
Advance Considerations
ust (Replaced with Exhaust Cam Phaser for
Boltings





A
B


E
Miscellane
Control Va
Bolt-
Bolt-


Cam Phaser, Camshaft, Intake
Sprocket, Camshaft, Exhaust




Bolt-Flange -Control Valve Oil To Cylinder Head
ous


ve -Oil, Intake VVT
analysis)




01



02
A

03
A


B



05


06

65

80
Jll, E


xhaust vv 1 ( Added into assumption tor cost



Tim ng Wheels (Sprockets)



A
B

Sprocket -
Sprocket -

Tensioners


Crankshaft, Timing Drive
Crankshaft, Oil Pump Drive


Tensioner - Camshaft Timing



Guides




Tensioner Arm Assembly - Timing Chain, Lower


A1
A2
Tensioner Arm - RHS
Tensioner Arm - LHS
Guide Assembly



Belts


Cove

B1
B2

Cha
A

- Tim ng Chain, Upper Cam to Cam
Bracket - Mounting
Guide Rail

ns


-Upper


Chain Assembly - Timing

s





Adaptors
A Nose
- Crankshaft, Timing Sprocket & Accessory Pulley
Boltings

X

X
X
X
X
X

X
X
X




X


X


X


X




X


X

X



















2007 Mini Cooper, 1.6LI4, 16VDOHC, Dl, Turbo, iVVT, 173hp
Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine Vehicle Class: Compact/Economy 2-4 Passenger
N0101 (N = New, 01 = Technology Package, 01 = Vehic e Class )
PART NUMBER

07

07
07


07

07
07




08
08


08


08


08




08




08

08

80
80


80

99





01
01


02


03


03




05




65





































N0101

N0101
N0101


N0101

N0101
N0101




N0101
N0101


N0101


N0101


N0101




N0101




N0101





































20

01
02


20

01





01
02


01


01


10




01




01

QTY;
P.T.

1

1
1


1

1
1




1
1


1


1


1




1




1

|

12

13
14
15
16
17

18





1
2


3


4


5




6




7

CHECK OFF ATTRIBUTES
WHICH ARE DIFFERENT
BETWEEN COMPARISON
TECHNOLOGY PACKAGES
•o
S
m
X
1




































Material/Finish(s)




































Weight/ Size





























X






Function




































Performance














X














X






QTY/P.T.




































33
•3














X





















BRIEF EXPLANATION OF DIFFERENCES
 - Item cost impact assumed
unaffected or negligibly affected by
technology differences

have Dual WT Thus exhaust sprocket is replaced with

NR
NR


NR

NR
NR




Smart sprocket required to help counter act cyclic loading
effects from Vacuum Pump and High Pressure Pump
Surrogate Design


NR


NR


NR




load created by the vacuum pump and high pressure fuel
pump




NR

Notes: Addititional Items Requiring
Investigation.














Cost impact approx $1 -$2/Engine Note, cost impact
is associated with royally fee, no manufacturing cost
impact














Turbo Dl has Roller Chain and NA PFI Engine has
Inverted Tool/Silent Chain? Verify and determine if
there is cost impact Perhaps MCR on Base?






Design modifications for Material
Cost Reductions (MCR's).




































Additional Technology Advances
or Performance Upgrades




































File:Appendix C.1 Final Report120809.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                 C.I, Page 8 of 18
  Author: Greg Kolwich
(248) 373-6000 Ext.2411

-------
                                APPENDIX C.I Comparison Bill of Materials Excerpt - Case Study #0101,
                                             2007 Mini Cooper 1.6L 14, Turbo, Direct Injection
 APPENDIX C.1,
   Printed:12/8/2009







ii
1 // GENERAL PART
If— fc Hff INFORMATION Technology Level:
If m^~ tSf Study Case*:
H
m
S

































ASY LVL |







X

























NAME/DECRIPTION
SUBSYSTEM






09

X




X


X

X


X

X

X

X




SUB-SUBSYSTEM








01


C

02
A

03

06


65

70

75

80




ASSEMBLY






!SSC

Pulle


SUBASSEMBLY
A
B
C
D


m FT! ndicates cost analysis potentially required, additional details
•Z. LJ required.
E ' * technology package, no cost analysis required.
O Same as above, however with potential MCR or Technology
|jy| ance
Bolt - Crankshaft Nose
Washer - Crankshaft Nose
Bolt - Guide, Timing Chain Upper to cylinder head.
Bolt - Tension Arm Subassembly to Block


rv Drives


fs
A
B
Pulley/Damper Assembly - Crankshaft
Wheel - Drive, Coolant Pump (Friction Driven)

X
X
X
X
X




X
•
I
Actuating Drive Assembly - Drive Pulley & Water Pump X
y



Tensioners | |
Tensioner Assembly - Accessory Drive



Guides

Belts


A

Belt - Accessory Drive

Adaptors

Pipes, Hoses, Ducting

Brackets

Bolting




A
B
C
D
Bolts - Pulley Crankshaft
Bolts - Drive Gear/Wheel Coolant Pump
Bolt - Tensioner Assembly (Secures to Alternator)
Bolt - Actuating Drive Assembly - Drive Pulley & Water Pump
X


X

X


X

X

X

X
1
X
•


















2007 Mini Cooper, 1.6LI4, 16VDOHC, Dl, Turbo, iVVT, 173hp
Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine Vehicle Class: Compact/Economy 2-4 Passenger
N0101 (N = New, 01 = Technology Package, 01 = Vehic e Class )
PART NUMBER

08
08
08
08





09
09
09


09




09








09
09
09
09
80
80
80
80





01
01
01


02




06








80
80
80
80
































N0101
N0101
N0101
N0101





N0101
N0101
N0101


N0101




N0101








N0101
N0101
N0101
N0101
































01
02
03
04





01
02
03


01




01








01
02
03
04
QTY;
P.T.

1
1
1
3





1
1
1


1




1








3
3
1
3
|

8
9
10
11





1
2
3


4




5








6
7
8
9
CHECK OFF ATTRIBUTES
WHICH ARE DIFFERENT
BETWEEN COMPARISON
TECHNOLOGY PACKAGES
•o
S
m
X
1
































Material/Finish(s)
































Weight/ Size









X






















Function
































Performance









X






















QTY/P.T.
































33
•3
































BRIEF EXPLANATION OF DIFFERENCES
 - Item cost impact assumed
unaffected or negligibly affected by
technology differences
NR
NR
NR
NR





NR - Turbo Dl has single mode damper similar to Base
NA PFI Engine
NR
NR


NR




NR








NR
NR
NR
NR
Notes: Addititional Items Requiring
Investigation.









Dual mode dampers (DMD) reduce vibration in two
directions DMD's are typical for Turbo Dl Engines
DMDs contain two separate dampers, one is for
torsional crankshaft vibration (twisting) and the other is






















Design modifications for Material
Cost Reductions (MCR's).
































Additional Technology Advances
or Performance Upgrades










If mechanical water pump + small auxiliary Turbo
pump was replaced with single larger electric
water , this item would be removed and cost
savings put towards electric pump
pump was replaced with single larger electric
water , this item would be removed and cost
savings put towards electric pump

















pump was replaced with single larger electric
savings put towards electric pump

If mechanical water pump + small auxiliary Turbo
pump was replaced with single larger electric
water , this item would be removed and cost
savings put towards electric pump
File:Appendix C.1 Final Report120809.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                 C.I, Page 9 of 18
  Author: Greg Kolwich
(248) 373-6000 Ext.2411

-------
                                APPENDIX C.I Comparison Bill of Materials Excerpt - Case Study #0101,
                                             2007 Mini Cooper 1.6L 14, Turbo, Direct Injection
 APPENDIX C.1,
   Printed:12/8/2009
M
1 // GENERAL PART
If— fc Hff INFORMATION Technology Level:
it m^~ tSf Study Case*:
H
m
S









































ASY LVL 1










































SUBSYSTEM
10




X


X


X


X

X





X


X












X

SUB-SUBSYSTEM
Inta

01
A

02
A

03


05
A

65

70





75


SO












85

ASSEMBLY
ceS,

SUBASSEMBLY
COMPONENT
stems
NAME/DECRIPTION
n
m
m
a
Indicates cost analysis potentially required, additional details
required.
technology package, no cost analysis required.
Same as above, however with potential MCR or Technology
Advance Considerations


Intake Manifolds
Mani old Assembly - Intake

Air Filter Box
AirF

Air h


ter Box Assembly

Iters
A


Air Filter




Throttle Housing Assembly; including Supplies
Throttle Body Assembly - Electronically Controlled

Adap

Pipe





Brae


Bolt












Seali


ters: Flanges for Port Shut-off

, Hoses, Ducting





rets
A

ngX
A
B
C
D
b
F
G
H
I
J
K

A
B
C
D


Tube
lube
- Elbow, Air Intake to Filter Box
- Flex, Air Intake to Elbow
Coupler - Tube Flex to Vehicle Mount
Tube
-Air Filter Box via MFS to Turbo Inlet


Bracket - Support, Intake Manifold

Clamps
Nut-
Nut-
ntake
Jrack
Bolt- Brack
Bolt-
Bolt -
Manifold Assembly to Cylinder Head
3t, Intake Manifold Support
et, Intake Manifold Support
Throttle Body to Intake Manifold
Manifold Absolute Pressure
Grommet -
Bolt-
Airh
Air Filter Box to Intake Manifold Mounting
ter Box To Intake Manifold
Duplicate Part to "F"
Inser
- Air Filter - Intake Torque Loss Prevention
Clamp - Tube, Mass Air Flow Outlet
Clamp - Tube, Turbo Inlet

ng Elemen

s


A | Gasket-Intake Manifold, Main Flange to Cylinder Head
new






X


X


X


X

X
X
X
X


X


X
X
X
X
X
X
X
X
X
X
X


X
2007 Mini Cooper, 1.6LI4, 16VDOHC, Dl, Turbo, iVVT, 173hp
Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine Vehicle Class: Compact/Economy 2-4 Passenger
N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )
PART NUMBER




10


10


10


10




10
10
10
10


10


10
10
10
10
10
10
10

10
10
10


10



01


02


03


05




70
m
70
70


75


80
80
80
80
80
80
80

80
80
80


85











































N0101


N0101


N0101


N0101




N0101
N0101
N0101
N0101


N0101


N0101
N0101
N0101
N0101
N0101
N0101
N0101

N0101
N0101
N0101


N0101











































01


01


01


01




01
02
03
04


01


01
02
03
04
05
06
(11

09
10
11


01
QTY;
P.T.




1


1


1


1




1
1
1
1


1


5
2
1
3
1
3
1

1
1
1


1
|




1


2


3


4




5
6
7
8


9


10
11
12
13
14
15
16
17
18
19
20


22
CHECK OFF ATTRIBUTES
WHICH ARE DIFFERENT
BETWEEN COMPARISON
TECHNOLOGY PACKAGES
•o
S
m
X
1








































Material/Finish(s)








































Weight/ Size



X




































Function



X




































Performance



X




































QTY/P.T.








































33
•3








































BRIEF EXPLANATION OF DIFFERENCES
 - Item cost impact assumed
unaffected or negligibly affected by
technology differences



Assumptions Intake manifold of Turbo Dl is approximate^
half size of NA PFI Engine Also base engine has intake
tumbler to improve fuel atomization which helps meet cold
start and idling targets Although FEV feels additional
tumbler device may be avoided with proper intake manifold
design and head design


NR


NR


NR




NR
NR
NR
NR - This would go direct to ETB on Base Engine


NR


NR
NR
NR
NR
NR
NR
NR

NR
NR
NR - This would clamp would be used to secure inlet tube
directly to ETB


NR
Notes: Addititional Items Requiring
Investigation.



Long runner intake manifolds are required in NA




































Design modifications for Material
Cost Reductions (MCR's).








































Additional Technology Advances
or Performance Upgrades








































File:Appendix C.1 Final Report120809.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                 C.I, Page 10 of 18
  Author: Greg Kolwich
(248) 373-6000 Ext.2411

-------
                                APPENDIX C.I Comparison Bill of Materials Excerpt - Case Study #0101,
                                             2007 Mini Cooper 1.6L 14, Turbo, Direct Injection
 APPENDIX C.1,
   Printed:12/8/2009
II
1 // GENERAL PART
If— fc Hff INFORMATION Technology Level:
it m^~ tSf Study Case*:
H
m
S





































ASY LVL 1






































SUBSYSTEM


X



11


















X










SUB-SUBSYSTEM


99
A
B

Fue.

01
A
A1
A2

04
A
07
A
m
A
B
B1
B2



75
D

SO







ASSEMBLY



SUBASSEMBLY
B
C

COMPONENT
NAME/DECRIPTION
n
m
LU
Indicates cost analysis potentially required, additional details
required.
technology package, no cost analysis required.
Same as above, however with potential MCR or Technology
Advance Considerations
Gasket-Electronic Throttle Body to Intake Manifold
Gasket - Mass Flow Sensor (MFS) - Air Filter Box
Miscellaneous
Sensor - Mass Flow M
ster, HotWire
Sensor - Manifold Absolute Pressure (MAP)



Fuel Rails
Fuel Rail w
Fuel Rail -
High Pressure Sensor Assembly
High Pressure
Sensor - Fuel, High Pressure

Fuel Injectors
Fuel Injector Assembly - Solenoid, 7 Hole
Fuel Injection Pumps
Fuel Pump
Pipe
, Hos
- High Pressure w. Vol.Cotrol Valve (Driven-Off Intake Cam)
es: Low Pressure, High Pressure
Pipe Assembly - Fuel,
High Pressure, Pump to Rail
Tube & Hose Fuel LP & Purge Assembly
Hose
Hose



-Hue
-Hue
B3
B4

Feed, Low Pressure
, Purge
Retainer - Fuel Hoses to Bracket, LP & Purge
Retainer- Fuel Hose, LP & Purge

Brackets
Bracket Assembly - Tu

Bolti
A
B
C
D
b
F

be, Fuel Low Pressure and Purge

ng
Bolt-
Bolt-
Fuel Rail

Fuel Pump
Retainer - Fuel Injector
Washer, Retainer - Fuel Injector
O-ring Retainer,
Spac
Fuel Injector
sr - Retainer, Fuel Injector

„,„
X
X

X
X














X
X
X
X
X


X









2007 Mini Cooper, 1.6LI4, 16VDOHC, Dl, Turbo, iVVT, 173hp
Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine Vehicle Class: Compact/Economy 2-4 Passenger
N0101 (N = New, 01 = Technology Package, 01 = Vehic e Class )
PART NUMBER

10
10

10
10




11
11
11


11

11

11
11
11
11
11
11


11


11
11
11
11
11
11

85
85

99
99




01
01
01


04

07

70
70
m
70
70
70


75


80
80
80
80
80
80





































N0101
N0101

N0101
N0101




N0101
N0101
N0101


N0101

N0101

N0101
N0101
N0101
N0101
N0101
N0101


N0101


N0101
N0101
N0101
N0101
N0101
N0101





































02
03

01
02




01
02
03


01

01

01
02
03
04
05
06


01


01
02
03
04
05
06

QTY/
P.T.

4
1

1
1




1
1
1


4

1

1
1
1
1
1
1


1


4
3
4
4
4
4

|

23
24

25
26





MP-1
MP-1


2

3

4
MP-4
MP-4
MP-4
MP-4
MP-4


MP-4


5
6
7
8
9
10

CHECK OFF ATTRIBUTES
WHICH ARE DIFFERENT
BETWEEN COMPARISON
TECHNOLOGY PACKAGES
•o
S
m
X
1











X




X

X











X
X
X
X
X

Material/Finishts)










X



X





















Weight/ Size










X



X





















Function














X





















Performance










X



X














X






QTY/P.T.





























X






33
*




































BRIEF EXPLANATION OF DIFFERENCES
 - Item cost impact assumed
unaffected or negligibly affected by
technology differences
NR
NR

NR
NR





As a result of higher fuel pressures (approx 1 200 psi), the
following upgrades are required for Dl versus PFI
1 Enhanced material grade
2 Thicker gauge material and structural enhancements
3 Additional attachment points
1 Require pressure senor on fuel rail for Dl, not required
for PFI engine


1 Replaces Low Pressure Port Injectors

1 , Required for Dl system, not required PFI system

1 Connects High Pressure Pump to Fuel Rail on Dl
Engine, not required for PFI system
NR
NR
NR
NR
NR


NR


Dl has increased fastener quantity and size for securing
fuel rail
Added for Dl
Added for Dl
Added for Dl
Added for Dl
Added for Dl

Notes: Addititional Items Requiring
Investigation.




































Design modifications for Material
Cost Reductions (MCR's).
















Look at cost Delta for Rotary pump which is driven off
need to consider entire subsystem which includes
head changes [additional cast material (Approx 1
kg) and added precision machining (Especially tappet
bore and flange face) ], cam changes ( Additional
lobe on intake cam), and a few others



















Additional Technology Advances
or Performance Upgrades




































File:Appendix C.1 Final Report120809.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                 C.I, Page 11 of 18
  Author: Greg Kolwich
(248) 373-6000 Ext.2411

-------
                                APPENDIX C.I Comparison Bill of Materials Excerpt - Case Study #0101,
                                             2007 Mini Cooper 1.6L 14, Turbo, Direct Injection
 APPENDIX C.1,
   Printed:12/8/2009
II
1 // GENERAL PART
If— fc Hff INFORMATION Technology Level:
it m^~ tSf Study Case*:
H
m
S


































ASY LVL 1



































SUBSYSTEM



12




X

X


X



X



X


X








SUB-SUBSYSTEM
85


Exh

01


04

05


07



08
A
B

65


m
A
B

75




ASSEMBLY
Seall


SUBASSEMBLY
ngbl
A


COMPONENT
NAME/DECRIPTION
n
m
m
"71
AJ
Indicates cost analysis potentially required, additional details
required.
technology package, no cost analysis required.
Same as above, however with potential MCR or Technology
Advance Considerations
sments
Seal
High Pressure Fuel Pump to Cylinder Head

lust Systems

bxha


Colic




ust Manifold
A

Manifold - Exhaust, Dual Wall



ctor Pipes

Catalysts
A
B
Silen
A
B

Close Couple Catalytic Converter Subassy- 3 Way (Exhaust Pipe Ass'Y)
Underbody Catalytic Converter Subassy - ? Way (Under Body Assy)
cers (Mufflers)
Resonator Subassembly (Under Body Ass'y)
Muffler & Tail Pipe Subassembly (Under Body Ass'y)




Oxygen Sensors
Sensor Assembly - Oxygen/Lambda Before Catalyst
Sensor Assembly - Oxygen/Lambda After Catalyst

Adap
A


teis






Flex Pipe Subassy - Under Body Exhaust Ass'y to Exhaust Pipe Assy

Pipes, HOE



es: Low Pressure, High Pressure
Exhaust Pipe Assembly
Underbody Exhaust Pipe Assembly

Brae
A
B
C
D

rets






Bracket Subassembly - Exhaust Manifold w. Integrated Gasket
Bracket Subassembly- Heat Shield, Top, Turbo
Bracket Subassembly - Heat Shield, Exhaust Outlet to Block
„,„









X

X
X

X
X


X
X


X


X
X




1
Bracket Subassembly - Exhaust Lower- CC. Cat. Conv.
2007 Mini Cooper, 1.6LI4, 16VDOHC, Dl, Turbo, iVVT, 173hp
Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine Vehicle Class: Compact/Economy 2-4 Passenger
N01 01 (N = New, 01 = Technology Package, 01 = Vehic e Class )
PART NUMBER


11




12




12
12

12
12


12
12


12


12
12


12
12
12
12

85




01




05
05

07
07


08
08


65


70
m


75
75
75
75


































N0101




N0101




N0101
N0101

N0101
N0101


N0101
N0101


N0101


N0101
N0101


N0101
N0101
N0101
N0101


































01




01




01
02

01
02


01
02


01


01
02


01
02
03
05
QTY/
P.T.


1




1




1
1

1
1


1
1


1


1
1


1
1
1
1
|


11




1











2
3


4


5
6


7
8
9
MP-9
CHECK OFF ATTRIBUTES
WHICH ARE DIFFERENT
BETWEEN COMPARISON
TECHNOLOGY PACKAGES
•o
S
m
X
1

X




























X


Material/Finishts)






X






















X



Weight/ Size

































Function





























X



Performance

































QTY/P.T.

































33
*

































BRIEF EXPLANATION OF DIFFERENCES
 - Item cost impact assumed
unaffected or negligibly affected by
technology differences

Added for Dl




Material upgrade required to a stainless steel capable of
operating @ 1050C Recommendation DIN 14826
Stainless Material




NR - Estimate close coupled catalytic converter
subsystem for Turbo Dl technology and NA PFI engine
approximately equivalent in cost for this study based on
NR

NR
NR


NR
NR


NR


NR
NR


1 3 layer sealing Turbo, 2 layer base NA PFI
Required to cover Turbo Assembly
NR
NR
Notes: Addititional Items Requiring
Investigation.











Consider higher temperatures and quicker light-off
with direct injection offset by heat sink from turbo





















Design modifications for Material
Cost Reductions (MCR's).






Fabricated dual wall manifolds may offer a 30% cost
reduction over the cast manifold but these designs
are package specific and require a significant amount
of engineering development


























Additional Technology Advances
or Performance Upgrades






Nodular Cast Iron
























As Turbo Dl becomes more main stream,
prediction is that heat shields will not only be usec
for heat control, but also be required to dampen
impact for composite type structures
As Turbo Dl becomes more main stream,
prediction is that heat shields will not only be usec
for heat control, but also be required to dampen
File:Appendix C.1 Final Report120809.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                 C.I, Page 12 of 18
  Author: Greg Kolwich
(248) 373-6000 Ext.2411

-------
                                APPENDIX C.I Comparison Bill of Materials Excerpt - Case Study #0101,
                                             2007 Mini Cooper 1.6L 14, Turbo, Direct Injection
 APPENDIX C.1,
   Printed:12/8/2009
II
1 // GENERAL PART
If— fc Hff INFORMATION Technology Level:
it m^~ tSf Study Case*:
H
m
S

































ASY LVL 1


































SUBSYSTEM
























13

X





SUB-SUBSYSTEM








SO







I



85



ASSEMBLY



H
I
J
K

Boltl







SUBASSEMBLY
E
F
G
COMPONENT
Strap
Strap
Strap
NAME/DECRIPTION
n
m
m
Indicates cost analysis potentially required, additional details
required.
technology package, no cost analysis required.
Same as above, however with potential MCR or Technology
Advance Considerations
- Manifold Mount Face (Torque Loss)
- Man fold Mount Face ( Torque Loss)
- Man fold Mount Face (Toque Loss)
Bracket Subassembly #1 - C.C. Catalytic Con. To Bed Plate
Bracket Subassembly #2 - C.C. Catalytic Con. To Bed Plate
Bracket Subassembly - O2 Sensor (Before CC Cat. Conv.)
Fixturing Hardware General - Exhaust Underbody Assembly

ig
A
B
D
b
F
G
H


Nut- Manifold Exhaust to Cylinder Head
Bolt-
Nut-
Nut-
Nut-
Nut-
Nut-
Clamp Assembly



Seali






ngbl
A
B

BRKT Heat Shield Turbo to Exhaust Manifold BRKT
BRKT
Heat Shield Exhaust to Exhaust Manifold BRKT
C.C. Catalytic Converter to Bed Plate (Copper Nut)
Turbo to C.C. Catalytic Converter
Exhaust Manifold to Turbo
Bracket, C.C. Catalytic Converter to Bed Plate
- CC Catalytic Converter to Exhaust Pipe







sments
Gasket - Turbo Inlet to Exhaust Manifold
Gasket - Turbo Outlet to Catalytic Converter

Uon Systems. Oil Pans/Sumps

01


02
A
06

Oil Pans (Oil Sump)


A

Pan -Oil

Oil Pumps
Oil Pump Assembly




Oil Filter
„,„
X
X
X
X
X
X
X



X
X
X


X
X
X
X



X




X




2007 Mini Cooper, 1.6LI4, 16VDOHC, Dl, Turbo, iVVT, 173hp
Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine Vehicle Class: Compact/Economy 2-4 Passenger
N0101 (N = New, 01 = Technology Package, 01 = Vehic e Class )
PART NUMBER

12
12
12
12
12
12
12


12
12
12
12
12
12
12
12




12
12




13


13

75
75
75
75
75
/b
75


80
80
80
80
80
80
80
80




85
85




01


02

































N0101
N0101
N0101
N0101
N0101
N0101
N0101


N0101
N0101
N0101
N0101
N0101
N0101
N0101
N0101




N0101
N0101




N0101


N0101

































06
07
08
09
10
11



01
02
04
05
06
07
08
09




01
02




01


01

QTY/
P.T.

1
1
1
1
1
1
NA


10
12
1
2
3
4
2
1




1
1




1


1

|

MP-10
MP-10
MP-10
MP-10
MP-10
MP-10



11
12
14
MP-14
MP-14
MP-14
MP-14
MP-14




15
MP-15




1


2

CHECK OFF ATTRIBUTES
WHICH ARE DIFFERENT
BETWEEN COMPARISON
TECHNOLOGY PACKAGES
•o
S
m
X
1













X







X










Material/Finishts)









X




X

















Weight/ Size
































Function
































Performance









X




X















X

QTY/P.T.
































33
*
































BRIEF EXPLANATION OF DIFFERENCES
 - Item cost impact assumed
unaffected or negligibly affected by
technology differences
Dl
NR -Components not industry standard for Base or Turbo
Dl
NR -Components not industry standard for Base or Turbo
Dl
NR
NR
NR
NR


temperatures
NR - Similar fasteners exist for both designs
NR - Similar fasteners exist for both designs
NR
Add for Turbo, Stainless Material?
If there was no Turbo, assume same four nuts would be
required to mount directly between manifold and exhaust
pipe or Catalytic Converter Subassembly However in
Turbo Dl case need to cover cost impact of Stainless
Steel Nuts Versus Standard
NR
NR




Required with Turbo
If there was no Turbo, assume gasket would be used to




NR


Piston Cooling Jets, Turbo Charge lubrication and
External Oil cooler will require increased oil capacity Will
pump

Notes: Addititional Items Requiring
Investigation.






























Typical oil pump pressure 50-60psi (1 Opsi/1 OOOrpm)
High volume pump typical has flow 20-25% higher
The physically larger surface area of the gears pushes
stock pump

Design modifications for Material
Cost Reductions (MCR's).
































Additional Technology Advances
or Performance Upgrades
































File:Appendix C.1 Final Report120809.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                 C.I, Page 13 of 18
  Author: Greg Kolwich
(248) 373-6000 Ext.2411

-------
                                APPENDIX C.I Comparison Bill of Materials Excerpt - Case Study #0101,
                                             2007 Mini Cooper 1.6L 14, Turbo, Direct Injection
 APPENDIX C.1,
   Printed:12/8/2009
II
1 // GENERAL PART
If— fc Hff INFORMATION Technology Level:
it m^~ tSf Study Case*:
H
m
S



































ASY LVL 1




































SUBSYSTEM


























14





X

SUB-SUBSYSTEM
A
70
A
B
80








86




99

B
C
D
b
F



01
A
B

02
A
ASSEMBLY
SUBASSEMBLY

COMPONENT
NAME/DECRIPTION
n
m
m
m
Filter Cooler Assembly
Indicates cost analysis potentially required, additional detai s
required.
technology package, no cost analysis required.
Same as above, however with potential MCR or Technology
Advance Considerations
- Oil (Includes Seals)
Pipes, Hoses: Suction Pipe for Oil Pump, Oil Return, High Pressure,
Low Pressure.
Tube Assembly- Oil, Cooler/Filter Ass'y Outlet to Turbocharger
Tube Assembly -
Oil, I
urbo to Engine Block (Piston Squirter's)
Boltings & Clamps








Seali

B


Misc

A
B
C
D
b
F
G

ng bl
A
Screw - Oil Pan to Bed Plate
Bolt-
Bolt-
Bolt-
Oil Pump Assembly
Filter Cooler Assembly
Tube Assembly , Oil, Turbo Inlet
Clamp - Tube Assembly, Oil, Cooler/Filter Outlet
Bolt-
Tube Assembly , Oil, Turbo Outlet & Block Inlet
Screw - Tube assembly Oil level Indicator

smen
s: Oil Pan Gasket,...
Gasket - Oil Pan (Deposit)
Plug & Gasket Subassembly - Oil Pan, Drain
C
D
Seal
lube
Assembly, Oil, Turbo Inlet
Compression Seal-Tube Ass'y, Oil Turbo Outlet & Block Inlet
3llaneous
A
Chain - Crank Shaft to Oil Pump
Tube Assembly -
Oil Level Indicator
Sensor - O I Pressure
Cover - Oil Pump Cha n
Sensor - Oil Temperature
Oil - Synthetic












Water Pumps
Pump Assembly
Pump- Aux
Coolant (Primary Mechanical)
iary Coolant, Electric

Thermostat Hous ng
Thermostat/Coolant Flow Valve Assembly -Coolant
„,„





X
X




X


X
X



X
X
X
X
X





;



X
2007 Mini Cooper, 1.6LI4, 16VDOHC, Dl, Turbo, iVVT, 173hp
Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine Vehicle Class: Compact/Economy 2-4 Passenger
N0101 (N = New, 01 = Technology Package, 01 = Vehic e Class )
PART NUMBER

13

13
13

13
13
13
13
13
13
13


13
13
13
13

13
13
13
13
13
13




14
14


14
06

m
70

80
80
80
80
80
80
80


85
86
85
85

99
99
99
99
99
99




01
01


02


































N0101

N0101
N0101

N0101
N0101
N0101
N0101
N0101
N0101
N0101


N0101
N0101
N0101
N0101

N0101
N0101
N0101
N0101
N0101
N0101




N0101
N0101


N0101


































01

01
02

01
02
03
09
06
06
07


01
02
03
04

01
02
03
06
04
08




01
02


01
QTY/
P.T.

1

1
1

16
3
4
1
1
2
1


1
1
1
4

1
1
1
1
1
1




1
1


1
|

3

4
5

6
7
8
9
10
11
12




15
16

17
18
19
MP
20





1
2


3
CHECK OFF ATTRIBUTES
WHICH ARE DIFFERENT
BETWEEN COMPARISON
TECHNOLOGY PACKAGES
•o
S
m
X
1
X

X
X



X
X
X
X





X
X












X



Material/Finishts)
























X









Weight/ Size


































Function


































Performance
























X









QTY/P.T.


































33
*


































BRIEF EXPLANATION OF DIFFERENCES
 - Item cost impact assumed
unaffected or negligibly affected by
technology differences
Require oil cooler in circuit to help cool oil going into Turbo
assembly

Required with Turbo
Required with Turbo

NR
NR
Required with Turbo
Required with Turbo
Required with Turbo
Required with Turbo
NR


NR
NR
Required for Turbo
Required for Turbo

NR
NR
NR
NR
NR
Synthetic oil required for turbocharged applications Need




NR
Required for Turbo Cooling following engine shut down


NR - Today having Integrated Electric Thermostat on
Turbo Dl and a conventional mechanical thermostat on the
NA PFI is more typical However 1 industry trend is
moving towards electric thermostats for both technology
levels Thus assumption is same technology would exist
in both applications
Notes: Addititional Items Requiring
Investigation.


































Design modifications for Material
Cost Reductions (MCR's).


































Additional Technology Advances
or Performance Upgrades





























Upgrade system from mechanical pump + smaller
auxiliary to single larger electric water pump for
reduced parasitic losses and 1 improved friction
characteristics Need to investigate cost impact
(Conventional Water Pump $25 50) Need to
single electric water pump is utilized




File:Appendix C.1 Final Report120809.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                 C.I, Page 14 of 18
  Author: Greg Kolwich
(248) 373-6000 Ext.2411

-------
                                APPENDIX C.I Comparison Bill of Materials Excerpt - Case Study #0101,
                                             2007 Mini Cooper 1.6L 14, Turbo, Direct Injection
 APPENDIX C.1,
   Printed:12/8/2009
II
1 // GENERAL PART
If— fc Hff INFORMATION Technology Level:
it m^~ tSf Study Case*:
H
m
S







































ASY LVL 1








































SUBSYSTEM





























X


15





SUB-SUBSYSTEM


70
A
B
C







75

SO













85


Indu

01
A

05
ASSEMBLY


SUBASSEMBLY
COMPONENT
NAME/DECRIPTION
n
m
m
3
Indicates cost analysis potentially required, additional details
required.
technology package, no cost analysis required.
Same as above, however with potential MCR or Technology
Advance Considerations
Sensor - Thermostat (Integrated into Housing?)
Sensor - Engine
femperature (Includes O-ring and Clip)
Pipes, Hoses, Ducting
Tube - Mech. Pump to Thermostat/Coolant Valve Ass'y
Hose Assembly -
Hose Assembly -







Brae
A
Bolti













Seali


ctioi

D
b
F
G
H


Turbo Assembly to Thermostat/Coolant Valve
Auxiliary Pump to Turbo
Hose Assembly - Oil Filer/Cooler Ass'y to Auxiliary Pump
Hose
Hose
Hose
Hose


 - Item cost impact assumed
unaffected or negligibly affected by
technology differences
Same as above
NR

NR
Required for Turbo Cooling
Required for Turbo Cooling
Required for Turbo Cooling
NR
NR
NR
NR



Required to secure auxiliary electric pump for cooling
turbo

NR
NR
NR
Required for Turbo Cooling
Required for Turbo Cooling
Required for Turbo Cooling
Required for Turbo Cooling
Required for Turbo Cooling
Required for Turbo Cooling
NR
NR
Required for Turbo Cooling


NR
NR



Require for Turbo System
Twin Scroll turbocharger capable of operating at 1 050C
EGT (Exhaust Gas Temperature) is currently the best
Same as above

Notes: Addititional Items Requiring
Investigation.






































Design modifications for Material
Cost Reductions (MCR's).



































Future cost reduction may include fabricated exhaus
manifold scrolls integrated with the exhaust manifold


Additional Technology Advances
or Performance Upgrades



































Future technology advances may include a
existence today capable of operating above 950C
EGT


File:Appendix C.1 Final Report120809.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                 C.I, Page 15 of 18
  Author: Greg Kolwich
(248) 373-6000 Ext.2411

-------
                                APPENDIX C.I Comparison Bill of Materials Excerpt - Case Study #0101,
                                             2007 Mini Cooper 1.6L 14, Turbo, Direct Injection
 APPENDIX C.1,
   Printed:12/8/2009
M
IFE¥
H
m
S







































ASY LVL |








































SUBSYSTEM






































SUB-SUBSYSTEM
A

65

/O
A
B



C








75


SO












99
A

ASSEMBLY
SUBASSEMBLY
COMPONENT
Cooler Assembly
GENERAL PART
INFORMATION Technology Level:
NAME/DECRIPTION
•T-l Indicates cost analysis potentially required, additional detai s
_J required.
^LJ technology package, no cost analysis required.
Same as above, however with potential MCR or Technology
"TT1 Advance Considerations
AiJ
- Charged Air

Adapters

Pipes, Hoses, Ducting
Tube Assembly -
Turbo Waste Gate Pneumatic Control
Tube Ass'y w. Vehicle Tie Down Resonator, Air Cooler Inlet



Bl
B2
B3
lube
Turbo Outlet to Vehicle Mount Coupler
Coupler - Turbo Outlet Tube to Cooler Intake Tube
Tube
Coupler to Charge Air Cooler
Tube Ass'y w. Vehicle Tie Down, Air Cooler Outlet








Brae


Bolt]












C1
C2
D
E
F
G
H

 - Item cost impact assumed
unaffected or negligibly affected by
technology differences
---"»——




Required for Turbo System

Part of air harge air cooling 8 delivery subsystem
Part of air harge air cooling 8 delivery subsystem
Part of air harge air cooling 8 delivery subsystem
Dart of air harge air cooling 8 delivery subsystem
Dart of air harge air cooling 8 delivery subsystem
Part of air harge air cooling 8 delivery subsystem
Part of air harge air cooling 8 delivery subsystem
Dart of air harge air cooling 8 delivery subsystem
Dart of air harge air cooling 8 delivery subsystem
Part of air harge air cooling 8 delivery subsystem
Part of air harge air cooling 8 delivery subsystem


Required to support mass of Turbo assembly hanging off
Exhaust Manifold




Required to support Turbo Assembly
Required to support Turbo Assembly
Required for Turbo Assembly Subsystem
Required for Turbo Assembly Subsystem

Part of air charge air cooling 8 delivery subsystem Note
one clamp is accounted for in intake subsystem which
would connect intake tube directly to ETB in base
Part of air charge air cooling 8 delivery subsystem
Part of air charge air cooling 8 delivery subsystem
Dart of air charge air cooling 8 delivery subsystem
Dart of air charge air cooling 8 delivery subsystem

Required for Turbo Assembly Subsystem

Notes: Addititional Items Requiring
Investigation.






































Design modifications for Material
Cost Reductions (MCR's).






































Additional Technology Advances
or Performance Upgrades
conventional air to air charge air cooler to water to
air charge air cooling subsystem Note that the
tooling bill is higher but the A-ACAC tooling
needs to be completely duplicated for a new
partially duplicated Improved performance for
stop and go city driving





































File:Appendix C.1 Final Report120809.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                 C.I, Page 16 of 18
  Author: Greg Kolwich
(248) 373-6000 Ext.2411

-------
                                APPENDIX C.I Comparison Bill of Materials Excerpt - Case Study #0101,
                                             2007 Mini Cooper 1.6L 14, Turbo, Direct Injection
 APPENDIX C.1,
   Printed:12/8/2009
II
1 // GENERAL PART
If— fc Hff INFORMATION Technology Level:
it m^~ tSf Study Case*:
H
m
S







































ASY LVL 1








































SUBSYSTEM



17








X



X

X

X

X

X

X

60

X







SUB-SUBSYSTEM
C
D

Bra

02
A





70
A
B

75

80

85

90

95

99

ASSEMBLY

SUBASSEMBLY

COMPONENT
NAME/DECRIPTION
n
m
m
Indicates cost analysis potentially required, additional details
required.
technology package, no cost analysis required.
Same as above, however with potential MCR or Technology
Advance Considerations
Sensor - Intake Temperature, Outlet Charged Air Cooler
Baffle

- Charge Air By-Pass




ther Svstems

Oil/A
r Separator
PCV ASSEMBLY - (Bu It into Cylinder Head Cover)
A1
A2
A3
A4
A6
Valve - Non Return Intake Hose Side
Sepa
Valvs
ator -
Cyclone
- Pressure Control
Valve - Oil Drain
Valve - Non Return Intake Manifold Side
Pipes, Hoses, Ducting
Hose Assembly- PCV H/W to Intake Manifold
Hose Assembly- Air Intake to PCV H/W (With Valve or Sensor??)

Brackets

Boltings

Sealing Elements

Bearing Elements

Tools

Miscellaneous


I A | Retainer - Hose Assembly - Air Intake to PCV H/W
Enaine Management S
vstems, Enaine Electronic Svstems,
Electrical Svstems

01
A

02
A
B

03

Spark Plugs, Glow Plugs
Spark Plug








Engine Management Systems, Engine Electronic Systems
Power Train Control Module (PCM) Assembly - Hardware
Power Train Control Module (PCM) Assembly - Software

Engine Electrical Systems (including Wiring Harnesses, Earth
Straps, Ignition Harness, Coils, Sockets)
„,„













X
X


X

X

X

X

X

X



X






2007 Mini Cooper, 1.6LI4, 16VDOHC, Dl, Turbo, iWT, 173hp
Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine Vehicle Class: Compact/Economy 2-4 Passenger
N0101 (N = New, 01 = Technology Package, 01 = Vehic e Class )
PART NUMBER

15
16





17
17
17
17
17

17
17












17



60


60
60


99
99





02
02
02
02
02

70
70












99



01


02
02








































N0101
N0101





N0101
N0101
N0101
N0101
N0101

N0101
N0101












N0101



N0101


N0101
N0101








































03
04





01
10
20
30
40

01
02












01



01


01
50


QTY/
P.T.

1
1





1
1
1
1
1

1
1












1



4






|

31
32











6
MP-6












6



1






CHECK OFF ATTRIBUTES
WHICH ARE DIFFERENT
BETWEEN COMPARISON
TECHNOLOGY PACKAGES
•o
S
m
X
1
X
X




































Material/Finishts)






X































Weight/ Size






































Function


































X
X


Performance






X



























X
X


QTY/P.T.






































33
*






































BRIEF EXPLANATION OF DIFFERENCES
 - Item cost impact assumed
unaffected or negligibly affected by
technology differences
Dart of air charge air cooling 8 delivery subsystem
Dart of air charge air cooling 8 delivery subsystem




difficult and requires better oil separation This may drive
not be engineered from a separator internal to the cam
Evaluate upon teardown of PCV Subsystem
Evaluate upon teardown of PCV Subsystem
Evaluate upon teardown of PCV Subsystem
Evaluate upon teardown of PCV Subsystem
Evaluate upon teardown of PCV Subsystem

NR
NR












NR



NR


The PCM H/W is carry over except for the PFI drivers
GDI drivers use a 75-80VDC Boost Circuit and 25A
Peak/Hold Drivers
1 V
• Control system is much more complicated in order to
control injection timing, split injections, fuel rail pressure,
electric water pump, electric thermostat, etc


Notes: Addititional Items Requiring
Investigation.


































Estimated cost from Tech Team on GDI PCM may
cost $40-45 more than a PFI PCM
Costs covered by Indirect Cost Multiplier


Design modifications for Material
Cost Reductions (MCR's).






































Additional Technology Advances
or Performance Upgrades






































File:Appendix C.1 Final Report120809.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                 C.I, Page 17 of 18
  Author: Greg Kolwich
(248) 373-6000 Ext.2411

-------
                                APPENDIX C.I Comparison Bill of Materials Excerpt - Case Study #0101,
                                             2007 Mini Cooper 1.6L 14, Turbo, Direct Injection
 APPENDIX C.1,
   Printed:12/8/2009
II
1 // GENERAL PART
If— fc Hff INFORMATION Technology Level:
it m^~ tSf Study Case*:
H
m
S




































ASY LVL 1





































SUBSYSTEM



X

70

X


X


X





X

X


X










SUB-SUBSYSTEM
A
B
C
80


Purr

01
A

02
A

03
A

04
A

06
A
m


75



80






ASSEMBLY
SUBASSEMBLY
COMPONENT
NAME/DECRIPTION
n
m
m
3
Ignition Coil Assembly
ndicates cost analysis potentially required, additional details
required.
technology package, no cost analysis required.
Same as above, however with potential MCR or Technology
Advance Considerations
- Single Spark
Battery Assembly
Wire Harness Assembly #1 - Engine, Main
Boltings
A Cover - COP harness
ps. etc)

naines. Generators, Power Steering


Starter Engines
Starter Motor Assembly



Generators


Alternator Assembly





Power Steering Pumps
Power Steering Pump Assembly -Electronic

Vacuum Pumps
Vacuum Pump Assembly

Air Conditioning Compressors
Air Conditioning Compressor Assembly
Pipes, Hoses, Ducting


Brae



Bolt






A

rets
A
B

ngs
A
B
D
b
F
G
Hose
- Vacuum Pump, Brake Booster


Bracket - AC Compressor Mount
Bracket - Retention tube and wire harness


Bolt-
Bolt-
Bolt-
Bolt-
Bolt-




Vacuum Pump
Starter Motor Assembly to Block
Alternator Assembly to Block
AC Comp. Mounting Bracket to Block & Bed Plate
AC Compressor Assembly to Mounting Bracket
Fastener - Steering Pump Assembly to Vehicle
„,„

X


X



X


X


X





X

X


X
X



X
X
X
X
X
2007 Mini Cooper, 1.6LI4, 16VDOHC, Dl, Turbo, IWT, 173hp
Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine Vehicle Class: Compact/Economy 2-4 Passenger
N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )
PART NUMBER

60
60
60

60



70


70


70


70


70

70


70
70


70
70
m
70
70
70
03
03
03

80



01


02


03


04


05

70


75
75


80
80
80
80
80
80



































N0101
N0101
N0101

N0101



N0101


N0101


N0101


N0101


N0101

N0101


N0101
N0101


N0101
N0101
N0101
N0101
N0101
N0101



































01
20
30

01



01


01


01


01


01

01


01
03


01
02
03
04
05
06
QTY/
P.T.

4
1
1

1



1


1


1


1


1

1


1
1


2
3
3
4
3
??
|

2

3

MP



1


2


3


4


5

6


7
MP


8
9
10
11
12
13
CHECK OFF ATTRIBUTES
WHICH ARE DIFFERENT
BETWEEN COMPARISON
TECHNOLOGY PACKAGES
•o
S
m
X
1


X














X











X





Material/Finishts)



































Weight/ Size


X
































Function


X
































Performance
X


































QTY/P.T.



































33
*



































BRIEF EXPLANATION OF DIFFERENCES
 - Item cost impact assumed
unaffected or negligibly affected by
technology differences
Require upgrade in ignition coils. Turbo typically 75-1 00
mJ, BaseNAPFI 40-45mJ
NR
Added wiring complexity due to more sensors and
actuators

NR



NR


NR


NR


On Turbo Dl Vacuum pump required for brakes and


NR

NR


NR
NR


Required to mount vacuum pump to head
NR
NR
NR
NR
NR
Notes: Addititional Items Requiring
Investigation.
Need to order ignition coil assembly


































Design modifications for Material
Cost Reductions (MCR's).














of a standard on both Turbo Dl as well as Base
Should include in second case cost model




















Additional Technology Advances
or Performance Upgrades



































File:Appendix C.1 Final Report120809.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                 C.I, Page 18 of 18
  Author: Greg Kolwich
(248) 373-6000 Ext.2411

-------
                APPENDIX D.I Design Profit® Mapping Symbols
      Examples of symbols used in the Design Profit® Mapping Process:
      Part: Solid objects  that are single  entities.   They  have no other components
      attached or inside them, i.e. flange head bolt, one piece stamped bracket, single
      plastic injected molding.
      Sub Assembly: As the symbol implies, are parts inside or attached to other parts or
      products which have components inside them, i.e. bolts with captured washers,
      welded brackets, insert molded parts, purchased assemblies.
      Pre-processed Part: Are parts that have undergone additional processes before
      they can be used, i.e. Anodizing, powder coat, or paint.  They typically contain a
      single part and one or more manufacturing processes.
      Multiple Touch Part: If a part or subassembly is handled more than once in the
      assembly of the product this stop sign symbol should be used in order to:
         •   Ensure our part count is still correct.
         •   Highlight the fact we are violating a good design principle
      Tool: Not all screwing operations can be done by hand like a jar lid; sometimes a
      tool will be needed.
EPA Contract: EP-C-07-069 WAI-3
D.I, Page 1 of 2

-------
      Fasten: Not all products and parts can be assembled right away.  Some need an
      extra step like screwing.  Get the part, put the part, and then fasten the part.
      Operation:  Operations  such  as  moving the product, operator movement,  or
      changes to the direction of insertion, part manipulation,  etc.  In many cases,
      Operations are non value added (NVA) activities.
      Material Modification: Anytime  the physical characteristics  of a  part are
      changed, such as heat treating, and freezing, or, anytime material is removed, as in
      machining operations such as milling, boring, punching, drilling, etc.
      Inspect: Represents inspection steps in an assembly.  Inspections are non-value
      added processes that should be eliminated or automated.
      In  addition to the standard part symbols, parts are also  further identified for
      fasteners and fluids:
      D
      Fastener: Used to join two or more parts.
      Includes threaded and non-threaded fasteners, i.e. screws, washers, and glue.
      Fluid:  Anything that is measured by volume  rather than count.  Includes oil,
      grease, coolant, and glue.
EPA Contract: EP-C-07-069 WA1-3            D.I, Page 2 of 2

-------
                                          APPENDIX E.I Material Costing Database Excerpt
                                                                          Appendix E.1
                                                                        Printed :12/9/2009
Ffl
Cat.
A.CA
Item
!BONi
I II A. Carbon/Alloy Steel j^ D. Cast Iron jj G. Magnesium Alloys j |" K. Nickel Alloys ^ \ N. ^\ a. Thermoplastics T. T WMisc. |
\ij B. HSLA& Micro Alloy j! E. Aluminum Alloys H. Titanium Alloys L Cobalt Alloys. o. R Thermosets. u Automotive Fluids. X.
! C. Stainless Steel l! F. Powder Metal j j J. Copper Alloys j M. ^
Material Description
i ALLOY STEELS (SAE1000-9000
A1. CARBON STEEL















A1 .1 10XX Plain Carbon Steel








Low Carbon Steel
Medium Carbon Steel

Low Carbon, Hot Dip Galvanized
Steed.

Medium Carbon Steel
High Carbon Steel

Industry Specification
Carbon Ranges: Low 0.05-0.1 5%, Mid. O.K

Mn 1.00% Max
SAE J403 1008/1 010
SAE J4031018

SAE J403 1008/1 010

SAE J4031018
SAE J403 1 040

A1 .3 12XX Resulfurized and Rephosphorized





12L14
1215
Low Carbon Steel Tubing


Leaded Bar
Replacement to 12L14
1215


A6. CHROMIUM-MOLYBDENUM (CHROMOLY) STEELS









A6.1 41XX








41 XX
Chrome-Moly-Vanadium Steel
4140RH

41 30 Spring Steel Heat-Treatable
4130
4130 Tight Thickness Tolerance.

Cr 0.50% Or 0.80% or 0.95%, Mo 0.12% or 0.2

32CrMoV13
42CrMoS4

C 0.28/0.33 Si 0.20/0.35, Mn 0.40/0.60, Cr
0.80/1.10, PSS 0.025 Max, Mo 0.15/0.25
C 0.28/0.33 Si 0.20/0.35, Mn 0.40/0.60, Cr
0.80/1.10, PSS 0.025 Max, Mo 0.15/0.25
C 0.28/0.33 Si 0.20/0.35, Mn 0.40/0.60, Cr
0.80/1.10, PSS 0.025 Max, Mo 0.15/0.25

A7. NICKLE-CHROMIUM-MOLYBDENUM STEELS







A7.1 43XX



A7.48


300M
Ni-Chrome-Moly

5XX
8620, Case Hardening Steel

A9. CHROMIUM STEELS









A9.451XX



A9.55


SAE5115
SAE 51 40/51 45

XXX
Chromium Steel, High Carbon,
Bearing Grade, Unpolished Mill
Finished, Annealed

A10. CHROMIUM-VANADIUM STEELS


A10.1 61XX
ISAE6150
Ni 1 .82%, Cr 0.50-0.80%, Mo 0.25%
SAE 4340Mod
SAE 4330/4340

Ni 0.55%, Cr 0.50 Mo 0.20%
SAE 8620, 21 NiCrMoSS



Cr 0.80% or 0.87% or 0.92% or 1 .00% or
1 .05%.
CO. 15, SiO.25, MnO.50, CrO.60,


Cr1.02%, C1.00%Min.
SAE 52 100


Cr 0.60% or 0.80% or 0.95%, V 0.10% or
0.15%

Supplemental
Specification
Information
-0.29%, High 0.30-1. 10°/


Coil
Coil

Coil

Bar
Bar (1-3")


Bar
Bar
Tube



3% or 0.25% or 0.30%
Bar
Bar
Bar

Coil
Coil, 0.04" to 0.1 25"
Coil, 0.05" to 0.08",
Tight Thickness
Tolerance



Vacuum melted high
strength, super alloy.
Bar 1-7"


Bar




Bar
Bar


Bar >0.5"



Bar 1 -8"
p. | S. Thermoplastic Elast. V. Plating & Coatings
Application Examples
, Ultra High 1-2%


Brackets, Spacers
Splash Pans, Dampers, Windage Tray

PCV Baffles





Bushings, Inserts, Couplings
Bushings, Inserts, Couplings
Metal Tubing coolant lines, oil lines, etc.




Injector Body
Bearings, Crank shafts
Crankshafts, axle journals, gears, pushrods.

Direct Injector Spring Clips





Drive shafts, Con. Rods
Planetary Gear Carrier, Shafts


Driving Bevel Gears, Crown Wheels, Gears,
Shafts, Bolts for automotive and gear
components.





Gears, Shafts


Bearing Races



Park pawl, park gear
Material Class



LC-Steel-1000S, Coil
MC-Steel-1000S, Coil

LC-GSteel-1000S, Coil

MC-Steel-1018, Bar
HC-Steel-1040S, Bar


LC-Steel-1214, Bar
LC-Steel-1215, Bar
LC-Steel-1215, Tubing




A-Steel-41XXS, Bar
MA-Steel-CrMoV, Bar
A-Steel-4140, Bar

HC-Steel-4130, Coil
HC-Steel-4130, Coil
0.04"-0.125"
HC-Steel-4130, Coil
0.04"-0.08"



MA-Steel-300M, Bar
MA-Steel-43XXM, Bar


A-Steel-8620, Bar




A-Steel-51XX, Bar
A-Steel-5140, Bar


A-Steel-52100Bar




Y.
Active Rate
2008



$ 0.45
$ 0.55

$ 0.48

$ 0.74
$ 0.80


$ 0.62
$ 0.62
$ 0.62




$ 0.78
$ 0.98
$ 0.78

$ 1.18
$ 1.18
$ 2.79



$ 0.89
$ 1.08


$ 0.70




$ 1.00
$ 1.00


$ 1.00



$ 0.67

Information Reference Source



AMM Reference, MEPS, USGS
Online Metals, Metals Depot, Speedy Metals, All Metals,
Industrial Metal Sales w/ AMM spot check

Premium Steel

Metals Express, Industrial Metal, Online Metals, Metals Depot
Online Metals, Speedy Metals, All Metals


Online Metals, Speedy Metals, All Metals
Purchasing Magazine
Estimated same pricing as 1215 bar.




Assigned same rate as A-Steel-41 40, Bar 0.875-2.75"
Composition analysis plus surcharge
Composition analysis plus surcharge

Surrogate pricing based on 4130 0.040"-0.125"
Online Metals, Aircraft Spruce & Specialty Co. & Specialty Co.
Kmac



Composition analysis plus surcharge
Online Metals, Metals Express, Hi Tech Metals quote


Composition analysis plus surcharge




Surrogate pricing based on "A-Steel-51 40, Bar"
Kmac, Raker, Continental Steel Quote


Kmac, Raker, Continental Steel Quote



Kmac
File:Final Report Costing Databases 120809.xls
EPA Contract: EP-C-07-069 WA 1-3
E.l,Pagelof7
 Form Author: G. Kolwich
(248) 373-6000 Ext. 2411

-------
                                          APPENDIX E.I Material Costing Database Excerpt
                                                                          Appendix E.1
                                                                        Printed :12/9/2009
Ffl
Cat.

B. Hl(
Item

HSTR
1 jj\ A. Carbon/Alloy Steel D. Cast Iron j
Iff \ B. HSLA & Micro Alloy JH E. Aluminum Alloys i
C. Stainless Steel | :[ F. Powder Metal
Material Description

ENGTH LOW ALLOY (HSLA) and IV
B2. Micro Alloy Steels






C. ST

A2.1




UNLES



C70S6
36MnVS4

3 STEELS (SAE100-600Series)
C1. 300 Series - Austenitic Chromium-Nickel Al


























C1.1 304 General Purpose





304
304/304L
304/304L
304

C1.1.1 316




316
31 6/31 6L
31 6/31 6L

C1.1.2309/309S


31 0/31 OS

C1 .1.5 303




303Se
303
303L

C1 .1.6 301

C1.1.7





MISC.
21-2N/21/4N (EV8)



C2. 400 Series Ferritic Chromium Alloys





C.2.1.1 442

422
G. Magnesium Alloys K. Nickel Alloys N. O. Thermoplastics T. WMisc.
H. Titanium Alloys L Cobalt Alloys. o R Thermosets. u Automotive Fluids. X
J. Copper Alloys M. p. S. Thermoplastic Elast. V. Plating & Coatings Y.
Industry Specification

CRO ALLOY STEELS


Mn 1.75%

CO. 72%, SiO.22%
VO.04%
MnO.49%, SO. 062%,



Supplemental
Specification
Information






Typical Air Cooled
Forging Steel
Bar


Application Examples






Forged tractured split rods
Crankshatts, Cracked Forged Rods, Short and
Long-shatt Ball Points, threaded heavy duty
anchor bolts.


Harden by cold working, can not be hardened by heat treating, Non Magnetic in annealed condition. Excellent corros on
resistance and usually good tormability.






Mo added to increase corrosion resistance.

C reduced tor weldability
C reduced tor weldability

CR & Ni increased tor high temperature.
Same as 309, only more so.

S added to improve machining.
Se (Selenium) added tor better machined
surtaces.



Cr and Ni lowered to increase work hardening.


Austenitic Precipitation Hardening Chrome
Manganese Nickel Steel: Cr:23/20%,
Ni4.50/3.25%, Mn: 10/8% etc.




Bar
Coil
Sheet or Cast
Tube


Bar
Coil
Cast/Sheet






Bar
Bar




Bar




Valves and Tubing
Exhaust Systems, Fuel tanks
Housings tor Catalytic Converters and
Turbochargers.
Fuel Rail


Valves and Tubing

Housings tor Catalytic Converters and
Turbochargers.


nternal Components tor Turbochargers (e.g..
Rotors)



Valves and Tubing
Valves and Tubing




ntake & Exhaust Va ves



Can not be hardened through heat treatment and only moderately hardened by cold working. The are magnetic, have
good ductility and resistance to corrosion and oxidation.

Cr Increased to improve scaling resistance,



Bar


ntake & Exhaust Va ves
Material Class






MA-Steel-C70S6, Bar
MA-Steel-MnVS, Bar




S-Steel-304, Bar
S-Steel-304, Coil
S-Steel-304, Cast
S-Steel-304, Tube


S-Steel-316, Bar
S-Steel-316, Coil
S-Steel-316, Cast


S-Steel-310, Cast



S-Steel-303, Bar
S-Steel-303L, Bar




S-Steel-21_14N, Bar






S-Steel-422, Bar
Active Rate
2008






$ 0.70
$ 0.73




$ 1.65
$ 1.64
$ 1.39
$ 1.65


$ 2.44
$ 2.72
$ 2.82


$ 4.23



$ 1.55
$ 1.65




$ 7.56






$ 7.56

Information Reference Source






Composition analysis plus surcharge
Composition analysis plus surcharge




MEPS, stainlesssteel.com, purchasing.com
MEPS, stainlesssteel.com, purchasing.com
MEPS, stainlesssteel.com, purchasing.com
Estimate, same pricing as 304Bar


MEPS, stainlesssteel.com, purchasing.com
MEPS, stainlesssteel.com, purchasing.com
MEPS, stainlesssteel.com, purchasing.com


Place Holder 1 .5 x $ "S-Steel-31 6, Cast"



MEPS, stainlesssteel.com, purchasing.com
MEPS, stainlesssteel.com, purchasing.com




Point Price trom Bundy with trend analysis.






Point Price trom Power Plant Services with trend analysis.
File:Final Report Costing Databases 120809.xls
EPA Contract: EP-C-07-069 WA 1-3
E.l,Page2of7
 Form Author: G. Kolwich
(248) 373-6000 Ext. 2411

-------
                                          APPENDIX E.I Material Costing Database Excerpt
                                                                         Appendix E.1
                                                                       Printed :12/9/2009
Ffl
Cat.
Item
I II A. Carbon/Alloy Steel D. Cast Iron jj G. Magnesium Alloys j | K. Nickel Alloys ~*\ N. ^\ a. Thermoplastics T. ~"T WMisc. |
\ij B. HSLA& Micro Alloy j E. Aluminum Alloys H. Titanium Alloys L Cobalt Alloys. o. R Thermosets. u Automotive Fluids. X.
! C. Stainless Steel I! F. Powder Metal j j J. Copper Alloys j M. ^
Material Description
C3. 400 Series Martensitic Chromium Alloys




D. CA

C3.1.5440C


STIRO
440B
440A
MS
^^^^^^^^
D1. Nodular/Ductile Cast Iron







D2. M








illeabk

Nodular /Ductile Iron (80-55-06)
Nodular /Ductile Iron (100-70-03)

Ni-resist cast iron, D5S

Silicon Molybdenum Cast Iron

Cast Irons
Malleable Cast Iron
D3. Grey Cast Iron

E. AL

JMINUH
Grey Cast Iron
I ALLOYS
E1. Wrought Alloys























E1.1 2XXX AI-Cu Alloys



2024
2024

E1 .2 3XXX AI-Mn Alloys




3003,3005,3012
3003-H14Uncladded
3003-H14 Uncladded

E1. 3 4XXXAI-SI Alloys


E1.45



E1.56



4032

as Fabricated, O>a
treated, usually solution heat-treated, quenc


2024-T3/T4/T351
2024-T3/T4/T351


Aluminum Magnesium
Aluminum-Manganese Sheet
Aluminum-Manganese Sheet


4032-T651


5052 H32



6062-T651 1
6061-T6511


Aluminum-Manganese Gladded Tube


Bar


Carbon, and 1-3%wt. S

$0.9041 .2/lb finished
casting
$0.9041. 2/lb finished
casting






$0.9041. 2/lb finished
casting


nnealed, H> Strain-hard
hed and precipitation \\z


Bar 00.5-2.5"
Sheet, 0.032"-0.125"



Thick. 0.032-0.125"
(0.75-3.1 5mm)
Thick. 0.003-0.009"
(0.075-0.22mm)


Bar 01. 0-2. 5"


Coil 0.025-0.125"



Bar 00.5-1 .5"
Bar 00.5-3.0"


Seamless welded tube -
thickness 0.01 2-0. 02"
(0.3-0.5mm)


ntake & Exhaust Valves


licon.

Crankshaft, blocks
High Strength Cam shafts i.e.., driving HP fuel
pumps.

Housing - Turbo Exhaust

Housing-Block Center, Turbo Support


Crankshaft, camshafts, blocks

Engine Blocks
sned, W>Solution heat-treated. T> Thermally
rdened.






Braze-clad welded radiator tubes, heater cores, radiator, heater
and evaporative lins, hea er inlet and outlet tubes, oil coolers,
and air conditbner Iquid ines, radiator heater and evaporative
parts, extruded condenser tubes
Heat Exchangers
Heat Exchangers









Spool valves



Heat Exchangers

Material Class


S-Steel-440C, Bar




Nodular Iron, Cast
Nodular Iron,
Gr1 00/70/03, Cast

NiResistlron, D5S, Cast

SiMo Ductile Iron, Cast


Malleable Cast Iron

Grey Iron, Cast



Aluminum-2024, Bar
Aluminum-2024, Sheet


Aluminum-SOOOS, Coil
Aluminum-3003, Coil A
Aluminum-3003, Coil B


Aluminum-4032, Bar


Aluminum-5052, Coil



Aluminum-6062, Bar
Aluminum-6061, Bar


Gladded Aluminum-
3003, Tube

Y.
Active Rate
2008


$ 4.56




$ 0.35
$ 0.42

$ 3.50

$ 0.60


$ 0.41

$ 0.35



$ 2.38
$ 3.41


$ 0.84
$ 1.41
$ 1.93


$ 1.44


$ 1.52



$ 1.45
$ 1.50


$ 2.28


Information Reference Source


Point Price from AK Steel with trend analysis.




AISI, MEPS
Estimate base on ASTM A536-80-55-06

Estimate from Turbocharger Industry Expert

Estimate from Turbocharger Industry Expert


AISI, MEPS

Estimate same pricing as ASTM A536-80-55-06



Aircraft Spruce & Specialty Co. & Specialty Co., Online
Metals, Industrial Metal
Online Metals, Kmac, Airparts


Aluminum.com, AMM reference.
Aluminum.com, AMM reference.
Lynch Estimate


Kmac


Online Metals, Metal Depot, Airparts, Enco, All Metals



Online Metals
Metals Express, Aircraft Spruce & Specialty Co., All Metals,
Metal Connection


Lynch Estimate

File:Final Report Costing Databases 120809.xls
EPA Contract: EP-C-07-069 WA 1-3
E.l,Page3of7
 Form Author: G. Kolwich
(248) 373-6000 Ext. 2411

-------
                                          APPENDIX E.I Material Costing Database Excerpt
                                                                          Appendix E.1
                                                                       Printed:12/9/2009
fi¥
Cat.
Item
A. Carbon/Alloy Steel D. Cast Iron j j G. Magnesium Alloys K. Nickel Alloys ~£j N.
| B. HSLA & Micro Alloy j E. Aluminum Alloys H. Titanium Alloys L Cobalt Alloys. o.
C. Stainless Steel \% F. Powder Metal j J. Copper Alloys M. £ j p.
Material Description
Industry Specification
E2. Casting Alloys ( Hypoeutectic 8.5-10.5, Eutectic 11-12, 16-18 Hypereutectic Material )














F. PO

2XXAI-CU Alloys

3XX Al-Si + Cu and/or Mg Alloys










iVDER
319T5
332
F132
356 T6 or A356
A380.1
B380
384
B390.0
A3 83
3HA Piston Alloy

/IETALS (Classification per MPIF £




AI-3.5CU-6SI
8.5-10SI, 2.0-4.0CU, NiO.10
7SI-0.3 Mg alloy
AI-9Si-3Cu(Fe)
AI-9Si-3Cu(Fe)

Hypereutectic aluminum-silicon
AISi10Cu2
AISi12Cu4Ni2Mg

tandard 35)
F1. PM Structural Materials: Ferrous and Non-ferrous




















Ferrous Materials

F1.1 Iron and C ••:



F1.10v



Sintered Powdered Metal (Iron
base powder alloy)



304/304L
31 6 Stainless

F1 .1 1 Stain ess Steel - 400 Series Alloy


F1.12

430 Stainless
410 Stainless
Miscellaneous

Non-Ferrous Materials
F1 .21 Aluminum and Aluminum Alloys



PM Aluminum - Structural
Components


F2. P/F Steel Part Materials





F2.0 Carbon Steel




Powdered forged






SAE1541




SS-316N2, 17Cr,12Ni,2.5Mo


SS-430N2, 17Cr
SS-41, 13Cr, O.SSi, O.SMn




4.4Cu/0.5Mg/0.6Si




HS 150/1 60



Supplemental
Specification
Information





Hypoeutectic/Perm.
Hypereutectic, common
grade, large recycled
composition (Die.)
Hypoeutectic (Perm.)
Hypoeutectic (Die.)
Hypoeutectic (Die)
Eutectic (Die)
Hypereutectic (Die.)
Hypoeutectic (Die.)












p=6.5g/cmA3,UTS=60ksi


p=7.1g/cmA3,UTS=60ksi
p=6.1g/cmA3,UTS=66.7
ksi




Ys/UTSinksi:w. T4HT,
31/38 W. T6HT
47.5/48.1








1 0. Thermoplastics ~£~ T. jUT" W Misc. a
R Thermosets. u Automotive Fluids. |"i X.
S. Thermoplastic Elast. V. Plating & Coatings Y.
Application Examples





Manifolds, cylinder
parts
heads, blocks, internal engine
Hypoeutectic
Engine blocks, flywheel, oil pan, pump bodies, cyl
heads, manifolds, transmission cases
Blocks, transmission housings/parts, fuel
metering devices, oil pump cyl heads,
Blocks, transmission housings/parts, fuel
metering devices, oil pump cyl heads,
Pistons, automatic transmissions
High-wear applications such as ring gears and
internal transmission parts, Hypereutectic pistons,
cylinder blocks
Blocks



Crank timing sprockets or gears, cam shaft timing
sprocket or gears, Transmission clutch hubs, ATM
planetary ring gear, Cam lobe on composite cam
shaft, impellers.








Good Corrosion Re
sistance, Appearance


Good Corrosion Re
sistance, Appearance
Dl Solenoids




Cam Caps




Connecting Rods



Material Class





Aluminum-A319-T5, Cas
Aluminum-332, Cast
Aluminum-356-T6, Cast
Aluminum-A380, Cast
Aluminum-B380, Cast
Aluminum-384, Cast
Aluminum-B390, Cast








PM-SMF-lron Base



PM-SMF-SS304
PM-SMF-SS316



PM-SMF-SS410




PM-SMNF-Aluminum




PF-SMF-HS150/160



Active Rate
2008





$ 1.15
$ 1.24
$ 1.20
$ 1.10
$ 1.18
$ 1.14
$ 1.20








$ 1.00



S 4.92
$ 8.16



$ 4.50




$ 3.50




S 0.70




Information Reference Source





CRU group, AMM reference
CRU group, AMM reference
CRU group, AMM reference
CRU group, AMM reference
CRU group, AMM reference
CRU group, AMM reference
CRU group, AMM reference












3x Cost of 304 Coil - reference above
3x Cost of 31 6 Coil - reference above



Need Pricing Confirmation









Composition analysis plus surcharge



File:Final Report Costing Databases 120809.xls
EPA Contract: EP-C-07-069 WA 1-3
E.l,Page4of7
 Form Author: G. Kolwich
(248) 373-6000 Ext. 2411

-------
                                          APPENDIX E.I Material Costing Database Excerpt
                                                                         Appendix E.1
                                                                       Printed :12/9/2009
Ffl
Cat.
G.UU

G2. C

G2.1

H. Til
Item
GNESI

1st Alto

AZ91
AZ91
ANIUM
Iff ^ A-Carbon/AII°ysteel D. Cast Iron j G. Magnesium Alloys j K. Nickel Alloys 1 |" N. n^ a. Thermoplastics T. WMisc. j
\ff ! B.HSLA& Micro Alloy * E. Aluminum Alloys * H. Titanium Alloys * L Cobalt Alloys. * o. RThermosets. u Automotive Fluids. * X.
C. Stainless Steel "[I F. Powder Metal i j J. Copper Alloys j" M. f
Material Description
JM WROUGHT & CASTING ALLOY




AZ91D
WROUGHT & CASTING ALLOYS
H1. Wrought Alloys





H2. C



J. CO





















K. NIC





st Alto



>PER

Titan urn (Sponge Only)
Titan urn
Titan urn


Titan urn


VROUGHT & CASTING ALLOYS (E
Industry Specification
s




Mg AI9Zn1




(6AL V4)
(6AL V4)


(6AL V4)


RONZE & BRASS)
J6.3 High Lead Tin Bronze & Lead Free Bronze (LC-M/H, T=H, C/E=G RS=G, H/W=H)




J6.4A



C93200
C89320
Oilite Bronze Bearing Alloy

jminum Bronze(LC-VH, T=VH, C/E=
ASTM C63000, C63020


SAE 660 Bearing Bronze
Lead Free Replacement to C93200
SAE841

P RS=M, H/W=VH)
Nickel Aluminum Bronze


J6.1 2 Silicon Brasses (LC=? , T=? , C/E=? , RS=?, H/W=?)




C87500 (500)
CDA 673 - Silicon Manganese
Brass


J6.13 Brass General


C36000

J6.1 4 Cooper General



KELW
Copper


ROUGHT & CASTING ALLOYS
K1. Wrought Alloys







K1.1 n





cone©
ncone»751/HEV3
ncone»713Coil
Silicon Brass, 82-4Si-14Zn
C67300



CDA 360


>99.0% Pure








Nickel Alloy - Internal Turbo Parts General
nconeH>713Coil
Supplemental
Specification
Information










Bar
Plate


Ingot





89%Cu, 6%Sn, and
5%Bi
1" Round Bar







Bar













Bar
Coil
Coil
Cast
p. | S. Thermoplastic Elast. V. Plating & Coatings
Application Examples





Valve Covers




High Pressure Bellows Pump









bushings, pump fixtures, pump impellers, fue
pump bushings, thrust washers, insert bearings,
gears, valves and valve components, etc.
Turbocharger Spindle Bushings (Floating Type)



Valve stems and trim, bearings and bushings,
fasteners, gears



Bearings, gears, impellers, rocker arms, valve
stems, brush holders, bearing races, small boat
propellers.




Fluid connectors, threaded inserts for plastic
parts, sensor bodies, thermostat parts


Wire harnesses






Exhaust Valves
Heat Shields, Turbo
Heat Shields, Turbo

Material Class





Magnesium-AZ91D,
Cast



Titanium-Sponge, Cast
Titanium-6AL4V, Bar
Titanium-6AL4V, Plate


Titanium-6AL4V, Cast





Bronze-932, Bar
Bronze-89320, Bar



Ni-AI-Bronze-630000,
Bar



Si-Brass-87500, Bar
Si-Brass-67300, Bar



Brass-36000, Bar


Copper-Pure, Wire






lnconel-751, Bar
lnconel-713C, Co
Nickel Alloy Gen, Cast
lnconel-713, Cast
Y.
Active Rate
2008





$ 2.42



$ 4.71
$ 34.37
$ 43.91


$ 21.30




$ 2.56
$ 2.56
$ 5.31


$ 2.44



$ 2.11
$ 3.71



$ 1.70


$ 2.45






$ 12.22
$ 6.00
$ 5.00
$ 6.00

Information Reference Source





USGS, AMM Reference, Purchasing
Centracore, Mark Luchese (09/1709) Low Volume Rate



USGS
Longbow
Longbow


Longbow




InfoMine for copper plus composition analysis
Estimate based on C93200
Wisco Alloys


InfoMine for copper plus composition analysis



InfoMine for copper plus composition analysis
Atlas Bronze Quote (quote price plus copper trend line)



InfoMine for copper plus composition analysis


InfoMine






Point price from Special Metals WV with trend analysis.
Estimate from Turbocharger Industry Expert
Need Material and Pricing Confirmation
Estimate from Turbocharqer Industry Expert
File:Final Report Costing Databases 120809.xls
EPA Contract: EP-C-07-069 WA 1-3
E.l,Page5of7
 Form Author: G. Kolwich
(248) 373-6000 Ext. 2411

-------
                                          APPENDIX E.I Material Costing Database Excerpt
                                                                         Appendix E.1
                                                                       Printed :12/9/2009
Ffl
Cat.
L CO
Item
JALTV
\ jj\ A. Carbon/Alloy Steel D. Cast Iron jj G. Magnesium Alloys K. Nickel Alloys l^j N.
\jj "| B.HSLA& Micro Alloy j E. Aluminum Alloys H. Titanium Alloys L Cobalt Alloys. o.
C. Stainless Steel Ij F. Powder Metal j J. Copper Alloys " M. [ [ p.
Material Description
rROUGHT & CASTING ALLOYS
L1. Wrought Alloys




Q. TH

































R. TH











L1.1 S


ERMOF

Q1. Po










Q3. Po




ellite®
Stellite® 6

LASTIC POLYMNERS

yamide (P A/Nylon)
Nylon 6
Nylon 6 (15% glass)
Nylon 6 (30 to 35% glass)
Nylon 66
Nylon 66 (30 to 35% glass)
Nylon 66 (50% glass)
Nylon 66, 40% Fibrous Minera
Reinforced
Nylon 1 2
Nylon 12, 30% glass

yethylem
HOPE Copolymer - blowmolding


Q4. Polybutylene Terephthalate (PBT)



Polybutylene Terephthalate


Q5. Acrylonitrile Butadiene Styrene (ABS)



ABS


Q6. Polypropylene (PP)


Random copolymer blow molding
grade.

Q9. Polyvinylchloride (PVC)


Blended NBR-PVC

Q9. Miscellaneous


ERMOS
Teflon® Polytetrafluoroethylene

ET POLYMERS
R1 Hydrocarbon, Unsaturated.









Natural rubber / TSR20
Synthetic poly-isoprene rubber
Styrene butadiene rubber
Butadiene rubber
Polubutadiene rubber
Polubutadiene rubber - glass filled
Butyl rubber
Chloro- and bromo- butyl rubber

Industry Specification




Base Co, Cr 27-32%, W4-6%, CO. 9-1 .4%,
Others Ni, Fe, Si, Mn, Mo




PA6
PA6GF15
PA6 GF30
PA66
PA66 GF30
PA66 GF50
PA66 FMR40%
PA12
PA12, GF30


HOPE



PBTGF20







PP









NR
IR
SBR
BR
PER
PBRGF20
IIR
CNR, BUR

Supplemental
Specification
Information




Bar










GMNA Spec PA66 060



































O. Thermoplastics T. p W Misc. •
R Thermosets. u Automotive Fluids. |«| X.
\ S. Thermoplastic Elast. V. Plating & Coatings jj|j Y. j"
Application Examples




Exhaust Valves





Air cooler tube outlet
Vacuum reservoir, Intake manifold
Fuel injector connector, hose asm end - pump to
turbo, chain tension guides
Intake manifold, cylinder cover, cooler asm end
caps
cooler asm end caps
Direct Injection Connectors
Reservior tube
PCV Hose Intake End


Rubberized blow molded air induction ducts and
couplings.



Silencer Air by-pass



Beta patch for battery closeout



High strength blow molded air induction ducts.


Rubberized blow molded air induction ducts and
couplings.






Hoses, O-rings, gaskets, tubes
Hoses, O-rings, gaskets, tubes
Hoses, O-rings, gaskets, tubes
Hoses, O-rings, gaskets, tubes
Hoses, O-rings, gaskets, tubes
Auxiliary water pump housing
Hoses, O-rings, gaskets, tubes
Hoses, O-rings, gaskets, tubes

Material Class




Stellite




Nylone, Inject.
Nylon6-15GF, Inject.
Nylon6-30GF, Inject.
Nylon66, Inject.
Nylon66-30GF, Inject.
Nylon66-50GF, Inject.
Nylon66-40FMR, Inject.
Nylon! 2, Inject.



HOPE BM Grade



PBT-GF20, Inject.







HD Polypro


NBR-PVC


PTFE, Inject.



The moset-NR
The moset-IR
The moset-SBR
The moset-BR
The moset-PBR
The moset-PBR-GF20
Thermoset-IIR


Active Rate
2008




$ 21.00




$ 1.65
$ 1.59
$ 1.76
$ 1.74
$ 1.54
$ 1.54
$ 1.54
$ 3.03
$ 3.41


$ 0.72



$ 1.46



$ 0.72



$ 0.87


$ 1.27


$ 6.70



$ 2.14

$ 1.32
$ 0.65
$ 0.82
$ 1.17
$ 1.37



Information Reference Source









IDES, Plastic News
IDES, Plastic News, Plastic Technology
IDES, Plastic News, Plastic Technology
IDES, Plastic News
IDES, Plastic News
IDES, Plastic News
Estimate based on PA
IDES, Plastic News, Plastic Technology
IDES, Plastic News, Plastic Technology






IDES, Plastic News



Plastic News









IDES, Plastic News



CMAI, Rubber Statistical Bulletin

CMAI, Rubber Statistical Bulletin
CMAI
The Innovation Group
The Innovation Group, Plastics News (for delta)
The Innovation Group


File:Final Report Costing Databases 120809.xls
EPA Contract: EP-C-07-069 WA 1-3
E.l,Page6of7
 Form Author: G. Kolwich
(248) 373-6000 Ext. 2411

-------
                                          APPENDIX E.I Material Costing Database Excerpt
                                                                         Appendix E.1
                                                                       Printed :12/9/2009
fi¥
Cat.
























S. TH


U. AU



V. PL






Item
| A. Carbon/Alloy Steel jf D. Cast Iron j
[ B. HSLA& Micro Alloy I E. Aluminum Alloys
P C. Stainless Steel I [ F. Powder Metal j
Material Description
Hydrocarbon Sa:. • ite :


Ethylene propylene (diene) rubber

R3. Nitrile


Nitri
e butadiene rubber

R8. Fluorocarbon


Fluoro elastomer

R10. Polyimide



Polyimide - Vespel SP-21
Polyimide - Vespel SP-21

R12. Polyur


sthane
Polyurethane elastomer, ester-
based

R13. Silicone



Silicone rubber


R14. Miscellaneous



;RMOP


•QMOI



LTINGS
SBR Tubing w. Fiber
Reinforcement
SBR Tubing w. Metal
Reinforcement
SBR Tubing w. Fiber
Reinforcement and outer wrap.
LASTIC ELASTOMERS
Olefinic
Olefinic

IVE FLUIDS
Engine Oil - Synthetic
Engine Oil - Regular

& COATINGS
V.1 Aluminum Cladding





Aluminum-Silicon Cladding
Aluminum-Silicon Cladding
Brake and Oil Line Platings


G. Magnesium Alloys K. Nickel Alloys 1 |" N.
H. Titanium Alloys L Cobalt Alloys. o.
J. Copper Alloys jf M. p.
Industry Specification

EPM/EPDM


NBR


FKM


PI 30%Carbon filled
PI 30%G lass filled


AU


MVQ



SBR Reinforced Tubing
SBR Reinforced Tubing
SBR Reinforced Tubing
Syn Rubber
TPE+TD33


(Price/Quart)
(Price/Quart)



3003 Sheet w. 4047 Cladding
Single Cladding, Combined Material
Thickness <0.060"
3003 Sheet w. 4047 Cladding
Single Cladding, Combined Material
Thickness >0.060"
GALFAN Hot Dipped


Supplemental
Specification
Information
























M-group Synthetic








Thickness tolerance
1 0% Base Material
Thickness
Thickness tolerance
1 0% Base Material
Thickness
Thickness 4mil or 0.1
mm


^ 0. Thermoplastics T. ""~ W Misc. j
R Thermosets. U Automotive Fluids. X.
| S. Thermoplastic Elast. V. Plating & Coatings Y.
Application Examples

Hoses, O-rings, gaskets, tubes


Hoses, O-rings, gaskets, tubes


ERG valve seals


thrust washers, bearings and seals — low-friction
properties, work with or without lubrication.



Hoses, O-rings, gaskets, tubes


Hoses, O-rings, gaskets, tubes






Hoses, O-rings, gaskets, tubes
Cooling Fan Shroud







Oil Coolers, Radiators, etc
Oil Coolers, Radiators, etc



Material Class

Thermoset-EPDM


Thermoset-NBR


Thermoset-FKM


Thermoset-Vespel
SP21CF30
Thermoset-Vespel
SP21GF30


Thermoset-AU


Thermoset-MVQ



SBR-Fiber Rein.,
Extruded
SBR-Metal Rein.,
Extruded
SBR-Fiber Rein. W.
Outer Wrap, Extruded
TPE-PP/EPDM, Inject.



Engine Oil-Synthetic
Engine Oil-Regular



Aluminum-3003/4047A,
Cladding
Aluminum-3003/4047B,
Cladding
GALFAN


Active Rate
2008

$ 1.83


$ 1.27


$ 12.50


$ 35.18
$ 24.36


$ 1.77


$ 4.50



$ 1.85
$ 2.24
$ 2.05
$ 0.99
$ 1.04


$ 1.40
$ 0.60



$ 1.65
$ 2.10
$ 0.56



Information Reference Source

The Innovation Group


The Innovation Group


Plastics News


PT online, Plastic News - Trend line from surrogate materials
PT online, Plastic News - Trend line from surrogate materials


Rubber and Plastics News






1.40x$SBR
1.70x$SBR
1.55x$SBR
Plastics News
Plastics News, Hutsmann


Need Pricing Confirmation Source
Need Pricing Confirmation Source



Sue received feedback from Alcoa (3/27/09)
Sue received feedback from Alcoa (3/27/09)
http://metalprices.com/


J Notes
j 1 . Material composition analysis was used when published data on specific materials was not available. Materials in related categories with similar compositions and established price points were compared to the mater a under investigation. Elemental compositions were then
jcompared and deltas defined to determine cost d fferences. Since the cost differences are calculated from the elemental deltas, it was necessary to obtain the cost of the base elements. The costs of base elements such as zinc, copper and magnesium are readily available and
J published in several websites. Next, the cost per pound for each element that varied was multipl ed by the delta percentage difference. These incremental elemental cost differences (plus/minus) were added to the base price point to establish a price per pound of the material under
j investigation. Lastly the surcharge was added to the cost to obtain the final alloy price per pound. A surcharge is a special charge to cover unexpected or temporary costs in the production of alloys. Surcharges are also posted on various manufacturers websites to alert their
j customers of pending price fluctuations.
File:Final Report Costing Databases 120809.xls
EPA Contract: EP-C-07-069 WA 1 -3
E.l,Page7of7
 Form Author: G. Kolwich
(248) 373-6000 Ext. 2411

-------
APPENDIX E.2 Labor Costing Database Excerpt
      Appendix E.2
    Printed:12/9/2009
II I^ISf
I


1
2
3
4
5
6
7
8
9
10
11
12
13
14
socs
Code
(BLS)

or Vehic
51-2022
51-2023
51-2031
51-2092
51-2093
51-2099
51-4011
51-4021
51-4022
51-4031
51-4032
51-4033
51-4034
51-4035
Direct Labor Title
(BLS)

e Parts Manufacturing - NA
Electrical and Electronic
Equipment Assemblers
Electromechanical
Equipment Assemblers
Engine and Other Machine
Assemblers
Team Assemblers
Timing Device Assemblers,
Adjusters and Calibrators
Assemblers and Fabricators,
All Other
Computer-Controlled
VlachineTool Operators
(Metal & Plastic)
Extruding and Drawing
Vlachine setters, Operators,
and Tenders, Metal & Plastic
Forging Machine Setters,
Operators, and Tenders,
Metal and Plastic
Cutting, Punching, and
Press Machine Setters,
Operators and Tenders,
Metal and Plastic
Drilling and Boring Machine
Tool Setters, Operators, and
Tenders, Metal and Plastic
Grinding, Lapping, Polishing
, and Buffing Machine Tool
Setters, Operators, and
Tenders, Metal and Plastics
Lathe and Turning Machine
Tool Setters, Operators, and
Tenders, Metal and Plastic
Milling and Planing Machine
Setters, Operators, and
Tenders, Metal and Plastic.
Direct Labor Description (BLS)

CS 336300
Assemble or modify electrical or electronic equipment,
such as computers, test equipment telemetering
systems, electric motors, and batteries.
Assemble or modify electromechanical equipment or
devices, such as servomechanisms, gyros,
dynamometers, magnetic drums, tape drives, brakes,
control linkage, actuators, and appliances.
Construct, assemble, or rebuild machines, such as
engines, turbines, and similar equipment used in such
industries as construction, extraction, textiles, and
paper manufacturing.
Work as part of a team having responsibility for
assembling an entire product or component of a
product. Team assemblers can perform all tasks
conducted by the team in the assembly process and
rotate through all or most of them rather than being
assigned
Perform precision assembling or adjusting, within
narrow tolerances, of timing devices, such as watches,
clocks, or chronometers. Exclude "Watch Repairers"
(49-9064).
All assemblers and fabricators not listed separately.
Operate computer-controlled machines or robots to
perform one or more machine functions on metal or
plastic work pieces.
Set up, operate, or tend machines to extrude or draw
thermoplastic or metal materials into tubes, rods, hoses,
wire, bars, or structural shapes.
Set up, operate, or tend forging machines to taper,
shape, or form metal or plastic parts.
Set up, operate, or tend machines to saw, cut, shear,
slit, punch, crimp, notch, bend, or straighten metal or
plastic material.
Set up, operate, or tend drilling machines to drill, bore,
ream, mill, or countersink metal or plastic work pieces.
Set up, operate, or tend grinding and related tools that
remove excess material or burrs from surfaces, sharpen
edges or corners, or buff, hone, or polish metal or
plastic work pieces.
Set up, operate, or tend lathe and turning machines to
turn, bore, thread, form, or face metal or plastic
materials, such as wire, rod, or bar stock.
Set up, operate, or tend milling or planing machines to
mill, plane, shape, groove, or profile metal or plastic
work pieces.
Typical Application
Association


Sensors, Controllers,
PCM
Electro Mechanical
Assemblies, Motors,
Actuators, etc.
Complex Assembly
General Assembly
Assembly operations
requiring feedback during
assembly
Stand alone complete
assembly stations.
CMC Stations,
Extrusion, Seals,
Gaskets, Grommets, etc.
(Considered to be mostly
polymer materials with
exception of some very
ductile metals)
Cold or Hot Forgings (
Majority Metals).
Stamping & Forming,
Metal or Plastic
Smaller Machining
Stations and/or with less
automation
Smaller Grinding/Honing
Stations and/or with less
automation
Smaller Turning Station
and/or with less
automation
Milling Operations
Labor Classification

Average Rate
Electrical Assembly
Electromechanical Assembly
Complex Assembly
General Assembly
Precision Assembly
Work Cell Assembly
CMC Operator
Extruding/Drawing Operator
Forging Operator
Cut/Punch/Forming Operator
Drilling/Boring Operator
Grinding/Polishing Operator
Lathe/Turning Operator
Milling/Planing Operator
Active
Rate
2008

— »
$29.69
$37.35
$42.90
$35.51
$25.74
$49.78
$35.70
$54.35
$38.52
$42.18
$43.35
$44.48
$37.60
$35.37
Production Year Start (Baseline) 2008
Mean
Hourly
Wage

$16.42
$12.85
$16.06
$17.64
$13.66
$11.07
$19.38
$15.25
$18.92
$14.65
$16.04
$18.52
$17.63
$16.49
$15.41
Indirect
Labor
Rate
Ratio
ILRR
"%"


40%
40%
43%
52%
40%
50%
42%
67%
54%
54%
40%
50%
38%
40%
Indirect
Labor
Contribution
$/Hour

$8.18
$5.14
$6.42
$7.59
$7.10
$4.43
$9.69
$6.41
$12.68
$7.91
$8.66
$7.41
$8.82
$6.27
$6.16
MRO
Labor
Rate
Ratio
MLRR
"%"

16.16%
12%
13%
17%
19%
13%
19%
12%
22%
19%
19%
14%
16%
12%
11%
MRO Labor
Contribution
$/Hour

$2.67
$1.54
$2.09
$3.00
$2.60
$1.44
$3.68
$1.83
$4.16
$2.78
$3.05
$2.59
$2.82
$1.98
$1.70
Fringe
Allocation
"%"

52.00%
52%
52%
52%
52%
52%
52%
52%
52%
52%
52%
52%
52%
52%
52%
Fringe
Contribution
$/Hour

$14.18
$10.16
$12.78
$14.68
$12.15
$8.81
$17.03
$12.21
$18.59
$13.18
$14.43
$14.83
$15.22
$12.86
$12.10
Total
Labor
Rate
$/Hour

$41.45
$29.69
$37.35
$42.90
$35.51
$25.74
$49.78
$35.70
$54.35
$38.52
$42.18
$43.35
$44.48
$37.60
$35.37

Information Source


US Department of Labor, May 20007 National Industry-Specific
Occupational Employment and Wage Estimates
NAICS 336300 - Motor Vehicle Parts Manufacturing
http //www bis gov/oes/current/naics4_336300 htm
US Department of Labor, May 20007 National Industry-Specific
Occupational Employment and Wage Estimates
NAICS 336300 - Motor Vehicle Parts Manufacturing
http //www bis gov/oes/curreni/naics4_336300 htm
US Department of Labor, May 20007 National Industry-Specific
Occupational Employment and Wage Estimates
NAICS 336300 - Motor Vehicle Parts Manufacturing
http //www bis gov/oes/curreni/naics4_336300 htm
US Department of Labor, May 20007 National Industry-Specific
Occupational Employment and Wage Estimates
NAICS 336300 - Motor Vehicle Parts Manufacturing
http //www bis gov/oes/curreni/naics4_336300 htm
US Department of Labor, May 20007 National Industry-Specific
Occupational Employment and Wage Estimates
NAICS 336300 - Motor Vehicle Parts Manufacturing
http //www bis gov/oes/curreni/naics4_336300 htm
US Department of Labor, May 20007 National Industry-Specific
Occupational Employment and Wage Estimates
NAICS 336300 - Motor Vehicle Parts Manufacturing
http //www bis gov/oes/current/naics4_336300 htm
US Department of Labor, May 20007 National Industry-Specific
Occupational Employment and Wage Estimates
NAICS 336300 - Motor Vehicle Parts Manufacturing
http //www bis gov/oes/current/naics4_336300 htm
US Department of Labor, May 20007 National Industry-Specific
Occupational Employment and Wage Estimates
NAICS 336300 - Motor Vehicle Parts Manufacturing
http //www bis gov/oes/current/naics4_336300 htm
US Department of Labor, May 20007 National Industry-Specific
Occupational Employment and Wage Estimates
NAICS 336300 - Motor Vehicle Parts Manufacturing
http //www bis gov/oes/curreni/naics4_336300 htm
US Department of Labor, May 20007 National Industry-Specific
Occupational Employment and Wage Estimates
NAICS 336300 - Motor Vehicle Parts Manufacturing
http //www bis gov/oes/curreni/naics4_336300 htm
US Department of Labor, May 20007 National Industry-Specific
Occupational Employment and Wage Estimates
NAICS 336300 - Motor Vehicle Parts Manufacturing
http //www bis gov/oes/curreni/naics4_336300 htm
US Department of Labor, May 20007 National Industry-Specific
Occupational Employment and Wage Estimates
NAICS 336300 - Motor Vehicle Parts Manufacturing
http //www bis gov/oes/curreni/naics4_336300 htm
US Department of Labor, May 20007 National Industry-Specific
Occupational Employment and Wage Estimates
NAICS 336300 - Motor Vehicle Parts Manufacturing
http //www bis gov/oes/curreni/naics4_336300 htm
US Department of Labor, May 20007 National Industry-Specific
Occupational Employment and Wage Estimates
NAICS 336300 - Motor Vehicle Parts Manufacturing
http //www bis gov/oes/curreni/naics4_336300 htm
File:Final Report Costing Databases120809.xls
EPA Contract: EP-C-07-069 WA13
                       E.2, Page 1 of 4
  Author: Greg Kolwich
(248) 373-6000 Ext 2411

-------
APPENDIX E.2 Labor Costing Database Excerpt
      Appendix E.2
    Printed:12/9/2009
njfcjy



I

15


16


17



18




19





socs
Code
(BLS)

51-4072


51-4081


51-4122



51-4191




51-4193






Direct Labor Title
(BLS)

Molding, Core making, and
Casting Machine Setters,
Operators, and Tenders,
Metal & Plastic
Multiple Machine Tool
Setters, Operators, and
Tenders, Metal and Plastic.
Welding, Soldering, and
Brazing Machine Setters,
Operators, and Tenders.


Heat Treat Equipment
Setters, Operators, and
Tenders, Metal and Plastic


Plating and Coating Machine
Setters, Operators, and
Tenders, Metal and Plastic




Direct Labor Description (BLS)

Set up, operate, or tend metal or plastic molding,
casting, or core making machines to mold or cast metal
or thermoplastic parts or products.

Set up, operate, or tend to more than one type of
cutting or forming machine tool or robot.

Set up, operate, or tend welding, soldering, or brazing
machines or robots that weld, braze, solder, or heat
treat metal products, components, or assemblies.
Include workers who operate laser cutters or laser-beam
machines.
Set up, operate, or tend heating equipment, such as
heat-treating furnaces, flame-hardening machines,
induction machines, soaking pits, or vacuum equipment
to temper, harden, anneal, or heat-treat metal or plastic
objects.
Set up, operate, or tend plating or coating machines to
coat metal or plastic products with chromium, zinc,
copper, cadmium, nickel, or other metal to protect or
decorate surfaces. Include electrolytic processes.



Typical Application
Association

Molding and Casting
Operators





Various Welding
Operations



Heat Treat




Plating & Finishes






Labor Classification

Mold/Cast/Sinter Operator


Will not use, too general and
overlap with other categories.

Welding/Soldering Operator



Heat Treat Operator




Plating/Coating Operator



Active
Rate

2008

$43.52


$44.85


$44.96



$46.52




$55.17



Production Year Start (Baseline) 2008



Mean
Hourly

$15.15


$17.46


$18.72



$16.28




$20.86



Indirect
Labor
Rate
Ratio
ILRR
66%


52%


42%



69%




60%




Indirect
Labor
Contribution
$/Hour
$10.00


$9.08


$7.86



$11.23




$12.52



MRO
Labor
Rate
Ratio
MLRR
23%


17%


16%



19%




14%




MRO Labor
Contribution

$3.48


$2.97


$3.00



$3.09




$2.92




Fringe
Allocation




52%


52%



52%




52%




Fringe
Contribution




$15.34


$15.38



$15.92




$18.87




Total
Labor
Rate
$/Hour



$44.85


$44.96



$46.52




$55.17







Information Source

US Department of Labor, May 20007 National Industry-Specific
Occupational Employment and Wage Estimates


US Department of Labor, May 20007 National Industry-Specific

http //www bis gov/oes/current/naics4_336300 htm
US Department of Labor, May 20007 National Industry-Specific
Occupational Employment and Wage Estimates



US Department of Labor, May 20007 National Industry-Specific




US Department of Labor, May 20007 National Industry-Specific



File:Final Report Costing Databases120809.xls
EPA Contract: EP-C-07-069 WA13
                       E.2, Page 2 of 4
  Author: Greg Kolwich
(248) 373-6000 Ext 2411

-------
APPENDIX E.2 Labor Costing Database Excerpt
      Appendix E.2
    Printed:12/9/2009
njfcjy
|

1
2
3
4
5
6
7
8
9
10
11
12
13
14
socs
Code
(BLS)

51-2022
51-2031
51-2092
51-2099
51-4011
51-4022
51-4031
51-4032
51-4033
51-4034
51-4035
51-4072
51-4081
51-4122
Direct Labor Title
(BLS)

Electrical and Electronic
Equipment Assemblers
Engine and Other Machine
Assemblers
Team Assemblers
Assemblers and Fabricators,
All Other
Computer-Controlled
VlachineTool Operators
(Metal & Plastic)
Forging Machine Setters,
Operators, and Tenders,
Metal and Plastic
Cutting, Punching, and
Press Machine Setters,
Operators and Tenders,
Metal and Plastic
Drilling and Boring Machine
Tool Setters, Operators, and
Tenders, Metal and Plastic
Grinding, Lapping, Polishing
, and Buffing Machine Tool
Setters, Operators, and
Tenders, Metal and Plastics
Lather and Turning Machine
Tool Setters, Operators, and
Tenders, Metal and Plastic
Milling and Planing Machine
Setters, Operators, and
Tenders, Metal and Plastic.
Molding, Core making, and
Casting Machine Setters,
Operators, and Tenders,
Metal & Plastic
Multiple Machine Tool
Setters, Operators, and
Tenders, Metal and Plastic.
Welding, Soldering, and
Brazing Machine Setters,
Operators, and Tenders.
Direct Labor Description (BLS)

Assemble or modify electrical or electronic equipment,
such as computers, test equipment telemetering
systems, electric motors, and batteries.
Construct, assemble, or rebuild machines, such as
engines, turbines, and similar equipment used in such
industries as construction, extraction, textiles, and
paper manufacturing.
Work as part of a team having responsibility for
assembling an entire product or component of a
product. Team assemblers can perform all tasks
conducted by the team in the assembly process and
rotate through all or most of them rather than being
assigned
All assemblers and fabricators not listed separately.
Operate computer-controlled machines or robots to
perform one or more machine functions on metal or
plastic work pieces.
Set up, operate, or tend forging machines to taper,
shape, or form metal or plastic parts.
Set up, operate, or tend machines to saw, cut, shear,
slit, punch, crimp, notch, bend, or straighten metal or
plastic material.
Set up, operate, or tend drilling machines to drill, bore,
ream, mill, or countersink metal or plastic work pieces.
Set up, operate, or tend grinding and related tools that
remove excess material or burrs from surfaces, sharpen
edges or corners, or buff, hone, or polish metal or
plastic work pieces.
Set up, operate, or tend lathe and turning machines to
turn, bore, thread, form, or face metal or plastic
materials, such as wire, rod, or bar stock.
Set up, operate, or tend milling or planing machines to
mill, plane, shape, groove, or profile metal or plastic
work pieces.
Set up, operate, or tend metal or plastic molding,
casting, or core making machines to mold or cast metal
or thermoplastic parts or products.
Set up, operate, or tend more than one type of cutting
or forming machine tool or robot.
Set up, operate, or tend welding, soldering, or brazing
machines or robots that weld, braze, solder, or heat
treat metal products, components, or assemblies.
Include workers who operate laser cutters or laser-beam
machines.
Typical Application
Association

Electronic Subassembly
Bui Id- Up/Assembly
Complex Assembly:
Engines, Transmissions
General Assembly
Stand alone complete
assembly stations.
CMC Stations,
Cold or Hot Forgings,
Metal or Plastic
Stamping & Forming,
Metal or Plastic
Smaller Machining
Stations and/or with less
automation
Smaller Grinding/Honing
Stations and/or with less
automation
Smaller Turning Station
and/or with less
automation
Milling Operations
Molding and Casting
Operators
Smaller Machines and/or
with High Automation for
Injection Molding or
Casting
Various Welding
Operations
Labor Classification
Average Rate
Electrical Assembly-OEM
Complex Assembly-OEM
General Assembly-OEM
Work Cell Operator-OEM
CMC Operator-OEM
Forging Operator-OEM
Cut/Punch/Forming Operator-
OEM
Drilling/Boring Operator-OEM
Grinding/Polishing Operator-OEM
Lathe/Turning Operator-OEM
Milling/Planing Operator-OEM
Mold/Cast/Sinter Operator-OEM
Will not use, too general and
overlap with other categories.
Welding/Soldering Operator-OEM
Active
Rate
2008
— *
$71.82
$97.34
$83.31
$95.87
$68.07
$58.96
$96.00
$112.19
$98.71
$83.05
$71.22
$77.92
$87.55
$1 03.78
Production Year Start (Baseline) 2008
Mean
Hourly
Wage

$18.54
$26.18
$20.28
$24.42
$17.00
$12.74
$20.86
$28.02
$22.87
$21.73
$18.02
$15.69
$19.47
$27.34
Indirect
Labor
Rate
Ratio
ILRR
"%"

38%
34%
44%
38%
42%
58%
58%
40%
50%
37%
41%
68%
56%
35%
Indirect
Labor
Contribution
$/Hour

$7.05
$8.90
$8.92
$9.28
$7.14
$7.39
$12.10
$11.21
$11.44
$8.04
$7.39
$10.67
$10.90
$9.57
MRO
Labor
Rate
Ratio
MLRR
"%"

11%
9%
14%
13%
12%
20%
19%
14%
16%
10%
11%
23%
17%
11%
MRO Labor
Contribution
$/Hour

$2.04
$2.36
$2.84
$3.17
$2.04
$2.55
$3.96
$3.92
$3.66
$2.17
$1.98
$3.61
$3.31
$3.01
Fringe
Allocation
"%"
160.00%
160%
160%
160%
160%
160%
160%
160%
160%
160%
160%
160%
160%
160%
160%
Fringe
Contribution
$/Hour

$44.20
$59.90
$51.27
$59.00
$41.89
$36.28
$59.08
$69.04
$60.74
$51.11
$43.82
$47.95
$53.88
$63.87
Total
Labor
Rate
$/Hour

$71.82
$97.34
$83.31
$95.87
$68.07
$58.96
$96.00
$112.19
$98.71
$83.05
$71.22
$77.92
$87.55
$103.78

Information Source

US Department of Labor, May 20007 National Industry-Specific
Occupational Employment and Wage Estimates
http //www bis gov/oes/current/naics4_3361 00 htm
US Department of Labor, May 20007 National Industry-Specific
Occupational Employment and Wage Estimates
NAICS 3361 00 - Motor Vehicle Manufacturing
http //www bis gov/oes/current/naics4_3361 00 htm
US Department of Labor, May 20007 National Industry-Specific
Occupational Employment and Wage Estimates
http //www bis gov/oes/current/naics4_3361 00 htm
US Department of Labor, May 20007 National Industry-Specific
Occupational Employment and Wage Estimates
NAICS 3361 00 - Motor Vehicle Manufacturing
http //www bis gov/oes/current/naics4_3361 00 htm
US Department of Labor, May 20007 National Industry-Specific
Occupational Employment and Wage Estimates
NAICS 3361 00 - Motor Vehicle Manufacturing
http //www bis gov/oes/current/naics4_3361 00 htm
US Department of Labor, May 20007 National Industry-Specific
Occupational Employment and Wage Estimates
NAICS 3361 00 - Motor Vehicle Manufacturing
http //www bis gov/oes/current/naics4_3361 00 htm
US Department of Labor, May 20007 National Industry-Specific
Occupational Employment and Wage Estimates
NAICS 3361 00 - Motor Vehicle Manufacturing
http //www bis gov/oes/current/naics4_3361 00 htm
US Department of Labor, May 20007 National Industry-Specific
Occupational Employment and Wage Estimates
NAICS 3361 00 - Motor Vehicle Manufacturing
http //www bis gov/oes/current/naics4_3361 00 htm
US Department of Labor, May 20007 National Industry-Specific
Occupational Employment and Wage Estimates
NAICS 3361 00 - Motor Vehicle Manufacturing
http //www bis gov/oes/current/naics4_3361 00 htm
US Department of Labor, May 20007 National Industry-Specific
Occupational Employment and Wage Estimates
NAICS 3361 00 - Motor Vehicle Manufacturing
http //www bis gov/oes/current/naics4_3361 00 htm
US Department of Labor, May 20007 National Industry-Specific
Occupational Employment and Wage Estimates
NAICS 3361 00 - Motor Vehicle Manufacturing
http //www bis gov/oes/current/naics4_3361 00 htm
US Department of Labor, May 20007 National Industry-Specific
Occupational Employment and Wage Estimates
NAICS 3361 00 - Motor Vehicle Manufacturing
http //www bis gov/oes/current/naics4_3361 00 htm
US Department of Labor, May 20007 National Industry-Specific
Occupational Employment and Wage Estimates
NAICS 3361 00 - Motor Vehicle Manufacturing
http //www bis gov/oes/current/naics4_3361 00 htm
US Department of Labor, May 20007 National Industry-Specific
Occupational Employment and Wage Estimates
NAICS 3361 00 - Motor Vehicle Manufacturing
http //www bis gov/oes/current/naics4_3361 00 htm
File:Final Report Costing Databases120809.xls
EPA Contract: EP-C-07-069 WA13
                       E.2, Page 3 of 4
  Author: Greg Kolwich
(248) 373-6000 Ext 2411

-------
                                                    APPENDIX E.2 Labor Costing Database Excerpt
                                                                                   Appendix E.2
                                                                                 Printed:12/9/2009
njfcjy



I

15



16


I . M

1


socs
Code
(BLS)

51-4191



51-9122


scellane
NA




Direct Labor Title
(BLS)

Heat Treat Equipment
Setters, Operators, and
Tenders, Metal and Plastic


Painters, Transportation
Equipment

IUS
Not Applicable




Direct Labor Description (BLS)

Set up, operate, or tend heating equipment, such as
heat-treating furnaces, flame-hardening machines,
induction machines, soaking pits, or vacuum equipment
to temper, harden, anneal, or heat-treat metal or plastic
objects.
Operate or tend painting machines to paint surfaces of
transportation equipment, such as automobiles, buses,
trucks, trains, boats, and airplanes. Include painters in
auto body repair facilities.

Category to be referenced when there is no impact on
Labor associated with technology change.



Typical Application
Association

Heat Treat



Painting








Labor Classification

Heat Treat Operator-OEM



Painter Operator-OEM



Not Applicable

Active
Rate

2008

$1 37.35



$1 05.77



$0.00

Production Year Start (Baseline) 2008



Mean
Hourly

$28.10



$23.38





Indirect
Labor
Rate
Ratio
ILRR
69%



60%






Indirect
Labor
Contribution
$/Hour




$14.03





MRO
Labor
Rate
Ratio
MLRR
19%



14%






MRO Labor
Contribution





$3.27






Fringe
Allocation

160%



160%






Fringe
Contribution





$65.09






Total
Labor
Rate
$/Hour




$105.77



$0.00





Information Source

US Department of Labor, May 20007 National Industry-Specific
Occupational Employment and Wage Estimates
htt //www bis ov/oes/curreni/naics4 3361 00 htm


US Department of Labor, May 20007 National Industry-Specific
NAICS 3361 00 - Motor Vehicle Manufacturing




File:Final Report Costing Databases120809.xls
EPA Contract: EP-C-07-069 WA13
E.2, Page 4 of 4
  Author: Greg Kolwich
(248) 373-6000 Ext 2411

-------
                                      APPENDIX E.3 Manufacturing Overhead Costing Database Excerpt
                                                                               Appendix E.3
                                                                             Printed:12/9/2009
FE¥
Cat.















Item


A1.
A1.1
A1.2
A1.3
A1.4
A1.5

C1.
C1.1
C1.2
C1.3
C1.4
C1.5
Burden Title

CLASTIC PROCESSING
Injection Molding ( General, Station
Injection Molding, Large Size and/or
High Complexity
Injection Molding, Medium-Large Size
and/or Moderate-High Complexity
Injection Molding, Medium Size and/or
Moderate Complexity
Injection Molding, Small-Medium Size
and/or Low-Moderate Complexity
Injection Molding, Small Size and/or
Low Complexity

Diecasting - Aluminum (General, St
Aluminum Diecasting, Large,
Complex Components with Inserts
Aluminum Diecasting, Large Size
and/or High Complexity.
Aluminum Diecasting, Medium-Large
Size and/or Moderate-High
Complexity.
Aluminum Diecasting, Medium Size
and/or Moderate Complexity.
Aluminum Diecasting, Small-Medium
Size and/or Low-Moderate Complexity



Ba
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5

tie
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
j A Thermoplastic j j D. Forging • G. Machining j j K. Balancing j f N. Washing ! ! R. OEM Assembly ! j u. X.
j B.Thermoset !j E. Stamping & Forming ![ H. Turning ! f L. Heat Treat jj p. T1/T2/T3 AssV jf S. !j V. If Y. Miscellaneous !
f c. Casting jj F. Powder Metal ! f J. Grinding j j M. Plating |f Q. OEM Machining jj T. jj W. | Z. j
Primary Processing Equipment


sed, Potential for Material Considerations)
Injection Molding Machines (1 500-3000 Ton)
Injection Molding Machines (800-1500 Ton)
Injection Molding Machines (400-800 Ton)
Injection Molding Machines (200-400 Ton)
Injection Molding Machines (55-1 50 Ton)

n Based )
Cold Chamber Die Casting Machine (2600-3800 Ton)
Cold Chamber Die Casting Machine (2600-3800 Ton)
Cold Chamber Die Casting Machine (1 800-2600 Ton)
Cold Chamber Die Casting Machine (1 000-1 800 Ton)
Cold Chamber Die Casting Machine (500-1000 Ton)




1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5


1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
7
Secondary Process Equipment



Chiller
Dryer
Mold Temperature Control Unit
Basic Material Handling Equipment
Chiller
Dryer
Temperature Control Unit
Basic Material Handling Equipment
Chiller
Dryer
Mold Temperature Control Unit
Basic Material Handling Equipment
Chiller
Dryer
Mold Temperature Control Unit
Basic Material Handling Equipment
Chiller
Dryer
Mold Temperature Control Unit
Basic Material Handling Equipment


Melting Equipment
Automation for applying mold release agents, removing
cast parts, etc.
Die Cast Mold Temperature Control Unit
Robotic equipment for loading inserts into the tool.
Melting Equipment
Automation for applying mold release agents, removing
cast parts, etc.
Die Cast Mold Temperature Control Unit
Melting Equipment
Automation for applying mold release agents, removing
cast parts, etc.
Die Cast Mold Temperature Control Unit
Melting Equipment
Automation for applying mold release agents, removing
cast parts, etc.
Die Cast Mold Temperature Control Unit
Melting Equipment
Automation for applying mold release agents, removing
cast parts, etc.
Die Cast Mold Temperature Control Unit
Product Examples




Intake Manifolds,

Timing Chain Tensioner, Guides,



Engine Blocks, Bed Plates, etc




Burden Classification



Inject. Mold, LS
Inject. Mold, MLS
Inject. Mold, LS
Inject. Mold, SMS
Inject. Mold, SS


Diecast, LS, HC, w. Inserts
Diecast, LS
Diecast, LS, HC
Diecast, MLS
Diecast, MHC
Diecast, MS
Diecast, SMS
Diecast, LMC

Active Rate
2008



$151.77
$90.59
$50.58
$28.80
$16.39


$318.10
$301.91
$301.91
$247.89
$247.89
$197.05
$197.05
$116.73
$116.73

Information Source




Harry Manvel-Mitsubishi
Sales>harry@towerklean.com
Rates calculated using acquired data and Burden
Calculator Template.
Where possible, rates were validated with T1 /T2
supplier data.
Same as above
Same as above
Same as above
Same as above


Die casting equipment source: Buhler Prince
Mark.Los@Buhlerprince.com
Rates calculated using acquired data and Burden
Calculator Template.
When possible, rates were validated with T1 /T2
supplier data.
Same as above
Same as above
Same as above
Same as above
File:Final Report Costing Databases120809.xls
EPA Contract: EP-C-07-069 WA13
E.3, Page 1 of 9
Form Author: G. Kolwich
(248) 373-6000 Ext. 2411

-------
                                      APPENDIX E.3 Manufacturing Overhead Costing Database Excerpt
                                                                               Appendix E.3
                                                                             Printed:12/9/2009
FE¥
Cat.












Item
C1.6
mpmc
E1.
E1.1
E1.2
E1.3
E1.4
E1.5
E1.6
E1.7
E1.8
E1.9
Burden Title
Aluminum Diecasting, Small Size
and/or Low Complexity
& Forming Processes
Stamping & Forming, General, Stati
Stamping & Forming, 2X Large Size
Stamping & Forming, Extra Large
Size,
Stamping & Forming, Large Size
Stamping & Forming, Medium-Large
Size
Stamping & Forming, Medium Size
Stamping & Forming, Small-Medium
Size
Stamping & Forming, Small Size
Stamping & Forming, Extra Small
Size
Stamping & Forming, Terminals

1
2
3
4
5

A Thermoplastic j j D. Forging G. Mac
B. Thermoset !j E. Stamping & Forming ![ H. Tu
ining j j K. Balancing j f N. Washing ! [ R. OEM Assembly j j u.
ning ! f L. Heat Treat j | p. T1/T2/T3 AssV j[ s- !j V.
JL==?==I
! f Y. Miscellaneous !
f c. Casting jj F. Powder Metal jf J. Grinding j j M. Plating jf Q. OEM Machining jj T. jj W. !j Z. j
Primary Processing Equipment
Cold Chamber Die Casting Machine (0-500 Ton)

•n Based
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
2
3
4
5
1
2
3
4
5
Vertical Stamping Press, Tonnage 2000-3000
Vertical Stamping Press, Tonnage 1 500-2000
Vertical Stamping Press, Tonnage 1 000-1 500
Vertical Stamping Press, Tonnage 800-1000
Vertical Stamping Press, Tonnage 600-800
Vertical Stamping Press, Tonnage 400-600
Vertical Stamping Press, Tonnage 200-400
Vertical Stamping Press, Tonnage 60-200
Vertical Stamping Press, Tonnage 0-60

1
2
3
4
7


1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
Secondary Process Equipment
Melting Equipment
Automation for applying mold release agents, removing
cast parts, etc.
Die Cast Mold Temperature Control Unit


Uncoiler & Straightener
Uncoiler & Straightener
Uncoiler & Straightener
Uncoiler & Straightener
Uncoiler & Straightener
Uncoiler & Straightener
Uncoiler & Straightener
Uncoiler & Straightener
Uncoiler & Straightener
Product Examples











Electrical Terminals
Burden Classification
Diecast, SS


Stamp/Form, 2XLS
Stamp/Form, XLS
Stamp/Form, LS
Stamp/Form, MLS, MHC
Stamp/Form, MLS
Stamp/Form, SMS, MHC
Stamp/Form, MS
Stamp/Form, SMS
Stamp/Form, SMS, LMC
Stamp/Form, SS
Stamp/Form, XSS
Stamp/Form, Terminals

Active Rate
2008
$70.80


$281.92
$199.37
$141.76
$141.76
$106.69
$0.00
$83.80
$60.65
$60.65
$42.91
$24.60
$15.50

Information Source


Same as above


Pricing information from Emprotech and
Confidential Business Information (CBI) source.
Rates calculated using acquired data and Burden
Calculator Template.
Where possible, rates were validated with T1 /T2
supplier data.
Same as above
Same as above
Same as above
Same as above
Same as above
Same as above
Same as above
Same as above
File:Final Report Costing Databases120809.xls
EPA Contract: EP-C-07-069 WA13
E.3, Page 2 of 9
Form Author: G. Kolwich
(248) 373-6000 Ext. 2411

-------
                                      APPENDIX E.3 Manufacturing Overhead Costing Database Excerpt
                                                                               Appendix E.3
                                                                             Printed:12/9/2009
FE¥
Cat.
G. Ma










Item
chinin
G1.
G1.1
G1.2
G1.3
G1.4
G1.5
G2.
G2.1
G2.2
G2.3
Burden Title
3
<4 Axis, Manual Load, CMC Horizon
CMC Machining, Large Size and/or
High Complexity
(7.5% Premium paid for machining
aggressive materials, i.e.,
Hypereutectic Aluminums)
CMC Machining, Medium-Large Size
and/or Moderate-High Complexity.
(7.5% Premium paid for machining
aggressive materials)
CMC Machining, Medium Size and/or
Moderate Complexity
(7.5% Premium paid for machining
aggressive materials)
CMC Machining, Small-Medium Size
and/or Low-Moderate Complexity.
(7.5% Premium paid for machining
aggressive materials)
CMC Machining, Small Size and/or
Low Complexity
(7.5% Premium paid for machining
aggressive materials)
5 Axis and/or Automatic L> CMC
5 Axis and/or Auto Load, CMC
Machining, Large Size and/or High
Complexity
(7.5% Premium paid for machining
aggressive materials, i.e.,
Hypereutectic Aluminums)
5 Axis and/or Auto Load, CMC
Machining, Auto Load, Medium-Large
Size and/or Moderate-High
Complexity.
(7.5% Premium paid for machining
aggressive materials)
5 Axis and/or Auto Load, 5 Axis CMC
Machining, Auto Load, Medium Size
and/or Moderate Complexity
(7.5% Premium paid for machining
aggressive materials)


al
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
Ho
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
j A Thermoplastic j j D. Forging j j G. Machining j j K. Balancing ! N. Washing ! ! R. OEM Assembly ! j u. X.
j B.Thermoset !j E. Stamping & Forming |[ H. Turning j f L. Heat Treat jj p. T1/T2/T3 AssV |( S. jj V. If Y. Miscellaneous !
f C. Casting jj F. Powder Metal ! f J. Grinding j j M. Plating jl" Q. OEM Machining jj T. jj W. |j Z. j
Primary Processing Equipment

Machining Center (X,Y,Z and Rotation "B"), General
HS-7R - Pallet Size 2032X1 01 6 mm, 1 0,000 Ib
Capacity (PC:
Work piece Envelop (02450 x 1 000 mm)
Travel X,Y,Z (2134, 1676, 1524) & 360 Rotation
Dual Pallet Changer
38 Tool, Tool changer
EC-630 - Pallet Size 630 mm square, 2645 Ib Capacity
Workpiece Envelop (0891 x 798mm)
Travel X,Y,Z (1 01 6, 838, 889) & 360 Rotation
Dual Pallet Changer
50 Tool, Tool changer
EC-550 - Pallet Size 550 mm square, 2205 Ib Capacity
Workpiece Envelop (0778 x 798mm)
Travel X,Y,Z (762, 864, 813) & 360 Rotation
Dual Pallet Changer
40 Tool, Tool changer
EC-400 - Pallet Size 400 mm square, 1 000 Ib Capacity
Workpiece Envelop (0500 x 762mm)
Travel X,Y,Z (508,508,508) & 360 Rotation
Dual Pallet Changer
24 Tool, Tool changer
EC-300 - Pallet Size 300 mm square, 550 Ib Capacity
Workpiece Envelop (0381 x 572mm)
Travel X,Y,Z (508,457,356) & 360 Rotation
Dual Pallet Changer
24 Tool, Tool changer
izontal Machining Center (X,Y,Z and Rotation "B", T
HS-7R - Pallet Size 2032X1 01 6 mm, 1 0,000 Ib
Capacity (PC:
Workpiece Envelop (02450 x 1 000 mm)
Travel X,Y,Z (21 34, 1 676, 1 524), Rotation & Tilt
Dual Pallet Changer
38 Tool, Tool changer
EC-630 - Pallet Size 630 mm square, 2645 Ib Capacity
Workpiece Envelop (0891 x 798mm)
Travel X,Y,Z (1 01 6, 838, 889), Rotation & Tilt
Dual Pallet Changer
50 Tool, Tool changer
EC-550 - Pallet Size 550 mm square, 2205 Ib Capacity
Workpiece Envelop (0778 x 798mm)
Travel X,Y,Z (762, 864, 813), Rotation & Tilt
Dual Pallet Changer
40 Tool, Tool changer


S
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
f
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
Secondary Process Equipment

ation Based
Chip Removal
Self-contained Coolant Delivery & Filtration
Chip Removal
Self-contained Coolant Delivery & Filtration
Chip Removal
Self-contained Coolant Delivery & Filtration
Chip Removal
Self-contained Coolant Delivery & Filtration
Chip Removal
Self-contained Coolant Delivery & Filtration
Hydraulic Clamping
Tool Probing System
A"), General, Station Based
Chip Removal
Self-contained Coolant Delivery & Filtration
Hydraulic Clamping
Tool Probing System
Robotic Part Load/Unload
Chip Removal
Self-contained Coolant Delivery & Filtration
Hydraulic Clamping
Tool Probing System
Robotic Part Load/Unload
Chip Removal
Self-contained Coolant Delivery & Filtration
Hydraulic Clamping
Tool Probing System
Robotic Part Load/Unload
Product Examples


Supplier Machining of large complex
castings, e.g. Engine Blocks
Exhaust Manifolds, Cylinder Head Covers,
Front Cover

Rear Covers - Block, Main Bearing Cap
Brace





Burden Classification


CMC Machining, LS, HC
CMC Machining, LS, HC,
PREM.
CMC Machining, MHC
CMC Machining, MHC,
PREM.
CMC Machining, MC
CMC Machining, MC, PREM.
CMC Machining, LMC
CMC Machining, LMC,
CMC Machining, LC
CMC Machining, LC, PREM.

CMC Machining, LS, HC,
Automatic Load
CMC Machining, LS, HC,
Automatic Load, PREM.
CMC Machining, MHC,
Automatic Load
CMC Machining, MHC,
Automatic Load, PREM.
CMC Machining, MC,
Automatic Load
CMC Machining, MC,
Automatic Load, PREM.

Active Rate
2008


$68.33
$73.45
$54.19
$58.25
$46.31
$49.78
$35.42
$38.08
$31.33
$33.68

$91.21
$98.05
$69.96
$75.21
$59.86
$64.35

Information Source



Primary cost data acquired from HAAS website,
http://www.haascnc.com/home.asp (1 0/09)
Pricing information was also acquired from
Precision Machining Technology Show 04/09).
Rates calculated using acquired data and Burden
Calculator Template.
Where possible, rates were validated with T1 /T2
supplier data.
Same as above
Same as above
Same as above
Same as above

Primary cost data acquired from HAAS website,
http://www.haascnc.com/home.asp (1 0/09)
Pricing information was also acquired from
Precision Machining Technology Show 04/09).
Rates calculated using acquired data and Burden
Calculator Template.
Where possible, rates were validated with T1 /T2
supplier data.
Same as above
Same as above
File:Final Report Costing Databases120809.xls
EPA Contract: EP-C-07-069 WA13
E.3, Page 3 of 9
Form Author: G. Kolwich
(248) 373-6000 Ext. 2411

-------
                                      APPENDIX E.3 Manufacturing Overhead Costing Database Excerpt
                                                                               Appendix E.3
                                                                             Printed:12/9/2009
II
ir=7MLy
iriEw
Cat.































































Item


G2.4






G2.5





G3.
G3.1









G3.2








G3.3








G4.
G4.1








G4.2








Burden Title


5 Axis and/or Auto Load, CNC
Machining, Small-Medium Size and/or
Low-Moderate Complexity.
(7.5% Premium paid for machining
aggressive materials)


5 Axis and/or Auto Load, CNC
Machining, Small Size and/or Low
Complexity
(7.5% Premium paid for machining
aggressive materials)


CNC Rotary or Linear Transfer Mach
Automated Rotary or Linear Semi
dedicated transfer machines. Part
stationary fixtu red/chucked

(7.5% Premium paid for machining
aggressive materials)




Automated Rotary or Linear Semi
dedicated transfer machines. Part
Indexing capability @ each
machining station.

(7.5% Premium paid for machining
aggressive materials)


Automated Rotary or Linear Semi
dedicated transfer machines. Part
Turning or Indexing capability @
each machining station.

(7.5% Premium paid for machining
aggressive materials)


Customized Machining Equipment,
Tier 1/2 Dedicated Machining Station,
Large Size and/or High Complexity







Tier 1/2 Dedicated Machining Station,
Medium -Large Size and/or Moderate-
High Complexity









1

2

3
4
5
1

2
3
4
5
in
1

2

3
4
5

6

1

2

3
4
5
6
7
1

2

3
4
5
6
7
A Thermoplastic j j D. Forging | j G. Machining j \ K. Balancing j f N. Washing ! f R. OEM Assembly ! j U. X.
B.Thermoset ! j E. Stamping & Forming ! [ H. Turning j f L. Heat Treat j | P. T1/T2/T3 AssV j [ s- V. Y. Miscellaneous
r C. Casting j j F. Powder Metal ! f J- Ending j j M. Plating j f Q. OEM Machining jj T. j j W. ! j Z. j
Primary Processing Equipment


EC-400 - Pallet Size 400 mm square, 1 000 Ib Capacity

Workpiece Envelop (0500 x 762mm)

Travel X,Y,Z (508,508,508), Rotation & Tilt
Dual Pallet Changer
24 Tool, Tool changer
EC-300 - Pallet Size 300 mm square, 550 Ib Capacity

Workpiece Envelop (0381 x 572mm)
Travel X,Y,Z (508,457,356), Rotation & Tilt
Dual Pallet Changer
24 Tool, Tool changer
ng Centers, Option #1 -> Stationary Part, Option #2 -
Hydromat Trunnion V8 or V1 2 Type Equipment

Max 12 Stations

1 2 Max Horizontal & 6 Max Vertical Tooling Spindle
Automated Part Flipping
Part is stationary fixtured/chucked, thus no indexing.

Base Machine Cost 6 or less Stations, +5% Station)

Hydromat Index Chuck Machine V1 2 or V1 6 Type
Equipment
\Aax 16 Stations

Horizontal & Vertical Tooling Spindle
Automated Part Flipping
3art Indexing Capabilities @ each machining station.
Base Machine Cost 8 or less Stations, +5% Station)

Hydromat AT Advanced Technology Type Equipment

\Aax 10 Stations

Horizontal & Vertical Tooling Spindle
Automated Part Flipping
3art Turning Capabilities @ each machining station.
Base Machine Cost 6 or less Stations, +5% Station)

High Volume, Finite Repetitive Operation, General, Sta
1



2
3

4
5
1



2
3

4
5
Rate based on $/Hour for a average station in a High
Complexity Machining Center (i.e. 4 Axis). Add
Number of stations in Manufacturing Assumption -
Quote Summary Worksheet to calculate Burden Rate.
Total Value of Equipment: $400-500K
Stations could be linked with additional machining
and/or other assembly stations.


Rate based on $/Hour for a average station in a High
Complexity Machining Center (i.e. 4 Axis). Add
Number of stations in Manufacturing Assumption -
Quote Summary Worksheet to calculate Burden Rate.
Total Value of Equipment: $300K-$400K
Stations could be linked with additional machining
and/or other assembly stations.





1

2

3
4
5
1

2
3
4
5

1

2

3
4
5

6
7
1

2

3
4
5
6
7
1

2

3
4
5
6
7
0
1



2
3

4
5
1



2
3

4
5
Secondary Process Equipment


Chip Removal

Self-contained Coolant Delivery & Filtration

Hydraulic Clamping
Tool Probing System
Robotic Part Load/Unload
Chip Removal

Self-contained Coolant Delivery & Filtration
Hydraulic Clamping
Tool Probing System
Robotic Part Load/Unload
rt Indexing Stations, Option #3 - Part Turning Statio




























Based ( Categorized on Cost)


















Product Examples















General, Station Based
Small Casting Applications, Forgings,
Irregular Bar Stock Components, etc.




Custom application, fittings for brake tubes,
oil lines etc


Small Casting Applications, Forgings,
Irregular Bar Stock Components, etc.







Small Casting Applications, Forgings,
Irregular Bar Stock Components, etc.
(Pistons)

























Burden Classification


CNC Machining, LMC,
Automatic Load
CNC Machining, LMC,
Automatic Load, PREM.



CNC Machining, LC,
Automatic Load
CNC Machining, LC,
Automatic Load, PREM.




Rot./Lin. Trans. Machining
Line, SP
Rot./Lin. Trans. Machining
Line, SP, PREM.
CNC Milling, LMC

CNC Milling, SMS, LC



Rot./Lin. Trans. Machining
Line, IP
Rot./Lin. Trans. Machining
Line, IP, PREM.





Rot./Lin. Trans. Machining
Line, TP
Rot./Lin. Trans. Machining
Line, TP, PREM.
CNC Milling, LS, HC





Dedicated Machining Center -
Single Station, HC, Base







Dedicated Machining Center -
Single Station, MHC, Base








Active Rate
2008
$43.09

$46.32




$37.95

$40.80




$125.00

$181.25

$125.00

$100.00



$175.00

$280.00






$250.00

$362.50

$250.00





$68.33








$54.19








Information Source



Same as above






Same as above






T1/T2 supplier data.









T1/T2 supplier data.








T1/T2 supplier data.









Surrogate rate to 4 Axis CNC machining, large
size.







Surrogate rate to 4 Axis CNC machining, medium-
large size.







File:Final Report Costing Databases120809.xls
EPA Contract: EP-C-07-069 WA13
E.3, Page 4 of 9
Form Author: G. Kolwich
(248) 373-6000 Ext. 2411

-------
APPENDIX E.3 Manufacturing Overhead Costing Database Excerpt
      Appendix E.3
    Printed:12/9/2009
FE¥
Cat.










Item
G4.3
G4.4
G4.5
G5.
G5.1

HI.
H1.1
H1.2
H1.3
Burden Title
Tier 1/2 Dedicated Machining Station,
Medium Size and/or Moderate
Complexity
Tier 1/2 Dedicated Machining Station,
Small-Medium Size and/or Low-
Moderate Complexity
Tier 1/2 Dedicated Machining Station,
Small Size and/or Low Complexity
Machining, Component Specific, Lir
Average Cost per Hour per Piece of
primary Camshaft Machining
Equipment
img
CMC Turning, Auto Bar Feed (BF), D
CMC Turning, Bar Fed, Machining in
"C" and "Z" Axis Only, Medium-Large
Size Parts
CMC Turning, Bar Fed, Machining in
"C" and "Z" Axis Only, Medium Size
Parts
CMC Turning, Bar Fed, Machining in
"C" and "Z" Axis Only, Small-Medium
Size Parts

1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
e
1
2
3
4
5

ua
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
j A Thermoplastic j j D. Forging B G. Machining j \ K. Balancing j f N. Washing ! ! R. OEM Assembly ! j U. X.
j B.Thermoset ! j E. Stamping & Forming ! [ H. Turning ! f L. Heat Treat j j P. T1/T2/T3 AssV j( s- !j V. If Y. Miscellaneous !
f C. Casting j j F. Powder Metal ! f J- Ending j j M. Plating j f Q. OEM Machining jj T. j j W. 	 j 	 Z. j
Primary Processing Equipment
Rate based on $/Hour for a average station in a High
Complexity Machining Center (i.e. 4 Axis). Add
Number of stations in Manufacturing Assumption -
Quote Summary Worksheet to calculate Burden Rate.
Total Value of Equipment: $200K-300K
Stations could be linked with additional machining
and/or other assembly stations.
Rate based on $/Hour for a average station in a High
Complexity Machining Center (i.e. 4 Axis). Add
Number of stations in Manufacturing Assumption -
Quote Summary Worksheet to calculate Burden Rate.
Total Value of Equipment: $100K-200K
Stations could be linked with additional machining
and/or other assembly stations.
Rate based on $/Hour for a average station in a High
Complexity Machining Center (i.e. 4 Axis). Add
Number of stations in Manufacturing Assumption -
Quote Summary Worksheet to calculate Burden Rate.
Total Value of Equipment: $0-$100K
Stations could be linked with additional machining
lase Rate per Primary Equipment Count
Average cost per primary equipment using in machining
process of Camshaft (e.g. establishing camshaft
datum's, turning journals and grinding lobes)

Axis (DA) Machining ( "C" And "Z" Axis), General, S
SL-40BB, Bar Capacity=01 78mm
Max Cutting Diameter = 0648mm, Max Cutting Length
=1 1 18 mm
12 Station Turret, Bolt on Tooling
Automatic Bar Feeder
SL-30BB, Bar Capacity=01 02mm
Max Cutting Diameter = 0432mm, Max Cutting Length
=864mm
12 Station Turret, Bolt on Tooling
Automatic Bar Feeder
SL-20BB, Bar Capacity=064mm
Max Cutting Diameter = 0262mm, Max Cutting Length
=508mm
1 2 Station Turret, Bolt on Tooling
Automatic Bar Feeder

1
2
3
4
5
1
2
3
4
5
1
2
3
4
5

1
2
3
4
5

ta
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
Secondary Process Equipment




Calculated using( H.7.3) CNC Turning, Auto Load,
Machining in "C","X", "Y" and "Z" Axis Only, Automated
Unload, Small-Medium Size Parts ($32.17/Hour) * 1.70
Factor (Ratio of primary to secondary support
equipment costs for cylinder head line)

ion Based with multiplier for added complexity over
Lathe Work Gauging Probe
Parts Catcher System
Tool Presetter System
Chip Auger with Mobile Chip Lift
High-Pressure Coolant, 300 psi (21 bar)
Auxiliary Coolant Filter System, 25-micron filter
Lathe Work Gauging Probe
Parts Catcher System
Tool Presetter System
Chip Auger with Mobile Chip Lifl
High-Pressure Coolant, 300 psi (21 bar)
Auxiliary Coolant Filter System, 25-micron filter
Lathe Work Gauging Probe
Parts Catcher System
Tool Presetter System
Chip Auger with Mobile Chip Lifl
High-Pressure Coolant, 300 psi (21 bar)
Auxiliary Coolant Filter System. 25-micron filter
Product Examples
Connecting Rods, Head Riser & Gate Cut-
off and Debarring



Camshafts

base assumptions.



Burden Classification
Dedicated Machining Center -
Single Station, MC, Base
Dedicated Machining Center -
Single Station, LMC, Base
Dedicated Machining Center -
Single Station, LC, Base

Camshaft Machining
Equipment


CNC Turning, MLS, BF, DA
CNC Turning, MS, BF, DA
CNC Turning, SMS, BF, DA

Active Rate
2008
$46.31
$35.42
$31.33

$54.69


$33.30
$27.50
$23.14

Information Source


Surrogate rate to 4 Axis CNC machining, medium
size.
Surrogate rate to 4 Axis CNC machining, small-
medium size.
Surrogate rate to 4 Axis CNC machining, small
size.

Calculated using( H.7.3) CNC Turning, Auto Load,
Machining in "C","X", "Y" and "Z" Axis Only,
Automated Unload, Small-Medium Size Parts
($32.17/Hour) * 1 .70 Factor (Ratio of primary to
secondary support equipment costs for cylinder
head line)


Primary cost data acquired from HAAS website,
http://www.haascnc.com/home.asp (1 0/09)
Pricing information was also acquired from
Precision Machining Technology Show 04/09).
Rates calculated using acquired data and Burden
Calculator Template.
Where possible, rates were validated with T1 /T2
supplier data.
Same as above
Same as above
File:Final Report Costing Databases120809.xls
EPA Contract: EP-C-07-069 WA13
                                 E.3, Page 5 of 9
Form Author: G. Kolwich
(248) 373-6000 Ext. 2411

-------
                                      APPENDIX E.3 Manufacturing Overhead Costing Database Excerpt
                                                                               Appendix E.3
                                                                             Printed:12/9/2009
FE¥
Cat.










Item
H1.4
H2.
H2.1
H2.2
H2.3
H2.4
H3.
H3.1
H3.2
H3.3
Burden Title
CMC Turning, Bar Fed, Machining in
"C" and "Z" Axis Only, Small Size
Parts
CMC Turning, Auto Bar Feed (BF), G
multiplier for added complexity ove
CMC Turning, Bar Fed, Machining in
"C" , "X","Y" and "Z" Axis Only,
Automated Unload, Medium-Large
Size Parts
CMC Turning, Bar Fed, Machining in
"C" ,"X","Y" and "Z" Axis Only,
Automated Unload, Medium Size
Parts
CMC Turning, Bar Fed, Machining in
"C","X", "Y" and "Z" Axis Only,
Automated Unload, Small-Medium
Size Parts
CMC Turning, Bar Fed, Machining in
"C","X", "Y" and "Z" Axis Only,
Automated Unload, Small Size Parts
Double Sided (DS) Part, CMC Turnin
Double Sided Part, CMC Turning, Bar
Fed, Machining in "C" and "Z" Axis
Only, Medium-Large Size Parts
Double Sided Part, CMC Turning, Bar
Fed, Machining in "C" and "Z" Axis
Only, Medium Size Parts
Double Sided Part, CMC Turning, Bar
Fed, Machining in "C" and "Z" Axis
Only, Small-Medium Size Parts

1
2
3
4
5
6
A Thermoplastic j j D. Forging G. Mac
B. Thermoset ! j E. Stamping & Forming ! [ H. Tu
ning j j K. Balancing j f N. Washing ! [ R. OEM Assembly jj lj.
ning ! f L. Heat Treat j| P. T1/T2/T3 AssV j[ s- !j V.
JL:::=:==A:=:=:=j
! f Y. Miscellaneous !
f C. Casting j j F. Powder Metal ! f J- G' "ding j j M. Plating j f Q. OEM Machining jj T. j j W. ! j Z. j
Primary Processing Equipment
SL-10BB, BarCapacity=051mm
Max Cutting Diameter = 0279mm, Max Cutting Length
=356mm
12 Station Turret, Bolt on Tooling
Automatic Bar Feeder
uad Axis (QA) Machining ("C" , "X", "Y" and "Z" Axis),
base assumptions.
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
y-
1
2
3
4
5
6
2
3
4
5
6
1
2
3
4
5
6
SL-40BB, Bar Capacity=01 78mm
Max Cutting Diameter = 0648mm, Max Cutting Length
=1118 mm
1 2 Station Turret: Average (6 Fixed, 3 Axial Live Tools
and 3 Radial Live Tools)
Automatic Bar Feeder
SL-30BB, Bar Capacity=01 02mm
Max Cutting Diameter = 0432mm, Max Cutting Length
=864mm
1 2 Station Turret: Average (6 Fixed, 3 Axial Live Tools
and 3 Radial Live Tools)
Automatic Bar Feeder
SL-20BB, Bar Capacity=064mm
Max Cutting Diameter = 0262mm, Max Cutting Length
=508mm
1 2 Station Turret: Average (6 Fixed, 3 Axial Live Tools
and 3 Radial Live Tools)
Automatic Bar Feeder
SL-10BB, BarCapacity=051mm
Max Cutting Diameter = 0279mm, Max Cutting Length
=356mm
1 2 Station Turret: Average (6 Fixed, 3 Axial Live Tools
and 3 Radial Live Tools)
Automatic Bar Feeder
Auto Bar Feed (BF), Dual Axis (DA) Machining ( "C" /
THEO-TL-35BB, Bar Capacity=0178mm
Max Cutting Diameter = 0648mm, Max Cutting Length
=1 1 18 mm
12 Station Turret, Bolt on Tooling
Automatic Bar Feeder
TL-25 BB, Bar Capacity=01 02mm
Max Cutting Diameter = 0406mm, Max Cutting Length
=864mm
12 Station Turret, Bolt on Tooling
Automatic Bar Feeder
TL-15BB, Bar Capacity=064mm
Max Cutting Diameter = 0208mm, Max Cutting Length
=445mm
12 Station Turret, Bolt on Tooling
Automatic Bar Feeder

1
2
3
4
5
6
Secondary Process Equipment
Lathe Work Gauging Probe
Parts Catcher System
Tool Presetter System
Chip Auger with Mobile Chip Lifl
High-Pressure Coolant, 300 psi (21 bar)
Auxiliary Coolant Filter System, 25-micron filter
Tiutomated Unload, General, Station Based with
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
nc
1
2
3
4
5
6
2
3
4
5
6
1
2
3
4
5
6
Lathe Work Gauging Probe
Automated part unload
Tool Presetter System
Chip Auger with Mobile Chip Lift
High-Pressure Coolant, 1000 psi (21 bar;
Auxiliary Coolant Filter System, 25-micron filter
Lathe Work Gauging Probe
Automated part unload
Tool Presetter System
Chip Auger with Mobile Chip Lifl
High-Pressure Coolant, 1000 psi (21 bar;
Auxiliary Coolant Filter System, 25-micron filter
Lathe Work Gauging Probe
Automated part unload
Tool Presetter System
Chip Auger with Mobile Chip Lifl
High-Pressure Coolant, 1000 psi (21 bar;
Auxiliary Coolant Filter System, 25-micron filter
Lathe Work Gauging Probe
Automated part unload.
Tool Presetter System
Chip Auger with Mobile Chip Lifl
High-Pressure Coolant, 1000 psi (21 bar;
Auxiliary Coolant Filter System, 25-micron filter
"Z" Axis), General, Station Based with multiplier fo
Lathe Work Gauging Probe
Parts Catcher System
Tool Presetter System
Chip Auger with Mobile Chip Lift
High-Pressure Coolant, 300 psi (21 bar)
Auxiliary Coolant Filter System, 25-micron filter
Lathe Work Gauging Probe
Parts Catcher System
Tool Presetter System
Chip Auger with Mobile Chip Lifl
High-Pressure Coolant, 300 psi (21 bar)
Auxiliary Coolant Filter System, 25-micron filter
Lathe Work Gauging Probe
Parts Catcher System
Tool Presetter System
Chip Auger with Mobile Chip Lifl
High-Pressure Coolant, 300 psi (21 bar)
Auxiliary Coolant Filter System, 25-micron filter
Product Examples






added complexity over base assumptio



Burden Classification
CMC Turning, SS, BF, DA
CMC Turning, LC

CMC Turning, MLS, BF, QA
CMC Turning, MS, BF, QA
CMC Turning, SMS, BF, QA
CMC Turning, SS, BF, QA
CMC Turning, MC
CMC Turning, HC
s.
DS-CNC Turning, MLS, BF,
DA
DS-CNC Turning, MS, BF, DA
DS-CNC Turning, SMS, BF,
DA

Active Rate
2008
$20.90
$20.90

$52.75
$43.29
$34.77
$30.84
$30.84
No Longer Valid

$37.91
$32.11
$28.18

Information Source


Same as above

Primary cost data acquired from HAAS website,
http://www.haascnc.com/home.asp (1 0/09)
Pricing information was also acquired from
Precision Machining Technology Show 04/09).
Rates calculated using acquired data and Burden
Calculator Template.
Where possible, rates were validated with T1 /T2
supplier data.
Same as above
Same as above
Same as above

Primary cost data acquired from HAAS website,
http://www.haascnc.com/home.asp (1 0/09)
Pricing information was also acquired from
Precision Machining Technology Show 04/09).
Rates calculated using acquired data and Burden
Calculator Template.
Where possible, rates were validated with T1 /T2
supplier data.
Same as above
Same as above
File:Final Report Costing Databases120809.xls
EPA Contract: EP-C-07-069 WA13
E.3, Page 6 of 9
Form Author: G. Kolwich
(248) 373-6000 Ext. 2411

-------
                                      APPENDIX E.3 Manufacturing Overhead Costing Database Excerpt
                                                                               Appendix E.3
                                                                             Printed:12/9/2009
FE¥
Cat.









Item
H3.4
H4.
H4.1
H4.2
H4.3
H4.4
H5.
H5.1
H5.2
Burden Title
Double Sided Part, CMC Turning, Bar
Fed, Machining in "C" and "Z" Axis
Only, Small Size Parts

1
2
3
4
5
6
j A Thermoplastic j j D. Forging I G. Mach ning j \ K. Balancing j f N. Washing ! ! R. OEM Assembly ! j U. X.
j B.Thermoset ! j E. Stamping & Forming ! [ H. Turn ng ! f L. Heat Treat j j P. T1/T2/T3 AssV j( s- !j V. If Y. Miscellaneous !
f C. Casting j j F. Powder Metal ! f J. Gr nd ng j j M. Plating j f Q. OEM Machining jj T. j j W. ! j Z. j
Primary Processing Equipment
HEO-TL-05BB, B Capacit"=051mm
Max Cutting Diameter = 0279mm, Max Cutting Length
=356mm
12 Station Turret, Bolt on Tooling
Automatic Bar Feeder
Double Sided (DS) Part, CNC Turning, Auto Bar Feed (BF), Quad Axis (QA) Machining ("C"
Station Based with multiplier for added complexity over base assumptions.
Double Sided Part, CNC Turning, Bar
Fed, Machining in "C" ,"X", "Y" and
"Z" Axis Only, Automated Unload,
Medium-Large Size Parts
Double Sided Part, CNC Turning, Bar
Fed, Machining in "C" ,"X", "Y"and "Z"
Axis Only, Automated Unload,
Medium Size Parts
Double Sided Part, CNC Turning, Bar
Fed, Machining in "C","X", "Y" and "Z"
Axis Only, Automated Unload, Small-
Medium Size Parts
Double Sided Part CNC Turning, Bar
Fed, Machining in "C","X", "Y" and "Z"
Axis Only, Automated Unload, Small
Size Parts
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
2
3
4
5
6
THEO-TL-35BB, Bar Capacity=0178mm
Max Cutting Diameter = 0648mm, Max Cutting Length
=1 1 18 mm
1 2 Station Turret: Average (6 Fixed, 3 Axial Live Tools
and 3 Radial Live Tools)
Automatic Bar Feeder
TL-25 BB, Bar Capacity=01 02mm
Max Cutting Diameter = 0406mm, Max Cutting Length
=864mm
1 2 Station Turret: Average (6 Fixed, 3 Axial Live Tools
and 3 Radial Live Tools)
Automatic Bar Feeder
Transfer Time to Sub-spindle 8 Seconds
TL-15BB, Bar Capacity=064mm
Max Cutting Diameter = 0208mm, Max Cutting Length
=445mm
1 2 Station Turret: Average (6 Fixed, 3 Axial Live Tools
and 3 Radial Live Tools)
Automatic Bar Feeder
Transfer Time to Sub-spindle 8 Seconds
THEO-TL-05BB, Bar Capacity=051mm
Max Cutting Diameter = 0279mm, Max Cutting Length
=356mm
1 2 Station Turret: Average (6 Fixed, 3 Axial Live Tools
and 3 Radial Live Tools)
Automatic Bar Feeder

1
2
3
4
5
6
Secondary Process Equipment
Lathe Work Gauging Probe
Parts Catcher System
Tool Presetter System
Chip Auger with Mobile Chip Lifl
High-Pressure Coolant, 300 psi (21 bar)
Auxiliary Coolant Filter System, 25-micron filter
"X", "Y" and "Z" Axis), Automated Unload, General,
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
IS*. CNC Turning, Auto Bar Feed (BF), Quad Axis (QA) Machining ("C" , "X", "Y
Unload, General, Station Based with mu tiplier for added complexity over base assumptions.
Multistation -16, CNC Turning, Auto
Bar Fed, Machining in "C" ,"X", "Y"
and "Z" Axis Only, Double Sided,
Automated Unload, Small-Medium
Size Parts
Multi Station -12, CNC Turning, Auto
Bar Fed, Machining in "C" ,"X", "Y"
and "Z" Axis Only, Double Sided,
Automated Unload, Small-Medium
Size Parts
2
3
4
5
6
7
1
2
3
4
5
6
7
Hydromat Rotary Transfer Machine - Max 16 Station
Bar Size = 044 and Length 150 mm
Up to 1 6 Horizontal & 8 Vertical Tooling Spindle
Automated Part Flipping
(Base Machine Cost 12 Stations, +10% Station)
Hydromat Rotary Transfer Machine - Max 12 Station
Bar Size = 025 and Length 100 mm
Up to 1 2 Horizontal & 6 Vertical Tooling Spindle
Automated Part Flipping
(Base Machine Cost 8 Stations, +1 0% Station)
2
3
4
5
6
7
1
2
3
4
5
6
7
Lathe Work Gauging Probe
Automated part unload
Tool Presetter System
Chip Auger with Mobile Chip Lift
High-Pressure Coolant, 1000 psi (21 bar;
Auxiliary Coolant Filter System, 25-micron filter
Lathe Work Gauging Probe
Automated part unload
Tool Presetter System
Chip Auger with Mobile Chip Lifl
High-Pressure Coolant, 1000 psi (21 bar;
Auxiliary Coolant Filter System, 25-micron filter
Lathe Work Gauging Probe
Automated part unload
Tool Presetter System
Chip Auger with Mobile Chip Lifl
High-Pressure Coolant, 1000 psi (21 bar;
Auxiliary Coolant Filter System, 25-micron filter
Lathe Work Gauging Probe
Automated part unload.
Tool Presetter System
Chip Auger with Mobile Chip Lifl
High-Pressure Coolant, 1000 psi (21 bar;
Auxiliary Coolant Filter System, 25-micron filter
' and "Z" Axis), Double Sided (DS) Part, Automated


Product Examples









Burden Classification
DS-CNC Turning, SS, BF, DA
S-CNC Turning, LC

DS-CNC Turning, MLS, BF,
QA
DS-CNC Turning, MS, BF, QA
DS-CNC Turning, SMS, BF,
QA
DS-CNC Turning, SS, BF, QA
S-CNC Turning, MC
S-CNC Turning, HC

MS-16Max, CNC Turning,
SMS, BF, QA
RTM Turning, HC, PP, Base
MS-12Max, CNC Turning,
SMS, BF, QA
RTM Turning, MC, PP, Base

Active Rate
2008
$25.94
$25.94

$56.00
$46.54
$42.28
$38.35
$38.35
No Longer Valid

$240.00
$240.00
$180.00
$180.00

Information Source


Same as above

Primary cost data acquired from HAAS website,
http://www.haascnc.com/home.asp (1 0/09)
Pricing information was also acquired from
Precision Machining Technology Show 04/09).
Rates calculated using acquired data and Burden
Calculator Template.
Where possible, rates were validated with T1 /T2
supplier data.
Same as above
Same as above
Same as above

Estimated based equipment investment and
surrogate equipment overhead rates..
Estimated based equipment investment and
surrogate equipment overhead rates..
File:Final Report Costing Databases120809.xls
EPA Contract: EP-C-07-069 WA13
E.3, Page 7 of 9
Form Author: G. Kolwich
(248) 373-6000 Ext. 2411

-------
                                      APPENDIX E.3 Manufacturing Overhead Costing Database Excerpt
                                                                               Appendix E.3
                                                                             Printed:12/9/2009
II
ir=7MLy
iriEw
Cat.

















































Item


H5.3









H5.4





H5.5




H6.


H6.1






H6.2





H6.3





H6.4



Burden Title


Multi Station -8, Long Part, CMC
Turning, Auto Bar Fed, Machining in
"C" ,"X","Y" and "Z" Axis Only,
Double Sided, Automated Unload,
Small -Medium Size Parts




Multi Station -8, CMC Turning, Auto
Bar Fed, Machining in "C" ,"X", "Y"
and "Z" Axis Only, Double Sided,
Automated Unload, Small-Medium
Size Parts



Multi Station-6, CMC Turning, Auto
Bar Fed, Machining in "C" ,"X", "Y"
and "Z" Axis Only, Double Sided,
Automated Unload, Small-Medium
Size Parts





1
2
3
4
5
6
7
1

2
3
4
5
6
1
2
3
4
5
6
Odd Form Part, CMC Turning, Manual
A Thermoplastic j j D. Forging | j G. Mach ning j \ K. Balancing j f N. Washing ! f R. OEM Assembly ! j U. X.
B.Thermoset ! j E. Stamping & Forming ! [ H. Turn ng ! f L. Heat Treat j | P. T1/T2/T3 AssV j [ s- V. Y. Miscellaneous
r C. Casting j j F. Powder Metal ! f J- G' "ding j j M. Plating j f Q. OEM Machining jj T. j j W. ! j Z. j
Primary Processing Equipment


Hydromat Inline Standard 8 - Max 8 Stations
Bar Size = 025 and Length 550 mm
Bar Stock or Blanks




THEO-ZPS 842, 8 Station Turning Machine

Bar Size = 042 and Length 125 mm
6 Station Turret: Average (8 Fixed, 4 Axial Live Tools
and 4 Radial Live Tools)
Automatic Bar Feeder


THEO-ZPS 642, 6 Station Turning Machine
Bar Size = 042 and Length 125 mm
2 Station Turret: Average (6 Fixed, 3 Axial Live Tools
and 3 Radial Live Tools)
Automatic Bar Feeder





1
2
3
4
5
6
7
1

2
3
4
5
6
1
2
3
4
5
6
Secondary Process Equipment









Lathe Work Gauging Probe

Automated part unload
Tool Presetter System
Chip Auger with Mobile Chip Lift
High-Pressure Coolant, 1000 psi (21 bar;
Auxiliary Coolant Filter System, 25-micron filter
Lathe Work Gauging Probe
Automated part unload.
Tool Presetter System
Chip Auger with Mobile Chip Lift
High-Pressure Coolant, 1000 psi (21 bar;
Auxiliary Coolant Filter System. 25-micron filter
Product Examples






















Burden Classification









MS-8Max, CMC Turning, SMS,






MS-6Max, CMC Turning, SMS,
BF, QA





oad (ML), Axis (DA) Machining ( "C" And "Z" Axis), General, Station Based with multiplier for added complexity over base assumptions. Category for odd form components, e.g.
pre-machine bar stock, forged parts, diecast


CMC Turning, Manual Load,
Machining in "C" and "Z" Axis Only,
Medium-Large Size Parts




CMC Turning, Manual Load,
Machining in "C" and "Z" Axis Only,
Medium Size Parts



CMC Turning, Manual Load,
Machining in "C" and "Z" Axis Only,




CMC Turning, Manual Load,
Machining in "C" and "Z" Axis Only,
Small Size Parts


1
2
3

4
5
6
1
2
3
4
5
6
1
2
3
4
b
6
1
2
3
4
b
6
SL-40BB, Chuck Capacity=0178mm
Max Cutting Diameter = 0648mm, Max Cutting Length
=1 1 18 mm
12 Station Turret, Bolt on Tooling




SL-30BB, Chuck Capacity=0102mm
Max Cutting Diameter = 0432mm, Max Cutting Length
=864mm
12 Station Turret, Bolt on Tooling



SL-20BB, Chuck Capacity= 064mm
Max Cutting Diameter = 0262mm, Max Cutting Length
1 2 Station Turret, Bolt on Tooling



SL-10BB, Chuck Capacity=051mm
Max Cutting Diameter = 0279mm, Max Cutting Length
=356mm
12 Station Turret, Bolt on Tooling



1
2
3

4
5
6
1
2
3
4
5
6
1
2
3
4
b
6
1
2
3
4
b
6
Lathe Work Gauging Probe
Parts Catcher System
Tool Presetter System

Chip Auger with Mobile Chip Lift
High-Pressure Coolant, 300 psi (21 bar)
Auxiliary Coolant Filter System, 25-micron filter
Lathe Work Gauging Probe
Parts Catcher System
Tool Presetter System
Chip Auger with Mobile Chip Lift
High-Pressure Coolant, 300 psi (21 bar)
Auxiliary Coolant Filter System, 25-micron filter
Lathe Work Gauging Probe
Parts Catcher System
Tool Presetter System
Chip Auger with Mobile Chip Lift
High-Pressure Coolant, 300 psi (21 bar)
Auxiliary Coolant Filter System, 25-micron filter
Lathe Work Gauging Probe
Parts Catcher System
Tool Presetter System
Chip Auger with Mobile Chip Lift
High-Pressure Coolant, 300 psi (21 bar)
Auxiliary Coolant Filter System, 25-micron filter

























CMC Turning, MLS, ML, DA






CMC Turning, ML, ML, DA





CMC Turning, SMS, ML, DA





CMC Turning, SS, ML, DA







2008
$0.00






$213.49






$161.86







$31.74






$25.79





$21.43





$19.15





Information Source










Primary pricing information was also acquired
from Precision Machining Technology Show
04/09).
Secondary cost data came from HAAS website,
http://www.haascnc.com/home.asp (1 0/09)
Rates calculated using acquired data and Burden
Calculator Template.
Where possible, rates were validated with T1 /T2
supplier data.


Same as above







Primary cost data came from HAAS website,
http://www.haascnc.com/home.asp (1 0/09)
Pricing information was also acquired from
Precision Machining Technology Show 04/09).
Rates calculated using acquired data and Burden
Calculator Template.
Where possible, rates were validated with T1 /T2
supplier data.


Same as above





Same as above





Same as above





File:Final Report Costing Databases120809.xls
EPA Contract: EP-C-07-069 WA13
E.3, Page 8 of 9
Form Author: G. Kolwich
(248) 373-6000 Ext. 2411

-------
                                      APPENDIX E.3 Manufacturing Overhead Costing Database Excerpt
                                                                               Appendix E.3
                                                                             Printed:12/9/2009
FE¥
Cat.





Q. C




Item
H7.
H7.1
H7.2
H7.3
H7.4

01.
Q1.1
Q1.2
Q1.3
Burden Title
Odd Form, CNC Turning, Auto Load
form components, e.g. pre-machine
CNC Turning, Auto Load, Machining
in "C" ,"X", "Y" and "Z" Axis Only,
Automated Unload, Medium-Large
Size Parts
CNC Turning, Auto Load, Machining
in "C" ,"X", "Y"and "Z" Axis Only,
Automated Unload, Medium Size
Parts
CNC Turning, Auto Load, Machining
in "C","X", "Y" and "Z" Axis Only,
Automated Unload, Small-Medium
Size Parts
CNC Turning, Auto Load, Machining
in "C","X", "Y" and "Z" Axis Only,
Automated Unload, Small Size Parts

OEM Machining, Component Specif
Crankshaft Machining
Cylinder Block Machining Line
(Average cost per primary piece of
manufacturing equipment on a
cylinder block machining line)
Cylinder Head Machining Line
(Average cost per primary piece of
manufacturing equipment on a
cylinder head machining line)

(A
ba
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6

c,
2
3
4
5
2
3
4
5
1
2
3
4
5
j A Thermoplastic j j D. Forging • G. Mach ning j \ K. Balancing j f N. Washing ! ! R. OEM Assembly ! j U. X. |
j B.Thermoset ! j E. Stamping & Forming ! [ H. Turning ! f L. Heat Treat j j P. T1/T2/T3 AssV jf s- !j V. If Y. Miscellaneous !
r C. Casting j j F. Powder Metal ! f J- G' "ding j j M. Plating j f Q. OEM Machining jj T. j j W. ! j Z. j
Primary Processing Equipment
L) and Unload, Quad Axis (QA) Machining ("C" , "X",
r stock, for
SL-40BB, Chuck Capacity=0178mm
Max Cutting Diameter = 0648mm, Max Cutting Length
=1 1 18 mm
1 2 Station Turret: Average (6 Fixed, 3 Axial Live Tools
and 3 Radial Live Tools)
Automatic Part Load & Unload System
SL-30BB, Chuck Capacity=0102mm
Max Cutting Diameter = 0432mm, Max Cutting Length
=864mm
1 2 Station Turret: Average (6 Fixed, 3 Axial Live Tools
and 3 Radial Live Tools)
Automatic Part Load & Unload System
SL-20BB, Chuck Capacity= 064mm
Max Cutting Diameter = 0262mm, Max Cutting Length
=508mm
1 2 Station Turret: Average (6 Fixed, 3 Axial Live Tools
and 3 Radial Live Tools)
Automatic Part Load & Unload System
SL-10BB, Chuck Capacity=051mm
Max Cutting Diameter = 0279mm, Max Cutting Length
=356mm
1 2 Station Turret: Average (6 Fixed, 3 Axial Live Tools
and 3 Radial Live Tools)
Automatic Part Load & Unload System

Line Based using Multiplier X number of pieces of p
Average cost per primary equipment using in machining
process of crankshaft (e.g. Machining Center for
Datums, Turn-Turn broach, OD Mill, Multi-wheel Main
Grinder, Pin Grinder etc)
4 & 5 Axis CNC Machines, or
Custom Machining Centers, or
n-line Washers, or
n-Line Inspection & Gauging
4 & 5 Axis CNC Machines, or
Custom Machining Centers, or
Head Assembly Equipment (on Machining line), or
n-line Washers, or
n-Line Inspection & Gauging

"V
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6

m
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
Secondary Process Equipment
Product Examples
Burden Classification
" and "Z" Axis), General, Station Based with multiplier for added complexity over base assumptions.
Lathe Work Gauging Probe
Tool Presetter System
Chip Auger with Mobile Chip Lift
High-Pressure Coolant, 1000 psi (21 bar;
Auxiliary Coolant Filter System, 25-micron filter
Lathe Work Gauging Probe
Tool Presetter System
Chip Auger with Mobile Chip Lift
High-Pressure Coolant, 1000 psi (21 bar;
Auxiliary Coolant Filter System, 25-micron filter
Lathe Work Gauging Probe
Tool Presetter System
Chip Auger with Mobile Chip Lift
High-Pressure Coolant, 1000 psi (21 bar;
Auxiliary Coolant Filter System, 25-micron filter
Lathe Work Gauging Probe
Tool Presetter System
Chip Auger with Mobile Chip Lift
High-Pressure Coolant, 1000 psi (21 bar;
Auxiliary Coolant Filter System, 25-micron filter

ary equipment
Calculated using( H.7.3) CNC Turning, Auto Load,
Machining in "C","X", "Y" and "Z" Axis Only, Automated
Unload, Medium Size Parts ($39.48/Hour) * 1 .70 Factor
(Ratio of primary to secondary support equipment costs
for cylinder head line)
Automation (Gantry robot w/automation) per CNC
machining operation
Main Line automation (gantry robot & automation) per
operation
Coolant System, Mist Collection, Process Water &
Waste, Misc. Department Equipment
Production Floor CMM
Automation (Gantry robot w/automation) per CNC
machining operation
Main Line automation (gantry robot & automation) per
operation
Coolant System, Mist Collection, Process Water &
Waste, Misc. Department Equipment
Production Floor CMM









CNC Turning, MLS, AL, QA
CNC Turning, MS, AL, QA
CNC Turning, SMS, AL, QA
CNC Turning, SS, AL, QA


CNC Machining, Crankshafts,
OEM
CNC Machining, Cylinder
Block, OEM
CNC Machining, Cylinder
Head, OEM

Active Rate
2008

$48.72
$82.82
$39.48
$32.17
$27.47


$67.12
$81.11
$79.05

Information Source



Primary cost data came from HAAS website,
http://www.haascnc.com/home.asp (1 0/09)
Pricing information was also acquired from
Precision Machining Technology Show 04/09).
Rates calculated using acquired data and Burden
Calculator Template.
Where possible, rates were validated with T1 /T2
Same as above
Same as above
Same as above


Calculated using( H.7.3) CNC Turning, Auto Load,
Machining in "C","X", "Y" and "Z" Axis Only,
Automated Unload, Medium Size Parts
($39.48/Hour) * 1 .70 Factor (Ratio of primary to
secondary support equipment costs for cylinder
head line)
Average rate per primary piece of equipment is
calculated by dividing the total estimated facility
costs (primary and ancillary tracked separately),
by the total primary equipment quantity, to
establish an average primary and ancillary
investment cost per unit of primary equipment.
These average costs, along with supporting cost
and specification data from surrogate equipment,
are fed into the burden calculator to establish a
manufacturing overhead rate.
Average rate per primary piece of equipment is
calculated by dividing the total estimated facility
costs (primary and ancillary tracked separately),
by the total primary equipment quantity, to
establish an average primary and ancillary
investment cost per unit of primary equipment.
These average costs, along with supporting cost
and specification data from surrogate equipment,
are fed into the burden calculator to establish a
manufacturing overhead rate.
File:Final Report Costing Databases120809.xls
EPA Contract: EP-C-07-069 WA13
E.3, Page 9 of 9
Form Author: G. Kolwich
(248) 373-6000 Ext. 2411

-------
                                                              APPENDIX E.4
                                        Manufacturing  Overhead Calculator Template
                                                                      Appendix E.4
                                                                  Printed: 12/9/2009
A. General Manufacturing Overhead Information
Burden Title:
Burden Primary Process Equipment Description:
Estimated Production Facility Size:
Primary Process Equipment Life Expectancy:
Process Support Equipment Life Expectancy:
General Plant & Office Life Expectancy:
Yearly Operating Capacity:
Operation Efficiency
Production Usage Efficiency
Cost To Borrow Money/Annual
Burden Classification: Injection Molding, Medium Size and/or Moderate Complexity
Injection Molding Station, SOOT Press
1.50E+05
12
12
10
4700
85.00%
81.99%
8.00%

Square Footage Options ( 1.5E5, 2.5E5, 5.0E5, 7.5E5, 10E5, 20E5)
Years
Years
Years
Hours
Percent
Percent
Percent

Utilization Rates Fed Reserve Rate by NAIC (2002-2007):
>Primary metal 79.87%,
>Fabricate Metal Products 75.19%,
>Electrical 78.99%,
>Motor Vehicle Parts 75.66%,
>Chemical (paints resins) 76.63%
>Plastic & Rubbers 81 .99%
B. Primary Processing Equipment
Yearly Rate
B.1 Primary Process Equipment Build
Primary Process Equipment Design (Customized equipment/machinery or highly complex integration of commodity
based equipment)
B.3 Primary Process Equipment Cost (B.1 +B.2)
B.4 Sales Tax (B.4*Rate)
B.5 Primary Process Equipment Cost Including Sales Tax
B.6 Freight (one time expense)
B.7 Installation (one time expense)
B.8 Installation to Power On (one time expense)
B.9 Set-up & Run-offs (Power on to Production Part Approval Process PPAP) (one time expense, value default 5%)
B.10 Primary Process Equipment Sub-total Including Freight, Installation, Set-up and Run-off. (B.5+B.6+B.7+B.8+B.9)
B.1 1 Annual Financing Expense for Primary Process Equipment Sub-total (B.10)
B.12 Personal Property Tax
B.13 Equipment Insurance Cost - Fire and General
B.14 Spare Parts-Maintenance & Repair, includes perishable goods (default 3%/year)

5.57%

1.00%
12.00%

| 5.00%

8%
0.66%

| 3.00%
Expense
Frequency


1

1
1
1
1

1
12
12
12
% of Primary
Equip. Exp.


5.57%

1.00%
12.00%
1.00%
5.00%

NA
0.66%
0.60%
3.00%
Value
$ 260,000.00
$
$ 260,000.00
$ 14,482.00
$ 274,482.00
$ 2,600.00
$ 31,200.00
$ 2,600.00
$ 13,000.00
$ 323,£
$ 42,070.43
$ 1,708.31
$ 1,560.00
$ 7,800.00
    B 15  Total Primary Equipment Costs per Annum
                                                                                                                                              53,138.74
C. Process Support Equipment - Process Dependent (Required to carry-out primary process)
Yearly Rate
C.1 Process Support Equipment Build
Process Support Equipment Design (Customized equipment/machinery or highly complex integration of commodity
based equipment)
C.3 Process Support Equipment Cost (C.1+C.2)
C.4 Sales Tax (C.4*Rate)
C.5 Process Support Equipment Cost Including Sales Tax
C.6 Freight (one time expense)
C.7 Installation (one time expense)
C.8 Installation to Power On (one time expense)
C.9 Set-up & Run-offs (Power on to Production Part Approval Process PPAP) (one time expense, value default 5%)
C.10 Process Support Equipment Sub-total Including Freight, Installation, Set-up and Run-off. (C.5+C.6+C.7+C.8+C.9)
C.11 Annual Financing Expense for Process Support Equipment Sub-total (C.10)
C.1 2 Personal Property Tax
C.13 Equipment Insurance Cost - Fire and General
C.14 Spare Parts-Maintenance & Repair, includes perishable goods (default 3%/year)

5.57%

1.00%
12.00%

| 5.00%

8%
0.66%

| 3.00%
Expense
Frequency


1

1
1
1
1

1
12
12
12
% of Primary
Equip. Exp.


5.57%

1.00%
12.00%
1.00%
5.00%

NA
0.66%
0.60%
3.00%
Value
$ 29,950.00
$
$ 29,950.00
$ 1,668.22
$ 31,618.22
$ 299.50
$ 3,594.00
$ 299.50
$ 1,497.50
$ 37,308.72
$ 4,846.19
$ 196.78
$ 179.70
$ 898.50
    C 15 Total Process Support Equipment Costs per Annum
                                                                                                                                               6,121.17
D. General Plant & Office Hardware/Equipment
                                                  % of Primary & Process
                                                 Support Equipment Costs
                                                                                                                                              Value
     D.1  Sum of Total Primary Process Equipment Costs/Year (B.15) & Process Support Equipment Costs/Year (C.15)
     D.2  Millwright, Electrician, Plumbing Tool Crib
     D.3  Production/Quality Communication and Data Tracking & Storage
     D.4  General Material Handling Equipment (e.g. Tow-Motors, Cranes, Fork Lifts)
     D.5  Storage, Shipping and Receiving Equipment
     D.6  Plant Cleaning Equipment
     D.7  General Quality Lab Equipment
     D.8  Office Equipment	
                                                           NA
                                                         2.00%
                                                         0.40%
                                                         0.20%
                                                         0.20%
                                                         0.20%
                                                         0.40%
                                                         1.00%
               59,259.91
                1,185.20
                 237.04
                 118.52
                 118.52
                 118.52
                 237.04
                 592.60
     D 9  Total General Plant & Office Hardware/Equipment Costs per Year
                                                                                                                           4.40%
                                                                                                                                           $    2,607.44
   File:Final Report Costing Databases 120809.xls
   EPA Contract: EP-C-07-069 WA1-3
E.4, Page  1 of 3
Form Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                              APPENDIX E.4
                             Manufacturing Overhead Calculator Template
   Appendix E.4
Printed: 12/9/2009
A. General Manufacturing Overhead Information
Burden Title:
Burden Primary Process Equipment Description:
Estimated Production Facility Size:
Primary Process Equipment Life Expectancy:
Process Support Equipment Life Expectancy:
General Plant & Office Life Expectancy:
Yearly Operating Capacity:
Operation Efficiency
Production Usage Efficiency
Cost To Borrow Money/Annual
Burden Classification: Injection Molding, Medium Size and/or Moderate Complexity
Injection Molding Station, SOOT Press
1.50E+05
12
12
10
4700
85.00%
81.99%
8.00%

Square Footage Options ( 1.5E5, 2.5E5, 5.0E5, 7.5E5, 10E5, 20E5)
Years
Years
Years
Hours
Percent
Percent
Percent

Utilization Rates Fed Reserve Rate by NAIC (2002-2007):
>Primary metal 79.87%,
>Fabricate Metal Products 75.19%,
>Electrical 78.99%,
>Motor Vehicle Parts 75.66%,
>Chemical (paints resins) 76.63%
>Plastic & Rubbers 81 .99%
Facilities Cost/Floor Space Includes (Cost/Square Foot) -> Primary Process Equipment, Process Support
' Equipment, & General Plant Office Hardware/Equipment
Total Primary Processing Equipment Floor Space Allocation
( Equipment Foot Print + 3 ft each side)
Total Process Support Equipment Floor Space Allocation:
( Equipment Foot Print + 3 ft each side)
E.3 General Plant & Office Equipment/Hardware Floor Space
E.4 Total Facilities Costs per Year
(Cost/
Square Foot)/
year
11.50
11.50
11.50
% of Primary
& Process
Support
Equipment
Area
NA
NA
75%
Total Square
Feet

418
321
554.25
1293.25
Value
$ 4,807.00
$ 3,691.50
$ 6,373.88
$ 14,872.38
Utilities for Primary Process Equipment, Process Support Equipment & General Plant and Office
Hardware/Equipment.


F.1
F.2
F.3
F.4
F.5
F.6
Utility

Electricity
Natural
Gas
Coke
Fuel Oil
Water
Compressed
Air
Units

Kilowatt Hour
Cubic Feet
Ton
Barrel
Gallons
CFM
Unit Cost

$ 0.0717
$ 0.01
$ 190.00
$ 46.40
$ 0.00
$ 0.025
Primary Process Equipment Usage
Input
129.5
0
0
0
0
0
Cost/Hour
$9.29
$0.00
$0.00
$0.00
$0.00
$0.00
Supporting Process
Equipment Utility Usage
Input
49
0
0
0
0
0
Cost/Hour
$3.51
$0.00
$0.00
$0.00
$0.00
$0.00
General Plant & Office Utilit]
Usage
Percent
Contribution
Cost/Hour
Facility costs in Section D
cover general plant and
office utility usage expenses.



F.7 Subtotals $9.29 $3.51
F 8 Total utilities expense/hour for all Primary and Supporting Process Equipment
$0.00
$12.80

G

Plant Salary Contribution to Manufacturing Overhead (Note, does not include, direct, indirect or Maintenance,
Repair or Other Labor)


G.1
G.2
G.3
G.4
G.5
G.6
Estimated Facility Square Footage
150,000
250,000
500,000
750,000
1 ,000,000
2,000,000
Est. Hourly
Employees
109
182
365
547
730
1460
Est. Salary Employees
13
22
44
66
88
Average Salary Contribution
per Square Foot
$5.12
$6.00
$7.05
$8.16
$9.29
$13.76


Enter equipment square
footage usage (E.4) in
corresponding overall
estimated facility square
1293
0
0
0
0
0
G 7 Total Plant Salary Contribution to Manufacturing Overhead/Year
$ 6,625.15
$
$
$
$
$
$ 6,625.15
File:Final Report Costing Databases 120809.xls Form Author: G. Kolwich
EPA Contract: EP-C-07-069 WA1 -3 E.4, Page 2 01 3 (248)373-6000 Ext. 241 1

-------
                                                          APPENDIX E.4
                                     Manufacturing Overhead Calculator Template
                                                                Appendix E.4
                                                             Printed: 12/9/2009
A. General Manufacturing Overhead Information
Burden Title: Burden Classification: Injection Molding, Medium Size and/or Moderate Complexity
Burden Primary Process Equipment Description: Injection Molding Station, SOOT Press
Estimated Production Facility Size: 1.50E+05 Square Footage Options ( 1.5E5, 2.5E5, 5.0E5, 7.5E5, 10E5, 20E5)

Primary Process Equipment Life Expectancy: 12 Years Utilization Rates Fed Reserve Rate bv NAIC (2002-2007):
Process Support Equipment Life Expectancy: 12 Years >Primary metal 79 87%,
General Plant & Office Life Expectancy: 10 Years >Fabricate Metal Products 75 19%,
Yearly Operating Capacity: 4700 Hours >Electrical 78 99%,
Operation Efficiency Percent >Motor Vehicle Parts 75 66%,
Production Usage Efficiency 81.99% Percent >Chemical (paints resins) 76.63%
Cost To Borrow Money/Annual Percent >Plastic & Rubbers 81 99%

H. Calculated Hourly Burden Rate at defined Efficiency and Utilization
H.1 Total Hourly Rate based on 100% efficiency and utilization
H.2 Total Hourly Rate base on defined efficiency and 100% utilization
H.3 Total Hourly Rate base on defined efficiency and utilization
H 4 Hourly Burden Rate loaded in Burden Database
Burden Rate "Minus" Utility
Rate Contribution
$17.74
$20.40
$24.07

Utility Rate
Contribution
(F.8)
12.798
14.718
14.718

Total
$ 30.54
$ 35.12
$ 38.79
$ 38.79
Note: The final rate for "Injection Molding, Medium Size and/or Moderate Complexity" is calculated by taking the hourly rates for equipment within this grouping (i.e.400-800 Ton
Presses) and calculating the group average.
    File:Final Report Costing Databases 120809.xls
    EPA Contract: EP-C-07-069 WA1-3
E.4, Page 3 of 3
Form Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                     APPENDIX E.5 Mark-up Rate Database Excerpt
                                                                                    Appendix E.5
                                                                                  Printed:12/9/2009
FEW
Cat.

A. T2



B. T2



C. T2






Item

/T3T1
A1.1
A1.2
A1.3
/T3TI
B1.1
B1.2
B1.3
/T3C)
C1.1
C1.2
C1.3
C3.1
C3.2
C3.3

| A.T2rT3ThermoPlast. I D.T2/T3 Forging ] j G.T2/T3 Machining J. T2rT3Assembly j M- j P. OEM Assembly j
j B.T2rT3Thermoset i E.T2/T3 Stamp-Form j | H. T2fT3 Heat Treat j K. T2/T3Misc. j j N.T1 Assembly j 0-
. 	 | 	 1 . 	 | 	 1 | 	 : | 	 ;
| C. T2/T3 Casting j F.T2/T3 Powder Metal j j I.T2fT3 Plating j 0- Z.MISC
Supplier/OEM Classification
(Based On Manufacturing
Overhead Categories)

IERMOPLASTIC PROCESSINC
Injection Molding
Injection Molding
Injection Molding
IERMOSET PROCESSING
Compression and Extrusion Molding
of Thermosetting Polymers
Compression and Extrusion Molding
of Thermosetting Polymers
Compression and Extrusion Molding
of Thermosetting Polymers
\STING PROCESS

Diecasting
(Aluminum, Magnesium, Z nc)
Diecasting
(Aluminum, Magnesium, Zinc)
Diecasting
(Aluminum, Magnesium, Z nc)
Sand Casting,
(Gravity and Low Pressure Casting)
(Cast Iron(s), Steel, Aluminum)
Sand Casting,
(Gravity and Low Pressure Casting)
(Cast Iron(s), Steel, Aluminum)
Sand Casting,
(Gravity and Low Pressure Casting)
(Cast Iron(s), Steel, Aluminum)



1
2
3
4
5
1
2
3
4
5
1
2
3
4
5

1
2
3
4
5
1
2
3
4
5
1
2
3
4
5

1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
Supplier/OEM Size &
Complexity Description


Large Size, High Complexity
Medium Size, Moderate Complexity
Small Size, Low Complexity

Large Size, High Complexity
Medium Size, Moderate Complexity
Small Size, Low Complexity

Large Size, High Complexity
Medium Size, Moderate Complexity
Small Size, Low Complexity
Large Size, High Complexity
Medium Size, Moderate Complexity
Small Size, Low Complexity



1
2
3
4
5
1
2
3
4
5
1
2
3
4
5

1
2
3
4
5
1
2
3
4
5
1
2
3
4
5

1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
OEM or Supplier
Classification


T2T3 Inject. Mold, LSHC
T2T3 Inject. Mold, MSMC
T2T3 Inject. Mold, SSLC

T2T3 Comp./Ext. Mold, LSHC
T2T3 Comp./Ext. Mold, MSMC
T2T3 Comp./Ext. Mold, SSLC

T2T3 Diecast, LSHC
T2T3 Diecast, MSMC
T2T3 Diecast, SSLC
T2T3 Sand Cast, LSHC
T2T3 Sand Cast, MSMC
T2T3 Sand Cast, SSLC
End Item
Scrap,
Active
Rate
2020


0.70%
0.50%
0.30%

0.70%
0.50%
0.30%

5.00%
5.00%
5.00%
5.00%
5.00%
5.00%
SG&A,
Active
Rate
2008


7.00%
6.50%
6.00%

7.00%
6.50%
6.00%

7.00%
6.50%
6.00%
7.00%
6.50%
6.00%
Profit,
Active
Rate
2008


8.00%
6.00%
4.00%

8.00%
6.00%
4.00%

8.00%
6.00%
4.00%
8.00%
6.00%
4.00%
ED&T/
R&D,
Active
Rate
2008


2.00%
1.00%


2.00%
1.00%
0.00%

2.00%
1.00%

2.00%
1.00%
0.00%
Production Year/Case Study


ED&T/R&D, Average Annual Adjustment Factor (AAF)
End Item
Scrap
Rate,
Baseline


0.70%
0.50%
0.30%

0.70%
0.50%
0.30%

5.00%
5.00%
5.00%
5.00%
5.00%
5.00%
SG&A
Rate,
Baseline


7.00%
6.50%
6.00%

7.00%
6.50%
6.00%

7.00%
6.50%
6.00%
7.00%
6.50%
6.00%
Profit
Rate,
Baseline


8.00%
6.00%
4.00%

8.00%
6.00%
4.00%

8.00%
6.00%
4.00%
8.00%
6.00%
4.00%
ED&T/
R&D
Rate,
Baseline


2.00%
1 .00%
0.00%

2.00%
1 .00%
0.00%

2.00%
1 .00%
0.00%
2.00%
1 .00%
0.00%
End
Item
Scrap,
AAF


0.00%
0.00%
0.00%

0.00%
0.00%
0.00%

0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
SG&A,
AAF


0.00%
0.00%
0.00%

0.00%
0.00%
0.00%

0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
Profit,
AAF


0.00%
0.00%
0.00%

0.00%
0.00%
0.00%

0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
ED&T/
R&D,
AAF






0.00%



0.00%





End Item
Scrap
Rate,
Adjusted


0.70%
0.50%
0.30%

0.70%
0.50%
0.30%

5.00%
5.00%
5.00%
5.00%
5.00%
5.00%
SG&A
Rate,
Adjusted


7.00%
6.50%
6.00%

7.00%
6.50%
6.00%

7.00%
6.50%
6.00%
7.00%
6.50%
6.00%
Profit
Rate,
Adjusted


8.00%
6.00%
4.00%

8.00%
6.00%
4.00%

8.00%
6.00%
4.00%
8.00%
6.00%
4.00%
ED&T/
R&D
Rate,
Adjusted


2.00%
1.00%
0.00%

2.00%
1.00%
0.00%

2.00%
1.00%
0.00%
2.00%
1.00%
0.00%
2008
0.00%
0.00%
0.00%
Notes
















File: Final Report Costing Databases 120809.xls
EPA Contract: EP-C-07-069 WA13
E.5, Page 1 of 5
 Form Author: G. Kolwich
(248) 373-6000 Ext. 2411

-------
                                                     APPENDIX E.5 Mark-up Rate Database Excerpt
                                                                                    Appendix E.5
                                                                                  Printed:12/9/2009
FEW
Cat.



D. T:







E. T2



Item
C4.1
C4.2
C4.3
/T3F(
D1.1
D1.2
D1.3

D2.1
D2.2
D2.3
/T3S'
E1.1
E1.2
E1.3

| A.T2rT3ThermoPlast. I D.T2/T3 Forging ] j G.T2/T3 Machining j J. T2rT3Assembly j M- j P. OEM Assembly j
j B.T2rT3Thermoset j E.T2/T3 Stamp-Form j | H. T2fT3 Heat Treat jj K. T2/T3Misc. j j N.T1 Assembly j 0-
. 	 | 	 1 . 	 , | 	 1 | 	 : | 	 ;
i C. T2/T3 Casting j F.T2/T3 Powder Metal j j I.T2fT3 Plating !j 0- Z.MISC

Supplier/OEM Classification
(Based On Manufacturing
Overhead Categories)
Investment Casting, Great for
Casting High Temp, Complex parts
in aluminum alloys, bronze alloys,
magnesium alloys, cast iron,
stainless steel and tool steel.
Investment Casting, Grea for
Casting High Temp, Complex parts
in aluminum alloys, bronze alloys,
magnesium alloys, cast iron,
stainless steel and tool steel.
Investment Casting, Great for
Casting High Temp, Complex parts
in aluminum alloys, bronze alloys,
magnesium alloys, cast iron,
stainless steel and tool stee .
IRGING PROCESS

Impression/Close Die Forging,
Impression/Close Die Forging,
Impression/Close Die Forging,

Cold Forgings, Includes Cold
Bending, Cold Drawing, Extrusions,
Etc.,
Cold Forgings, Includes Cold
Bending, Cold Drawing, Ex rusions,
Etc.,
Cold Forgings, Cold Heading,
Coining, Thread Rolling, etc.,
AMPING & FORMING PROCE
Stamping & Forming,
Stamping & Forming,
Stamping & Forming,

1
2
3
4
5
1
2
3
4
5
1
2
3
4
5

1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
:^
3
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
3S
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
Supplier/OEM Size &
Complexity Description
Large Size, High Complexity
Medium Size, Moderate Complexity
Small Size, Low Complexity

Large Size, High Complexity
Medium Size, Moderate Complexity
Small Size, Low Complexity

Large Size, High Complexity
Medium Size, Moderate Complexity
Small Size, Low Complexity

Large Size, High Complexity
Medium Size, Moderate Complexity
Small Size, Low Complexity

1
2
3
4
5
1
2
3
4
5
1
2
3
4
5

1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
\
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5

1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
OEM or Supplier
Classification
T2T3 Invest. Cast, LSHC
T2T3 Invest. Cast, MSMC
T2T3 Invest. Cast, SSLC

T2T3 Forge, LSHC
T2T3 Forge, MSMC
T2T3 Forge, SSLC

T2T3 Cold Forge, LSHC
T2T3 Cold Forge, MSMC
T2T3 Cold Forge, SSLC

T2T3 Stamp/Form, LSHC
T2T3 Stamp/Form, MSMC
T2T3 Stamp/Form, SSLC
End Item
Scrap,
Active
Rate
2020
5.00%
5.00%
5.00%

0.70%
0.50%
0.30%

0.70%
0.50%
0.30%

0.70%
0.50%
0.30%
SG&A,
Active
Rate
2008
7.00%
6.50%
6.00%

7.00%
6.50%
6.00%

7.00%
6.50%
6.00%

7.00%
6.50%
6.00%
Profit,
Active
Rate
2008
8.00%
6.00%
4.00%

8.00%
6.00%
4.00%

8.00%
6.00%
4.00%

8.00%
6.00%
4.00%
ED&T/
R&D,
Active
Rate
2008
2.00%
1.00%
0.00%

2.00%
1.00%
0.00%

2.00%
1.00%
0.00%

2.00%
1.00%

Production Year/Case Study


EDST/RSD, Average Annual Adjustment Factor (AAF)
End Item
Scrap
Rate,
Baseline

5.00%
5.00%
5.00%

0.70%
0.50%
0.30%

0.70%
0.50%
0.30%

0.70%
0.50%
0.30%
SG&A
Rate,
Baseline

7.00%
6.50%
6.00%

7.00%
6.50%
6.00%

7.00%
6.50%
6.00%

7.00%
6.50%
6.00%
Profit
Rate,
Baseline

8.00%
6.00%
4.00%

8.00%
6.00%
4.00%

8.00%
6.00%
4.00%

8.00%
6.00%
4.00%
ED&T;
R&D
Rate,
Baseline

2.00%
1 .00%
0.00%

2.00%
1 .00%
0.00%

2.00%
1 .00%
0.00%

2.00%
1 .00%
0.00%
End
Item
Scrap,
AAF

0.00%
0.00%
0.00%

0.00%
0.00%
0.00%

0.00%
0.00%
0.00%

0.00%
0.00%
0.00%
SG&A
AAF

0.00%
0.00%
0.00%

0.00%
0.00%
0.00%

0.00%
0.00%
0.00%

0.00%
0.00%
0.00%
Profit,
AAF

0.00%
0.00%
0.00%

0.00%
0.00%
0.00%

0.00%
0.00%
0.00%

0.00%
0.00%
0.00%
ED&T;
R&D,
AAF

0.00%



0.00%







0.00%


End Item
Scrap
Rate,
Adjusted

5.00%
5.00%
5.00%

0.70%
0.50%
0.30%

0.70%
0.50%
0.30%

0.70%
0.50%
0.30%
SG&A
Rate,
Adjusted

7.00%
6.50%
6.00%

7.00%
6.50%
6.00%

7.00%
6.50%
6.00%

7.00%
6.50%
6.00%
Profit
Rate,
Adjusted

8.00%
6.00%
4.00%

8.00%
6.00%
4.00%

8.00%
6.00%
4.00%

8.00%
6.00%
4.00%
ED&T;
R&D
Rate,
Adjusted

2.00%
1.00%
0.00%

2.00%
1.00%
0.00%

2.00%
1.00%
0.00%

2.00%
1.00%
0.00%
2008
0.00%
0.00%
0.00%
Notes
















File: Final Report Costing Databases 120809.xls
EPA Contract: EP-C-07-069 WA13
E.5, Page 2 of 5
 Form Author: G. Kolwich
(248) 373-6000 Ext. 2411

-------
                                                     APPENDIX E.5 Mark-up Rate Database Excerpt
                                                                                    Appendix E.5
                                                                                  Printed:12/9/2009
FEW
Cat.
Item

| A.T2rT3ThermoPlast. I D.T2/T3 Forging ] j G.T2/T3 Machining j J. T2rT3Assembly j M- j P. OEM Assembly j
j B.T2rT3Thermoset j E.T2^3 Stamp-Form j | H. T2fT3 Heat Treat jj K. T2^3Misc. j j N.T1 Assembly j 0-
. 	 | 	 1 . 	 , | 	 1 | 	 : | 	 ;
i C. T2^3 Casting j F.T2/T3 Powder Metal j | I.T2fT3 Plating !j 0- Z.MISC

Supplier/OEM Classification
(Based On Manufacturing
Overhead Categories)
F. T2/T3 POWDER METAL PROCESS




G. T5








H. T2


F1.1
F1.2
F1.3

/T3M
G1.1
G1.2
G1.3

G2.1
G2.2
G2.3

/T3H
H1.1
H1.2
Powder Metal, Structural
Components
Powder Metal, Structural & Bearing
Components,
Powder Metal, Structural & Bearing
Components,

VCHINING PROCESS

CMC and Rotary & Linear Transfer
Machining
CMC and Rotary & Linear Transfer
Machining
CMC and Rotary & Linear Transfer
Machining

CMC Turning
CMC Turning
CMC Turning

EAT TREATING PROCESS
Heat Treating,
Heat Treating,


1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
\

1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
I
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
I

1
2
3
4
5
1
2
3
4
5
Supplier/OEM Size &
Complexity Description

Large Size, High Complexity
Medium Size, Moderate Complexity
Small Size, Low Complexity


Large Size, High Complexity
Medium Size, Moderate Complexity
Small Size, Low Complexity

Large Size, High Complexity
Medium Size, Moderate Complexity
Small Size, Low Complexity


Large Size, High Complexity
Medium Size, Moderate Complexity


1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
i

1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
|
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
|

1
2
3
4
5
1
2
3
4
5
OEM or Supplier
Classification

T2T3 Powder Metal, LSHC
T2T3 Powder Metal, MSMC
T2T3 Powder Metal, SSLC


T2T3 CMC Milling, LSHC
T2T3 CMC Milling, MSMC
T2T3 CMC Milling, SSLC

T2T3 CMC Turning, LSHC
T2T3 CMC Turning, MSMC
T2T3 CMC Turning, SSLC


T2T3 Heat Treat, LSHC
T2T3 Heat Treat, MSMC
End Item
Scrap,
Active
Rate
2020

0.70%
0.50%
0.30%


0.70%
0.50%
0.30%

0.70%
0.50%
0.30%


0.70%
0.50%
SG&A,
Active
Rate
2008

7.00%
6.50%
6.00%


7.00%
6.50%
6.00%

7.00%
6.50%
6.00%


7.00%
6.50%
Profit,
Active
Rate
2008

8.00%
6.00%
4.00%


8.00%
6.00%
4.00%

8.00%
6.00%
4.00%


8.00%
6.00%
ED&T/
R&D,
Active
Rate
2008

2.00%
1.00%



2.00%
1.00%
0.00%

2.00%
1.00%
0.00%


2.00%
1.00%
Production Year;Case Study


ED&T;R&D, Average Annual Adjustment Factor (AAF)
End Item
Scrap
Rate,
Baseline

0.70%
0.50%
0.30%


0.70%
0.50%
0.30%

0.70%
0.50%
0.30%


0.70%
0.50%
SG&A
Rate,
Baseline

7.00%
6.50%
6.00%


7.00%
6.50%
6.00%

7.00%
6.50%
6.00%


7.00%
6.50%
Profit
Rate,
Baseline

8.00%
6.00%
4.00%


8.00%
6.00%
4.00%

8.00%
6.00%
4.00%


8.00%
6.00%
ED&T;
R&D
Rate,
Baseline

2.00%
1 .00%
0.00%


2.00%
1 .00%
0.00%

2.00%
1 .00%
0.00%


2.00%
1 .00%
End
Item
Scrap,
AAF

0.00%
0.00%
0.00%


0.00%
0.00%
0.00%

0.00%
0.00%
0.00%


0.00%
0.00%
SG&A
AAF

0.00%
0.00%
0.00%


0.00%
0.00%
0.00%

0.00%
0.00%
0.00%


0.00%
0.00%
Profit,
AAF

0.00%
0.00%
0.00%


0.00%
0.00%
0.00%

0.00%
0.00%
0.00%


0.00%
0.00%
ED&T;
R&D,
AAF

0.00%




0.00%








0.00%

End Item
Scrap
Rate,
Adjusted

0.70%
0.50%
0.30%


0.70%
0.50%
0.30%

0.70%
0.50%
0.30%


0.70%
0.50%
SG&A
Rate,
Adjusted

7.00%
6.50%
6.00%


7.00%
6.50%
6.00%

7.00%
6.50%
6.00%


7.00%
6.50%
Profit
Rate,
Adjusted

8.00%
6.00%
4.00%


8.00%
6.00%
4.00%

8.00%
6.00%
4.00%


8.00%
6.00%
ED&T;
R&D
Rate,
Adjusted

2.00%
1.00%
0.00%


2.00%
1.00%
0.00%

2.00%
1.00%
0.00%


2.00%
1.00%
2008
0.00%
0.00%
0.00%
Notes

















File: Final Report Costing Databases 120809.xls
EPA Contract: EP-C-07-069 WA13
E.5, Page 3 of 5
 Form Author: G. Kolwich
(248) 373-6000 Ext. 2411

-------
                                                     APPENDIX E.5 Mark-up Rate Database Excerpt
                                                                                    Appendix E.5
                                                                                  Printed:12/9/2009
FEW
Cat.

J. T2







N. T1





Item
H1.3
T3AE
J1.1
J1.2
J1.3

J2.1
J2.2
J2.3
Asse
N1.1
N1.2
N1.3
N1.4


| A.T2rT3ThermoPlast. I D.T2/T3 Forging ] j G.T2/T3 Machining J. T2rT3Assembly j M- j P. OEM Assembly j
j B.T2rT3Thermoset j E.T2/T3 Stamp-Form j | H. T2fT3 Heat Treat j K. T2T3Misc. j j N.T1 Assembly j 0-
. 	 | 	 1 , 	 | 	 1 | 	 : | 	 ,
| C. T2T3 Casting j F.T2T3 Powder Metal j j I.T2fT3 Plating j 0- Z.MISC
Supplier/OEM Classification
(Based On Manufacturing
Overhead Categories)
Heat Treating,
SEMBLY PROCESS

General Mechanical Assembly
General Mechanical Assembly
General Mechanical Assembly

General Electrical Assembly
General Electrical Assembly
General Electrical Assembly
mbly

T1 Complete System/System
Supplier
T1 High Complexity Component
Supplier
T1 Moderate Complexity Component
Supplier
T1 Low Complexity Component
Supplier


1
2
3
4
5

1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
:^
3
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5

1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5

Supplier/OEM Size &
Complexity Description
Small Size, Low Complexity

Large Size, High Complexity
Medium Size, Moderate Complexity
Small Size, Low Complexity

Large Size, High Complexity
Medium Size, Moderate Complexity
Small Size, Low Complexity







1
2
3
4
5

1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
\
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5

1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5

OEM or Supplier
Classification
T2T3 Heat Treat, SSLC

T2T3 Mech. Assembly, LSHC
T2T3 Mech. Assembly, MSMC
T2T3 Mech. Assembly, SSLC

T2T3 Elect. Assembly, LSHC
T2T3 Elect. Assembly, MSMC
T2T3 Elect. Assembly, SSLC

T1 System Assembly Complexity
T1 High Assembly Complexity
T1 Moderate Assembly Complexity
T1 Low Assembly Complexity

End Item
Scrap,
Active
Rate
2020
0.30%

0.70%
0.50%
0.30%

0.70%
0.50%
0.30%

0.70%
0.70%
0.50%
0.30%

SG&A,
Active
Rate
2008
6.00%

7.00%
6.50%
6.00%

7.00%
6.50%
6.00%

7.00%
7.00%
6.50%
6.00%

Profit,
Active
Rate
2008
4.00%

8.00%
6.00%
4.00%

8.00%
6.00%
4.00%

8.00%
8.00%
6.00%
4.00%

ED&T/
R&D,
Active
Rate
2008


2.00%
1.00%
0.00%

2.00%
1.00%
0.00%

6.00%
4.00%
2.50%
1.00%

Production Year/Case Study


EDST/RSD, Average Annual Adjustment Factor (AAF)
End Item
Scrap
Rate,
Baseline

0.30%

0.70%
0.50%
0.30%

0.70%
0.50%
0.30%

0.70%
0.70%
0.50%
0.30%

SG&A
Rate,
Baseline

6.00%

7.00%
6.50%
6.00%

7.00%
6.50%
6.00%

7.00%
7.00%
6.50%
6.00%

Profit
Rate,
Baseline

4.00%

8.00%
6.00%
4.00%

8.00%
6.00%
4.00%

8.00%
8.00%
6.00%
4.00%

ED&T;
R&D
Rate,
Baseline

0.00%

2.00%
1 .00%
0.00%

2.00%
1 .00%
0.00%

6.00%
4.00%
2.50%
1 .00%

End
Item
Scrap,
AAF

0.00%

0.00%
0.00%
0.00%

0.00%
0.00%
0.00%

0.00%
0.00%
0.00%
0.00%

SG&A
AAF

0.00%

0.00%
0.00%
0.00%

0.00%
0.00%
0.00%

0.00%
0.00%
0.00%
0.00%

Profit,
AAF

0.00%

0.00%
0.00%
0.00%

0.00%
0.00%
0.00%

0.00%
0.00%
0.00%
0.00%

ED&T;
R&D,
AAF

0.00%

0.00%







0.00%




End Item
Scrap
Rate,
Adjusted

0.30%

0.70%
0.50%
0.30%

0.70%
0.50%
0.30%

0.70%
0.70%
0.50%
0.30%

SG&A
Rate,
Adjusted

6.00%

7.00%
6.50%
6.00%

7.00%
6.50%
6.00%

7.00%
7.00%
6.50%
6.00%

Profit
Rate,
Adjusted

4.00%

8.00%
6.00%
4.00%

8.00%
6.00%
4.00%

8.00%
8.00%
6.00%
4.00%

ED&T;
R&D
Rate,
Adjusted

0.00%

2.00%
1.00%
0.00%

2.00%
1.00%
0.00%

6.00%
4.00%
2.50%
1.00%

2008
0.00%
0.00%
0.00%
Notes
















File: Final Report Costing Databases 120809.xls
EPA Contract: EP-C-07-069 WA13
E.5, Page 4 of 5
 Form Author: G. Kolwich
(248) 373-6000 Ext. 2411

-------
                                                     APPENDIX E.5 Mark-up Rate Database Excerpt
                                                                                    Appendix E.5
                                                                                  Printed:12/9/2009
FEW
Cat.
Item

| A.T2rT3ThermoPlast. I D.T2/T3 Forging ] j G.T2/T3 Machining J. T2rT3Assembly j M- j P. OEM Assembly j
j B.T2rT3Thermoset j E.T2^3 Stamp-Form j | H. T2fT3 Heat Treat j K. T2^3Misc. j j N.T1 Assembly j 0-
. 	 | 	 1 , 	 | 	 1 | 	 : | 	 ;
| C. T2^3 Casting j F.T2/T3 Powder Metal j j I.T2fT3 Plating j 0- Z.MISC
Supplier/OEM Classification
(Based On Manufacturing
Overhead Categories)
P. OEM ASSEMBLY







Z. Ml


P1.1
P1.2
P1.3
P1.4
P1.5
P1.6

SCELI
Z1.1
Z1.2
Bcdy & White Assembly - OEM,
Includes Press Shop, Welding and
Painting
Casting Major Engine Components
Machining Major Engine
Components
Engine Assembly
Vehicle Operations Assembly
Transmission Assembly

.ANEOUS

Not Applicable
T1 Assembly, Mark-up Captured @
Bottom of quote sheet.


1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5


1
2
3
4
5
1
2
3
4
5
Supplier/OEM Size &
Complexity Description









Category to be referenced when there is
no impact on Mark-up associated with
technology change.



1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5


1
2
3
4
5
1
2
3
4
5
OEM or Supplier
Classification

OEM Body 8 White Assembly
OEM Engine Casting
OEM Engine Machining
OEM Engine Assembly
OEM Vehicle Assembly
OEM Transmission Assembly


Not Applicable
n Assembly, Mark-up Applied @
Bottom.
End Item
Scrap,
Active
Rate
2020

0.00%
0.00%

0.00%

0.00%


0.00%
0.00%
SG&A,
Active
Rate
2008

0.00%
0.00%
0.00%
0.00%
0.00%
0.00%


0.00%
0.00%
Profit,
Active
Rate
2008

0.00%
0.00%
0.00%
0.00%
0.00%
0.00%


0.00%
0.00%
ED&T/
R&D,
Active
Rate
2008

0.00%
0.00%

0.00%

0.00%


0.00%
0.00%
Production Year;Case Study


ED&T;R&D, Average Annual Adjustment Factor (AAF)
End Item
Scrap
Rate,
Baseline

0.00%
0.00%
0.00%
0.00%
0.00%
0.00%


0.00%
0.00%
SG&A
Rate,
Baseline

0.00%
0.00%
0.00%
0.00%
0.00%
0.00%


0.00%
0.00%
Profit
Rate,
Baseline

0.00%
0.00%
0.00%
0.00%
0.00%
0.00%


0.00%
0.00%
ED&T;
R&D
Rate,
Baseline

0.00%
0.00%
0.00%
0.00%
0.00%
0.00%


0.00%
0.00%
End
Item
Scrap,
AAF

0.00%
0.00%
0.00%
0.00%
0.00%
0.00%


0.00%
0.00%
SG&A
AAF

0.00%
0.00%
0.00%
0.00%
0.00%
0.00%


0.00%
0.00%
Profit,
AAF

0.00%
0.00%
0.00%
0.00%
0.00%
0.00%


0.00%
0.00%
ED&T;
R&D,
AAF

0.00%




0.00%


0.00%
0.00%
End Item
Scrap
Rate,
Adjusted

0.00%
0.00%
0.00%
0.00%
0.00%
0.00%


0.00%
0.00%
SG&A
Rate,
Adjusted

0.00%
0.00%
0.00%
0.00%
0.00%
0.00%


0.00%
0.00%
Profit
Rate,
Adjusted

0.00%
0.00%
0.00%
0.00%
0.00%
0.00%


0.00%
0.00%
ED&T;
R&D
Rate,
Adjusted

0.00%
0.00%
0.00%
0.00%
0.00%
0.00%


0.00%
0.00%
2008
0.00%
0.00%
0.00%
Notes











File: Final Report Costing Databases 120809.xls
EPA Contract: EP-C-07-069 WA13
E.5, Page 5 of 5
 Form Author: G. Kolwich
(248) 373-6000 Ext. 2411

-------
                                              APPENDIX E.6 Packaging Costing Database Excerpt
                                                                                                                                                   Appendix E.6
Project
Freight Trailer Key Dimensions Trailer Size
Selection
1. Standard Lengths: (281, 32', 36', 40', 42', 43', 45', 48',
and53') Le"9'h
2. Standard Widths: 96"-102" Width
3. Standard Heights: 12.5'-13.5' Overall Height
53'
102"
13.5'
Exterior
Dimensions
"Inches"
636
102
162
"mm"
16154
2591
4115
Interior
Dimensions
"Inches"
570
98.5
107.375
"mm"
14478
2502
2727
FiV
Freight Trailer Information Source: www.worldtraderef.com/WTR_site/Truck_Trailers/Guide_to_Truck_Trailers.asp
Option

A

A1
A2
A3

A4
A5

B
B1

B2
B3
B4
c

C1

C2

C3

Packaging Description



Standard AIAG Container, 4 Door, Collapsible Side
Walls
Multi Use Rackable Pallet
Stackable Totes (Flexcon)

Stackable Totes (Generic)


Retunable I aqe
1/4" HOPE Vacuum Form Tier Pads

0.10" ABS Vacuum Form Tier Pads
0.10" Corrugated Plastic Dividers, Generic
Assumption
Seat Belt, Tie-down Straps
Expendable internal Dunnaae

Cardboard Tier Pads

Cardboard Divider Pads, Generic Assumption



Units



Inches
mm
nches
mm
nches
mm

nches
mm


nches
mm
nches
mm
nches
mm
inches
mm


Inches
mm

Inches
mm



Exterior Dimensions
Length



48
1214
	 48 	
1214
21.9
554

20
506

	 48 	
1214
19.7
498
44
1113




44
	 TiTs 	

44
1113



Width



45
	 i"l39 	
44
1113
15.2
385

12
304

	 45 	
1139
14
354
	 4l"5 	
1050




41.5
	 1050 	

41.5
1050



Height
or
Thickness



34
	 860 	
	 6 	
152
12.8
324

12
304

	 b'.25 	
6
0.10
2.5
	 NA 	
NA




0.12
	 3 	

NA
NA



Interior Dimensions
Length



44
	 Ti'i's 	
	 48 	
1214
19.7
498

19
481

	 48 	
1214
19.7
498
	 44 	
1113




44
	 Ti'i's 	

44
1113



Width



41.5
	 1050 	
	 44 	
1113
14
354

11
278

	 45 	
1139
14
354
	 4l"5 	
1050




41.5
	 1050 	

41.5
1050



Height
or
Thickness



27.5
	 696 	
	 6 	
152
11
278

11
278

	 b'.25 	
6
0.10
2.5
	 NA 	
NA




0.12
	 3 	

NA
NA



Dimension Notes:



Other Heights Considered (39", 42",
48", 50")
KtaWeiaMjcwoite^ZZZZZZ
M^^^^o^£IIIIIII2
























Associated Packaging



Internal dunnage either expendable
or returnable.
Returnable vacuum formed tier
pads.
Stacked on base pallet, 6
Totes/Layer, Max 7 Layers

Stacked on base pallet, 6
Totes/Layer, Max 7 Layers


Used with option A2 primary
packagmci. 	

Used with option A3 or A4 primary
packaging.
Used with option A1 primary
packaging. This is an average
estimated cost independent of
number of cells.
Estimated cost per pallet for
primary packaging option A2


Used with option A1 primary
packaging.

Used with option A1 primary
packaging. 	



Life
Expectancy
"Years"



5
5
5

5


5

5
2.5
5


0

0



Unit Cost
Estimate



$200
$100
$75

$75


$40

$5
$20
$100


$1

$3



Reference Source



Tier#1 CBI-MikeS.
Tier#1 CBI-MikeS.
Tier#1 CBI-MikeS.

Tier#1 CBI-MikeS.


Tier#1 CBI-MikeS.

Tier#1 CBI-MikeS.
Estimate
Tier#1 CBI


Tier#1 CBI-MikeS.

Tier#1 CBI-MikeS.



File:Final Report Costing Databases 120809.xls
EPA Contract: EP-C-07-069 WA1-3
E.6, Page 1 of 1
Form Author: G. Kolwich
(248) 373-6000 Ext. 2411

-------
            APPENDIX F.I MAQS Worksheet Task Reference Guide
 Note: Following the table is a sample MAQS worksheet identifying the major sections.

A






MAQS WORKSHEET SECTIONS
TASK DESCRIPTION
INPUT
SOURCE(S)
FOR TASK
REFERENCE
SOURCE(S) FOR
TASK
OUTPUT
SOURCE(S) FOR
TASK
SECTION A: MAQS HEADER INFORMATION
Al
A2




Project Details
Quote Assumptions




Capacity Planning
Assumptions
OEM/T1 Classification
Packaging Specification
Component Quote
Level
Enter case study
information into MAQS
header.

Enter capacity planning
volume assumptions into
MAQS header.
Enter Tier 1(T1)/OEM
classification for mark-up
factor designation.
Enter, packaging
specification assumptions
Check quote level box in
header to identify quoting
level.
CBOM

CFT & P-VCSM
CFT,
Markup
Database
CFT
C-BOM, Process
MiSlilllfe
P-VCSM

OEM Benchmark
Data
Supplier
Benchmark Data
Packaging
Database
NR
Costs captured in
Subsystem Cost Model
Analysis Templates
(CMAT) are referenced
by header information
in the MAQS
worksheet

weekly component
volume provides base
for all capacity
planning estimates in
MAQS worksheet.
Mark-up rates are
automatically loaded
into MAQS cost
summation section
Defines packaging
strategy to use when
developing packaging
costs.
Defines quote
methodology to be
used in MAQS
worksheet and how
costs are to be
presented in CMAT' s
EPA Contract: EP-C-07-069 WAI-3
F.I, Page 1 of 16

-------
            APPENDIX F.I MAQS Worksheet Task Reference Guide

B









MAQS WORKSHEET SECTIONS
TASK DESCRIPTION
INPUT
SOURCE(S)
FOR TASK
REFERENCE
SOURCE(S) FOR
TASK
OUTPUT
SOURCE(S) FOR
TASK
SECTION B: MAQS QUOTE SUMMARY
Bl





B2


General Component Information





Reference Number
Part Description
Part Number
Quantity per Assembly

Enter alpha numeric
reference number for each
process and/or part added
to the MAQS.
Enter, part
name/description.
Enter, part number
Enter quantity of a part
within the
component/assembly.

Defaults set in
MAQS
CBOM,
Process

CBOM,
Process
Mlllicilll^
CBOM,
Process
jVfagjljjjl

NR
FEV or Munro
historical naming
conventions
FEV historical
numbering
conventions
Teardown process,
service manuals,
etc.

Reference numbers are
a quick method of
reviewing multiple
processes performed on
same part.
Part description create
main field for
identifying parts within
Bill of Materials
Part Number creates
main field for
identifying processing
level of a part within
Bill of Materials
The quantity value
enter is used through
out the MAQS
worksheet. More
details are provided
below.

General Manufacturing Information


Primary Process
Description
OEM/Supplier
Classification

Enter summary
description of process
Enter OEM/Supplier
Classification for identified
process using Mark-up
Database nomenclature.
Process
jVtanpinj!
MAQS Burden
Classification
NR
Marlyipjjatabase
CFT makes
assessment on
what type of
manufacturing
facility makes the
part: Tl versus
OEM, Tl versus
T2/T3
Reference Only
Automatically loads
mark-up rate from
database into mark-up
cost section of MAQS
EPA Contract: EP-C-07-069 WAI-3
F.I, Page 2 of 16

-------
            APPENDIX F.I MAQS Worksheet Task Reference Guide









MAQS WORKSHEET SECTIONS




B3







OEM/Supplier
Classification
Material Specification
Labor Classification
Burden Classification
TASK DESCRIPTION
Enter predefined alpha
numeric characters to
direct commodity based
purchase part costs to
different areas of the
MAQS worksheet.
Enter material type
identified in process using
Material Database
nomenclature.
Enter Labor type used in
process using Labor
Database nomenclature.
Enter Burden type used in
process using Burden
Database nomenclature.
INPUT
SOURCE(S)
FOR TASK
MAQS Quote
Summary
section contains
legend of
applicable
values.
CBOM/ Process
MiBBiM

Process
MiBBiM

Process
MiBBiM'^
MAQS
Manufacturing
Assumptions
REFERENCE
SOURCE(S) FOR
TASK
OUTPUT
SOURCE(S) FOR
TASK
"S" = purchase component, cost binned to
Tl/OEM material cost.
"Alpha Numeric Characters" matching
reference number e.g., B2A, places the
purchase cost as T2/T3 material cost subject
to additional mark-up.
"SAC" = Purchase component cost is only
included in the MAQS worksheet to have a
Mark-up factor accounted for by the Tl (or
OEM if applicable). The actual component
cost is kept in a separate MAQS worksheet to
keep the cost resolution.
Material .Database
Labor. Database
Manufacturing
Oyerhead/Burden
Database
Automatically loads
material cost from
database into
manufacturing rates
section of MAQS
Automatically loads
labor rate from
database into
manufacturing rates
section of MAQS
Automatically loads
burden rate from
database into
manufacturing rates
section of MAQS
Manufacturing Rates



Finished Piece/Hour
Number of Operators
Number of lines
The rate parts are produced
at for the defined process.
Automatically populated
from Manufacturing
Assumption section of
MAQS
Number of operators
required for the defined
process. Automatically
populated from the
Manufacturing Assumption
Section of the MAQS
Number of pieces of
similar equipment/lines
required for the defined
process to meet rate.
Automatically populated
from the Mfg'ing
Assumption. Section of the
MAQS.
Process
Mnattgand
Manufacturing
Assumptions
section of
MAQS
MAQS
Manufacturing
Assumption
section
MAQS
Manufacturing
Assumption
section
NR
NR
NR
Variable used in the
calculation of labor and
burden costs.
Variable used in the
calculation of labor
costs.
Variable used in the
calculation of the
Applied Burden rate.
EPA Contract: EP-C-07-069 WAI-3
F.I, Page 3 of 16

-------
            APPENDIX F.I MAQS Worksheet Task Reference Guide











MAQS WORKSHEET SECTIONS






B4









Parallel Processing
Multiplier
Material Usage "Ibs"
Material Cost $/lb
Labor Rate $/Hr
Burden Rate $/Hr
Applied Burden Rate
$/Hour
TASK DESCRIPTION
Number of pieces of
parallel processing
equipment required for the
defined process to meet
rate. Automatically
populated from the
Manufacturing Assumption
section of the MAQS.
Enter total amount of
material used to process
single part per defined
process.
Automatically uploaded
from Material Database
Automatically uploaded
from Labor Database
Automatically uploaded
from Burden Database
Total burden rate
considering multiple piece
of equipment performing
the same task and/or using
equipment/lines with
parallel processing
capabilities.
Automatically calculated in
Quote Summary Section of
MAQS
INPUT
SOURCE(S)
FOR TASK
MAQS
Manufacturing
Assumption
section
Process
Magjitti
Material
Database
Lsb.°.r_Database
Burden J3atabase
Number of Lines
x Parallel
Processing
Multiplier x
Burden Rate =
Applied Burden
Rate.
REFERENCE
SOURCE(S) FOR
TASK
NR
NR
Material
Specification
Labor
Classification
Burden
Classification
Quote Summary
section of MAQS
OUTPUT
SOURCE(S) FOR
TASK
Variable used in the
calculation of Applied
Burden rate.
Variable used in the
calculation of material
costs.
Variable used in the
calculation of material
costs.
Variable used in the
calculation of labor
costs.
Variable used in the
calculation of Applied
Burden Rate.
Variable used in the
calculation of burden
costs.
Manufacturing Costs



Material Costs "$"
Labor/Part "$"
Burden/Part "$"
Material cost for defined
process. Automatically
calculated in Quote
Summary section of
MAQS
Labor cost for defined
process. Automatically
calculated in Quote
Summary section of
MAQS
Burden cost for defined
process. Automatically
calculated in Quote
Summary sec. of MAQS
Material Usage
"Ibs" x Material
Cost "$/lb"
=(Labor Rate
"$/Hr" x
Number of
Operators)/
Finished
Piece/Hour
=(Applied
Burden Rate
"$/Hr")/
Finished
Piece/Hour
Pull data from
Manufacturing
Rates section of
MAQS
Pull data from
Manufacturing
Rates section of
MAQS
Pull data from
Manufacturing
Rates section of
MAQS
Material contribution
to TMC "Total l"for
the defined process.
Labor contribution to
TMC "Total 1" for the
defined process.
Burden contribution to
TMC "Total 1" for the
defined process.
EPA Contract: EP-C-07-069 WAI-3
F.I, Page 4 of 16

-------
            APPENDIX F.I MAQS Worksheet Task Reference Guide










MAQS WORKSHEET SECTIONS


B5








Total 1 = Material +
Labor + Burden "$"

TASK DESCRIPTION
Total 1 = Total
Manufacturing Cost for the
defined value add process.
Automatically calculated in
Quote Summary section of
MAQS

INPUT
SOURCE(S)
FOR TASK
= Material Cost
"$" + Labor/Part
"$" + Burden/
Part "$"

REFERENCE
SOURCE(S) FOR
TASK
Pull data from
Manufacturing
Cost section of
MAQS

OUTPUT
SOURCE(S) FOR
TASK
Variable used to
calculate Mark-up
Contribution, "Total 2"
and "Total 3"
(additional details
below)

Mark-up Costs






End Item Scrap Rate
"%"
SG&A Rate "%"
Profit Rate "%"
ED&T Rate "%"
Total Mark-up Rate
"%"
Total Mark-up Costs
"
End Item Scrap Rate for
defined process.
Automatically uploaded
from Mark-up Database
SG&A rate for defined
process.
Automatically uploaded
from Mark-up Database
Profit rate for defined
process.
Automatically uploaded
from Mark-up Database
ED&T rate for defined
process.
Automatically uploaded
from Mark-up Database
Total Mark-up rate for
defined process.
Automatically calculated
in Quote Summary Section
of MAQS
Total Mark-up Cost for
defined process.
Automatically calculated in
Quote Summary Section of
MAQS
Mark-up
Database
Mark-up
Database
Mark-up
Database
Mark-up
Database
= End Item
Scrap + SG&A
+ Profit +ED&T
"%"
=Total Mark-up
Rate "%" x
Total 1 "$"
OEM Supplier
Classification
OEM Supplier
Classification
OEM Supplier
Classification
OEM Supplier
Classification
Calculated from
data in Mark-up
Cost section of
MAQS
Calculated from
data in Mark-up
Costs and
Manufacturing
Costs Sections of
MAQS
Used in calculation of
End Item Scrap costs
for defined process.
Used in calculation of
SG&A costs for
defined process.
Used in calculation of
profit costs for defined
process.
Used in calculation of
ED&T costs for
defined process.
Used in calculation of
Total Mark-up Costs
for defined process.
Used in calculation of
Total 2 (See below for
additional details)
EPA Contract: EP-C-07-069 WAI-3
F.I, Page 5 of 16

-------
            APPENDIX F.I MAQS Worksheet Task Reference Guide





































MAQS WORKSHEET SECTIONS

B6


















B7














TASK DESCRIPTION

INPUT
SOURCE(S)
FOR TASK
REFERENCE
SOURCE(S) FOR
TASK
OUTPUT
SOURCE(S) FOR
TASK
Total Costs


















Total 2 = Total 1 +
Total Mark-up







Total 3 = Total 2 *
QTY/Assembly







Total 2 is different than
Total 1 only for
components processed by
T2/T3 suppliers because of
the added mark-up.

Automatically calculated in
Quote Summary Section of
MAQS
Total 3 accounts for cases
where multiple pieces are
required in the assembly.
Automatically calculated in
Quote Summary Section of
MAQS



=Total 1 $ +
Total Mark-up
Cost$






Total 3 = Total 2
$ * QTY/
Assembly






Calculated from
data in Mark-up
Costs and
Manufacturing
Costs sections of
MAQS



Calculated from
data in Total Costs
& General
Component
Information
sections of MAQS




Used in calculation of
Total 3 (See below for
additional details)






The "Total 3" costs are
added up from all four
quote levels (Tl or
OEM, Purchase-High
Impact, Purchase-Low
Impact and Purchase-
Commodity) to arrive
at the component/
assembly Total
Manufacturing Cost.
Tooling and Investment













Tooling Assumptions







Investment
Assumptions



Enter those tooling costs
and assumptions which
cannot be excluded as a
result of the technology
differences between the
base and new technology
configurations.

Enter Unique investment
costs and assumptions
which may drive burden
rate changes.

CFT







CFT




NR







NR




Tooling is totaled for
the base and new
technology
configurations and a
differential calculated
in the Subsystem and
System Cost Model
Summary Templates.
Unique Investment
cases and costs are
captured for potential
development of new
burden rates.
EPA Contract: EP-C-07-069 WAI-3
F.I, Page 6 of 16

-------
            APPENDIX F.I MAQS Worksheet Task Reference Guide


c





























MAQS WORKSHEET SECTIONS

TASK DESCRIPTION

INPUT
SOURCE(S)
FOR TASK
REFERENCE OUTPUT SOURCE(S)
SOURCE(S) FOR TASK
FOR TASK
SECTION C: MAQS BREAKOUT CALCULATOR- REFERENCE ONLY "Costs
broken out into categories with quantity per assembly taken into account"
Cl













C2













Manufacturing Costs













Manufacturing Cost
(QTY)

>Material
>Labor

>Burden
>TMC





Takes into account quantity
(qty) of components per
assembly to calculate Total
Material, Labor and
Burden and TMC per
defined process.
Automatically calculated in
Breakout Calculator
section of MAQS




Total Material =
Material Cost x
QTY.

Total Labor =
Labor Cost x
QTY.
Etc....





Calculated from
the Manufacturing
Cost and General
Component
Information
sections of MAQS







The costs for each
manufacturing cost
element (material,
labor, etc) are added up
from all four quote
levels (Tl or OEM,
Purchase-High Impact,
rurchase-Low Impact,
and Purchase-
Commodity) to arrive
at the total cost
contribution, for each
element, for the
component/assembly.
Mark-up Costs













Mark-up Costs (QTY)

>End Item Scrap
>SG&A

>Profit

>ED&T
>Total Mark-up Cost




Takes into account qty. of
components per assembly
and sets mark-up rates to
calculate Total Mark-up
Costs for each mark-up
category per the defined
process.

Automatically calculated in
Breakout Calculator
section of MAQS



Total End Item
Scrap = QTY. x
Total 1 x End
Item Scrap rate.

Total SG&A =
QTY. x Total 1
x SG&A Rate
Etc 	




Calculated from
the General
Component
Information,
Manufacturing
Cost and Mark-up
Cost Sections of
MAQS





The costs for each
mark-up cost element
(scrap, SG@A etc) are
added up from all four
quote levels (Tl or
OEM, Purchase-High
Impact, Purchase-Low
Impact, and Purchase-
Commodity) to arrive
at the total cost
contribution, for each
mark-up element, for
the component/
assembly.
EPA Contract: EP-C-07-069 WAI-3
F.I, Page 7 of 16

-------
            APPENDIX F.I MAQS Worksheet Task Reference Guide

D










MAQS WORKSHEET SECTIONS
TASK DESCRIPTION
INPUT
SOURCE(S)
FOR TASK
REFERENCE
SOURCE(S) FOR
TASK
OUTPUT
SOURCE(S) FOR
TASK
SECTION D: MANUFACTURING ASSUMPIONS
Dl


D2






Process Information


Process and Equipment
Assumptions
Tooling, Fixturing and
Gauge Assumptions
Enter, define mass
production manufacturing
methodology based off
serial process mapping
Enter, define tooling
impact associated with
technology upgrade
features.
Process
Muffing and
CFT
Process
Maaaiyyffid
CFT
Historical industry
data and expertise
Historical industry
data and expertise
Process and equipment
assumptions provide
support information
for "Project Process
Requirement"
(Manufacturing
Assumption Section of
MAQS)
Tooling, fixture and
gauge assumptions
provide support
information for "Tool
Assumption Costs"
(Quote Summary
Section of MAQS)
Process Operation Pattern






Day/Week
Shifts/Day
Hrs./Shift
Hrs/Wk.
Wks./Yr.
Hrs./Yr.
Enter, default is 5,
assumption is everyone on
average operates 5
days/week to capitalize on
investment.
Enter, default is 2,
assumption is everyone on
average operates 2
shifts/day to capitalize on
investment.
Enter, default is 10,
Selected 10 as default
supporting heavy
automation, complex set-
ups and long change-over
times for majority of
components.
Automatically calculated,
average available hours per
week for manufacturing.
Enter, default is 47,
assumption is everyone on
average operates 47
week/year to capitalize on
investment.
Automatically calculated,
average available hours per
year for manufacturing
MAQS
Manufacturing
Assumption
section
MAQS
Manufacturing
Assumption
section
MAQS
Manufacturing
Assumption
section
=Day/week x
Shifts/Day x
Hrs/Shift
MAQS
Manufacturing
Assumption
section
=Hrs/Wk x
Wks/Yr.
NR
NR
NR
Manufacturing
Assumption
section of MAQS
NR
Manufacturing
Assumption
section of MAQS
Variable used in
calculation of available
hours/week for
manufacturing.
Variable used in
calculation of available
hours/week for
manufacturing.
Variable used in
calculation of available
hours/week for
manufacturing.
Variable used in
calculation of
Pieces/Hour.
Variable used in
calculation of available
Hours/Yr for
manufacturing.
NR
EPA Contract: EP-C-07-069 WAI-3
F.I, Page 8 of 16

-------
            APPENDIX F.I MAQS Worksheet Task Reference Guide








































MAQS WORKSHEET SECTIONS

D3




































TASK DESCRIPTION

INPUT
SOURCE(S)
FOR TASK
REFERENCE
SOURCE(S) FOR
TASK
OUTPUT
SOURCE(S) FOR
TASK
Minimum Calculated Cycle Times



































Pcs./Hr. (100% Eff.)









Cycle Time/Operation
"Sec."


Efficiency % (Stated
Efficiency)




Pcs./Hr. @ Stated
Efficiency









Cycle Time/Operation
@ State Efficiency
"Sec"

Automatically calculated,
number of piece required
per hour from the
manufacturer to support the
OEM facility (on weekly
basis) assuming 100%
efficiency





Automatically calculated,
tack time per part in
seconds @ 100%
efficiency
Enter, default 85%,
assumption with breaks,
downtime, etc., average
manufacturing time
available would be 8.5
hours out of 10.
Automatically calculated,
number of piece required
per hour from the
manufacturer to support the
OEM facility (on weekly
basis) assuming efficiency
"X"





Automatically calculated,
tack time per part in
seconds @ stated
efficiency
=(Weekly
Component-
Assembly
Volume xQTY
per Assembly) /
Hrs./Week





=(Pcs./Hr.)/
3600 Seconds


CFT





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








(Pcs./Hr. @
State
Efficiency)/
3600 Seconds
Manufacturing
assumption data
from MAQS Header
Sec., General
Component
Information from
MAQS Quote
Summary sec., and
HrsAVeek
information from
Manufacturing
Assumption sec. of
MAQS
Manufacturing
Assumption
section of MAQS

Historical industry
data and expertise




Manufacturing
assumption data
from MAQS Header
Sec., General
Component
Information from
MAQS Quote
Summary sec., and
HrsAVeek
information from
Manufacturing
Assumption sec. of
MAQS
Manufacturing
Assumption
section of MAQS

Variable used in
calculation or Pcs./Hr.
@ Stated Efficiency







Reference only



Variable used in
calculation of Pcs./Hr
at stated efficiency.



Value establishes
specification to ensure
defined mass
production process can
meet capacity.
"Resulting Pcs./Hr. >
"Pcs./Hr. @ Stated
Efficiency"




Reference Only



EPA Contract: EP-C-07-069 WAI-3
F.I, Page 9 of 16

-------
            APPENDIX F.I MAQS Worksheet Task Reference Guide








MAQS WORKSHEET SECTIONS
D4






TASK DESCRIPTION
INPUT
SOURCE(S)
FOR TASK
REFERENCE
SOURCE(S) FOR
TASK
OUTPUT
SOURCE(S) FOR
TASK
Project Process Requirements






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
(l=Nothing)
Number of Equivalent
Machines Required
Enter, total serial
processing time for a
defined process from
Process Map.
Enter, based on process
and equipment
assumptions is the total
number of operations
performed for a defined
process.
Enter, accounts for
equipment/processes where
multiple parts can be
produced at the same time
(e.g., multiple cavity
injection mold)
Enter, based on Process
and Equipment
Assumptions is the time it
takes for a given piece of
equipment from start to
finish to complete it' s
process cycle.
Enter, based on process
and equipments
assumptions is the
assignment of a burden
multiplier to account for
equipment with parallel
processing capabilities.
(e.g., 7 Part Spindle
Turning CNC Machine
versus a single part spindle
turning machine)
Enter, based on required
pieces/hr. @ stated
efficiency, is the number of
pieces of equipment
required to meet capacity
rates.
Process
Mmaii
Process and
Equipment
Assumptions
Process
MaEHflSJBd
Process and
Equipment
Assumptions
Process

Process and
Equipment
Assumptions
Process and
Equipment
Assumptions
Required
"Pcs./Hr. @
Stated
Efficiency" and
"Resulting
Pieces /Hour"
from defined
process and
equipment
assumptions
NR
MAQS
Manufacturing
Assumption
section
MAQS
Manufacturing
Assumption
section
MAQS
Manufacturing
Assumption
section
MAQS
Manufacturing
Assumption
section
MAQS
Manufacturing
Assumption
section
Total serial process time is
referenced to mass
production assumption
calculations e.g.,
(Piece/Cycle/ Machine) x
(Tack Time /Machine/
Cycle) x (Parallel
Processing Multiplier) x
(Number of Equip me nt/
Machine Required).
Pending situation mass
production assumption
calculation < total serial
process time.
Reference for
establishing parallel
processing
requirements and
number of equivalent
lines/equipment.
Variable used in
calculation of
"Resulting Piece/Hour"
Variable used in
calculation of
"Resulting Piece/Hour"
Populates "Parallel
Processing Multiplier"
in the Quote Summary
section of the MAQS
for Applied Burden
Rate calculation.
Populates "Number of
lines" in the Quote
Summary section of the
MAQS for Applied
Burden Rate
calculation.
Variable used in
calculation of
"Resulting Piece/Hour"
EPA Contract: EP-C-07-069 WAI-3
F.I, Page 10 of 16

-------
            APPENDIX F.I MAQS Worksheet Task Reference Guide






























MAQS WORKSHEET SECTIONS





















































Resulting Pieces/Hour









Resulting Cycle Time/
Part "Sec"







Total Number of Direct
Operators






TASK DESCRIPTION

Automatically calculated,
defines the pieces per hour
which can be manufactured
under the defined mass
production process and
equipment assumptions.




Automatically calculated.
defines the average tack
time per part based on
resulting pieces/hour.





Enter, the number of direct
laborers required to support
Process and equipment
assumptions



INPUT
SOURCE(S)
FOR TASK
= {3600
seconds/ (Tack
Time/Machine/C
ycle)} *
{(Pieces/
Machine/Cycle)
* ( Number of
Equivalent
Machines
Required)}
=3600 Seconds/
( Resulting
Pieces/Hour)






Process and
Equipment
Assumptions




REFERENCE
SOURCE(S) FOR
TASK
MAQS
Manufacturing
Assumption
section






MAQS
Manufacturing
Assumption
section





MAQS
Manufacturing
Assumption
section



OUTPUT
SOURCE(S) FOR
TASK
Populates "Finished
Pieces/Hour" in the
Quote Summary
section of the MAQS
which is then used in
the calculation of labor
and burden costs.



Checked with respect
to "Cycle
Time/Operation @
Stated Efficiency "Sec"
to ensure
manufacturing process
and equipment
assumptions can meet
capacity requirements.
Populates "Number of
Operators" in the
Quote Summary
section of the MAQS
which is then used in
the calculation of labor
Costs.
EPA Contract: EP-C-07-069 WAI-3
F.I, Page 11 of 16

-------
            APPENDIX F.I MAQS Worksheet Task Reference Guide

E











MAQS WORKSHEET SECTIONS
TASK DESCRIPTION
INPUT
SOURCE(S)
FOR TASK
REFERENCE
SOURCE(S) FOR
TASK
OUTPUT
SOURCE(S) FOR
TASK
SECTION E: PACKAGING CALCULATIONS

El


E2












Packaging Calculation


Package Calculation
Data Entry Box

Enter, the selected
packaging configuration,
part size and expected pack
density.

Packaging
Databasea Part
Measurements
Information

MAQS Header -
Packaging
Assumptions

Expected pack density
variables feed "Number
of Parts per
Pallet/Rack"
calculation.

Rack/Pallet Investment Amortization






Supplier, Customer and
In-transit Inventory
Requirements (Parts)
Supplier, Customer and
In-transit Inventory
Requirements (Weeks)
Number of Parts per
Pallet/ Rack
Total Number of
Pallets/ Racks Required
Cost per Pallet /Rack
Interest Rate
Automatically calculated.
defines the total inventory
required to support the
"Supplier, Customer and
In-transit Inventory
Requirements"
Enter, default 6 weeks,
number of weeks of
packaging required to
cover plant stock turn-over,
transit times, container
cleaning, etc
Enter, for base ballet
assumptions (48"x45")
how many parts can be
loaded onto pallet
maintaining height
requirements.
Automatically calculated
defines how many
complete pallets/racks are
required to support
supplier, customer and in-
transit inventory
requirements
Enter, cost of one
complete pallet/rack set.
Enter, default 5%, interest
rate to cover lost invest.
opportunity w. packaging
hardware purchase.
= Weekly
Component
Volume X
"Supplier,
Customer and
In-transit
inventory
requirements"
CFT
Packaging
Databasea
Package
Calculation
Entry Box
= (Supplier,
Customer and
In-transit
Inventory
Requirements
(Parts))/ (# of
Parts per Pallet/
Rack)
Packaging
Databasea
Package
Calculation
Entry Box
CFT
MAQS Header and
Packaging section.
NR
NR
MAQS Package
Calculation section
MAQS Package
Calculation section
NR
Variable used to
determine total number
of pallets/racks
required.
Variable used to
calculate "Supplier,
Customer and In-transit
Inventory
Requirements".
Variable used to
determine total number
of pallets/racks
required.
Variable used to
determine Total
Packaging Costs.
Variable used to
determine Total
Packaging Costs
Variable used in
calculation of
Returnable
"Cost/Piece"
EPA Contract: EP-C-07-069 WAI-3
F.I, Page 12 of 16

-------
            APPENDIX F.I MAQS Worksheet Task Reference Guide











MAQS WORKSHEET SECTIONS






E3









Number of Service
Months
Total # of Pieces/
Amortization Period
Lump Sum Payment
(%)
Total Amount
Cost/Piece (Returnable)

TASK DESCRIPTION
Enter, default 60 months,
expected service life of
packaging before it needs
to be replaced.
Automaticallv calculated.
defines the total number of
parts, during the defined
service life, which will be
used to amortize the
packaging costs.
Enter, default 0%, any
upfront customer payments
towards packaging,
Automaticallv calculated,
defines the total packaging
cost for the assumed
volumes, transit times,
inventory hold and service
life, etc.
Automaticallv calculated,
defines the additional cost
per part required to cover
the returnable packaging
expenditure.

INPUT
SOURCE(S)
FOR TASK
CFT
= Weekly
Component
Volume X
Number of
Service Months
X Average
Weeks/Month
CFT
= Total Number
of Pallets/ Racks
Required X Cost
per Pallet /Rack
Calculated using
standard
amortization
formula.

REFERENCE
SOURCE(S) FOR
TASK
NR
NR
NR
MAQS Package
Calculation
Section
MAQS Package
Calculation section

OUTPUT
SOURCE(S) FOR
TASK
Variable used in
calculation of
Returnable "Package
Cost/Piece"
Variable used in
calculation of
Returnable
"Cost/Piece"
Variable used in
calculation of
Returnable "Package
Cost/Piece"
Variable used in
calculation of
Returnable
"Cost/Piece"
Cost/Piece is added to
any contribution from
expendable packaging,
if applicable, to obtain
the Packaging Cost
Total / Part

Expendable Packing in Piece Cost



Tier Pad Piece Price,
Divider Pad Piece Price,
Other #1,2,3 Piece
Price, etc
Tier Pads per
Pallet/Rack, Divider
Pads per Pallet/Rack,
etc
Cost/piece
(Expendable)
Enter, from Packaging
database enter unit cost of
identified expendable
packing.
Enter, from Package
Calculation Data Entry
Box, enter quantity of
identified expendable
packaging required per
pallet.
Automaticallv calculated,
defines the additional cost
per part required to cover
the expendable packaging
expenditure.
Packaging
Database,,
Package
Calculation
Entry Box
Package
Calculation
Entry Box
=(Total
Expendable
Packaging
Expense for
Pallet) /(Number
of Parts/Pallet)
MAQS Package
Calculation section
MAQS Package
Calculation section
MAQS Package
Calculation
Section
Variable used in
calculation of
Expendable
"Cost/Piece"
Variable used in
calculation of
Expendable
"Cost/Piece"
Cost/Piece is added to
any contribution from
returnable packaging,
to obtain the
Packaging Cost Total /
Part
EPA Contract: EP-C-07-069 WAI-3
F.I, Page 13 of 16

-------
            APPENDIX F.I MAQS Worksheet Task Reference Guide



F































MAQS WORKSHEET SECTIONS


TASK DESCRIPTION

INPUT
SOURCE(S)
FOR TASK
REFERENCE
SOURCE(S) FOR
TASK
OUTPUT
SOURCE(S) FOR
TASK
SECTION 6: UNIT COST SUMMARY





























































Tl or OEM Total
Manufacturing Costs
(Includes TMC + T2/T3
Mark-up)



Tl or OEM Mark-up
Rates


(SAC) and Tl or OEM
Mark-up Values/Costs







Base Cost Impact to
Vehicle (Includes TMC
+ Tier 2/3 Mark-up and
Tier 1 Mark-up)




Net Cost Impact to
Vehicle



Automatically calculated,
presents the Total
Manufacturing Cost of the
components including all
Tier 2/Tier 3 mark-up
broken out into the 7 cost
elements.
Rates Automatically
loaded when the OEM/T1
Classification is receded in
the header.
Automatically calculated,
Tl (or OEM if applicable)
mark-up costs.
Note: If there are any
Purchase Parts -
Commodity based,
classified as "SAC's", the
values are subtracted out in
this area after Tl mark-up
costs are calculated.
Automatically calculates
the total base cost for the
component/assembly
broken out into the 7 cost
elements.
Note: In addition, tooling
and investment impact (if
applicable) are summed up
within this section.
Automatically calculated,
Final Unit Cost Impact to
Vehicle


MAQS
Worksheet
Calculations




Mark-up
Database,


=("T1 or OEM
TMC") x ("Tl
or OEM Mark-
up Rates")





= ("Tl or OEM
TMC") +
("(SAC) and Tl
or OEM Mark-
up Values/
Costs")




= Base Cost
Impact to
Vehicle +
Packaging

NR






MAQS Worksheet
Header


NR








NR




NR




Values are used to
calculate Base Cost
Impact to Vehicle.




Rates are used to
calculate Tier 1 (or
OEM if applicable)
mark-up costs.
Tl (or OEM if
applicable ) mark-up
costs are added to TMC
to obtain Base Cost
Impact to Vehicle





Total is added to
Packaging Cost to
obtain the Net Cost
Impact to Vehicle.
Note these values are
also carried into the
Subsystem Cost Model
Analysis Templates

FINAL UNIT COST



EPA Contract: EP-C-07-069 WAI-3
F.I, Page 14 of 16

-------
                                     APPENDIX F.I MAQS Worksheet Task Reference Guide
rjj— gg— 1| -^
wm^=mm^= wmv
Mr i_ !»
Technology Leve :
Vehicle Class:
Study Case*:
System Description:
' Component Description:
T Component Quote Level:
GENERAL COMPONENT INFORMATION
1 Part Description

fie 1 Supplier or OEM Processin
1A Fuel Injector Assembly
2A Seallnjecfar Tip
3A Solenoid Body preassernbled
4A Nee* Body Assembly
5A Needle Assembly
SA Needle Injector
if. Mating Waive assembly

}u chase Part - High Impact Item

1A Body Injector Solenoid
2A Sleeve winding to inlet separator
3A Sleeve Fuel Inlet
4ft Body needle
5A Inlet Tube
6A Spring Seat Lower
7A Needle waive
Part Number

q& Assembly (Full C(
1104-NQ101-01
1104N0101-01-30
11Q4N0101-Q1-10
1104N0101-01-50
1104M0101-01-11
11Q4N0101-01-13
1104-N0101-01-16

Full Cost Mapping)
1104N0101-01-20
1104N0101 -01-27
11i)4N0101-01-2S
1-1IM-N01Q1-0-1.3
1104M0101-01-21
1104N0101-01-14
1104N0101-01-24
g

st m
i
i
1
1
i
i
1








Downsized. Turbocharged. Gasoline Direct Inject ort
Assemble S Press Sleeve
Laser Weld Ball and Seal to
Needle
Laser Weld Plate to Valve



Marine Body
Machine and Roll Splines
Machine
Machine and Roll Splines
Cut and Flare
Machine
Centertess Grind
purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Materi;




'urchase Part - Commodity ( Value taken from Purchase Part Database)
1A Solenoid Windings
2A Ring winding locator
3A Spring - needle to metering valve
4A Spring Needle Return
5A Sleeve Screen Stop
6A Screen Fuel Inlet
7A circlip face seal retainer
f-f. Comprer •= ion hmtef - Oling











1104N0101-01-22

1104N0101-01-1S
1104N0101-01-12
1104N0101-01-25
11I34N0101-01-6
1104N0101-01-S
1104N0101-01-3


















0
0



























OEMfSupplier
Classification


T1 Assembly, MiatK-up
Applied (5) Bottom.
T1 Assembly, Mark-up
Applied @ Bottom.
T1 Assembly, Mark-up
Applied © Bottom.
T1 Assembly, Mark-up
Applied % Bottom.
T1 Assembly, Mark-up
Applied @ Bottom.
T1 Assembly, Mark-up
Applied (§ Bottom.
T1 Assembly, Mark-up
Applied ® Bottom.



2m GNC Turning, MSMG
2m CNC Turning, MSMC
2m CNC Turning, MSMC
2m CNC Tummg, MSMC
/T3 Hydro/CNC Form, SSL<
2m CNC Turning, MSMC
2m CNC Turning, MSMC
I Estimate + Actual


s
s
8
S
s
-1-
s








Material
Specification


Not Applicable
Nylon-HT, Inject.
NylonE6-40FMR, Inject.
Not Applicable
Not Applicable
Not Applicable
Not Applicable



S-Steel-«OC, Bar
S-Steel-4WC, Bar
S-Steel-440C, Bar
S-Steel-440C, Bar
S-Steel-304, Tube
S-Steel-440C, Bar
Not Applicable
Component Assemb




Labor
Classification


ilectromechanical Assembly
Electromechanical Assembiy
— '
Electromechanical Assembly
Electromechanical Assembly
Electromechanical Assembly



CNC Operator
CNC Operator
CMC Operator
CNC Operator
Forging Operator
CNC Operator
CNC Operator
y Process)




|"S"=lndicates Component is Supplied directly to T1
Assembly.
"SAC"=(Supplier Accounted Costs) Indicates Comp
or OEMIor Final or Sub- Assembly. In addition com
accounted for in T1 quote sheet. Thus component c
Marii-up Calcinations.
Guppliertor Subassemtily.


Burden
Classification


Vtech Assembly, LC, Base
Mech Assembly, MC, Base
^..^a,,.
Mech Assembly, MC, Base
Mech Assembly, MC, Base
Mech Assembly, MC, Base
Mech Assembly, MC, Base



CNC Turning, MC
CNC Turning, MC
CNC Turning, MC
CNC Turning, MC
Cold Forge, LMC
CNC Turning, MC
CNC Turning, MC
-
OEM Operating

Annual E
^attern (Weeks/Year):
ngine Volume (CPV):
| Components per Engine:
Annual Component Volume:
Weekly Component Volume:
Estimated Product Life:
MANUFACTURING RATES
Finished Pieces Per Hour


49)
41(1
410
410
410
114
HI



100
491
481
468
410
J40

&^^ ^| 4
SECT|I(
1
r OEM lor Final or Sub-
nent is Supplied direcfly to T1
ronent material cost is
3st will only be included lor
rts are brought in by T2/T3

















I
SECil

I

I
Kutnberof Operators


2
1
2
4
1
1
1



0.1
0.1
0.1
0.1
01
0.21
oa
Number at Lines


1
1
1
IS
1
1
1



i
t.i
li
li
1
"

^1
)N







rr^
I

_

Parallel Processing
Huttiplier


6
1
S
S
4
3
2













F



1
I
j


0.000
O.OD5
0.030
0.000
0.000
0.000
0.000



0.140
0.074
0.041
0.043
0.010
0.0002
0 0013

1
\



•



Material
cost
$flb


30.00
Mill
JtM
ntae
HUB
30.00
30.00



KM
34.16
34.16
34.16
31.6$
34.16
$0.00






TlorOE
Labor
Rate
$IHour


$37.3)
$37.31
«,
S37.M
537.31
$37.31
$37.3)



$31.70
$».70
$31.70
$31.70
$38.12
$3170
$3i_70






Burden
Rate
$IHour


$11.00
$30.00
$41.00
moo
$30.00
$30.00
»«,



341.00
$41.00
$41.00
$41.00
$100.09
$41.00
$41.00






Applie
d
Burden
Rate
$JHour


«WLOU
$30.00
$221.00
$369.00
1120.00
$90.00
warn



$2M.OO
£202.10
$117.10
$247.10
$ioao9
$67.10
$67.10






1 Total Manufarturing Cost
T1 or OCM Mart Up Rates:
Base Cod Impact to Ifthhlc:






47
450,000
4
UMUM
38,298

OEM Plant Location: North America
Supplier Plant Location:
OEMyTI Classification:

Shipping Method:
Packag ng Specification:
10
MANUFACTURING COSTS
Material
Cost


30.00
30.02
jaw
30.00
moo
$0.00
30.00



30.64
$03*
30.19
30.20
30.02
30.00
1000





Material
$2.18
-.> li


Labor/
Part


30.16
$003
$0.17
30.33
mos
$0.07
30.07



30.04
SUM
SttW
30.04
mm
$002
$002





Labor
$1.47




Burden


$ao7
SBLJO
30.80
JBL27
»13
jaw



$a«
3441
$0.33
$0.28
$0.11
$0.13





Burden
J8.44


Material + Labor +


$0.34
$0.17
$0.71
$1.13
$0.3
ma
«.



$1.12
30.T9
30.11
$0.77
$031
$ft17
$014





TMC
$10.07
110.07





MARK-UP COSTS
End
Item
Scrap
Rate
(OB)


100%
(LINK
0.00%
0,00%
0.00%
0.00%
0.011%

0.10%
0.10%
fan
0.10%
0.30%
0-10%
(am,





Srnp
30.03
0.70%
$0.11
SG&A
Rate


0.00%
0.00%
0.00%
0.00%
0.110%
0.00%

6.10%
6.10%
6.10%
aio%
6.10%





SGSA
$0.41
7.00%
$1.18


Profit
Rate


0.00ft
000%
0.00%
0.00%
0.00%
0.00%
0.00%

1X00%
6.00%
00%
00%
00%
00%
00%





Profit
30.3S
e.oo%
- .



EQ&Tf
ftao
Rate


0.00%
0.00%
000%
0.00%
0.00%
0.00%
0.00%

1.00%
1.00%
1.00%
0.00%
1.00%
100%





ED£T
•Si or,
4.00%
tfllO



Total
Mark-
up
Rate


0.00%
BLOK
0.00%
0.00%
0.00%
0.00%
0.00%

14.00%
14.00%
14.00%
14.00%
io.m
14.00%
14.00%


Accou
$0.00
$0.00
jaoo
$0.00
$0.00
$0.00
30.00
$0.00
30.00
$0.00

Total
Mart
up
tta
19.70%
$10)
Total
Mark-
up
Cost


moo
moo
$0.00
moo
m.oo
$0.00
30.00

30.16
tan
30. OS
$8.11
30.M
$anz
$ao2


Phcl*
10.25
30.03
to. 01
30.03
to. 0-1
30.05
30.02
30.03
38-85




North America

FOB Ship Point

i
1
•
1
1
TOTAL COSTS
Total 2 =
Total! * Total Mark-up


30.34
$0.17
$0.71
$1.13
$fl.3J
$0.19



$1.28
ia.sn
$0.63
30. S8
30.3S
$0-19
$0-16


e Price
Net. PIA
$0.00
$0.00
30.00
30.00
30.00
W.OO
30.00
30.00
30.00
30.00


Q
	 ^CI
• 	 *•
Pschaging Cost
Net Cost Impact to Vehicle:
Total 3 =
Total 2* QtyperAss'y


$0.34
$ai7
$a?i
$1.13
«L3J
$0.19



$1.26
30.90
30.63
30.38
$0.19
$0.16


c P.ioc
Net. End
30.21
30.0G
$0.0)
30.03
moi
SO.B
30.02
30.00
30.00
1

—r-
$10 »
410.9)
: ' 11
$0.01
$13.13
TOOLING S
Tooling Assumptions
"xiaon"






































$0



Investment Assumptions
"xlOOO "






































iu



EPA Contract: EP-C-07-069 WAI-3
F.I, Page 15 of 16

-------
                                     APPENDIX F.I MAQS Worksheet Task Reference Guide
Costs Broken Out Into Categories with Quantity per Assembly Taken into Account
Manufacturing Cost
Material



$0.00
$0.82
$0.05
$0.00
$O.BO

$0.00


$0.34
$8.19
$0.20
$0.02




30.08
$0.01
30.03
$0.01
50.01
$0-02
$0.03
_ JO.OO
San
Material
Labor



$0.16
$0.08
$0.17
$0.33
$0.08

$0.07


$0.04
$0.04
$0.04




Labor
Durden



$0.19
$0.07
10.50
$0.80
$0.27

$0.12


SE




Burden
Total Mfg'ing Cost
(Com ponentf Assembly)

$0.34
$0.17
$0.71
$1.13
$0.35
$0.19


iB'




$0.08
30.01
$0.03
30.01
30. (H
3003
$0.00
$0.00
TMC
Mark-up Cost
End Item
Scrap


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


IK




Scrape
SG&A


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


B




SG8A
Profit


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


$ffiw




Profit
ED&T-
R&D


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

$0.01
$0.
$0.
$0.
$0.




EDST
Total Marftup Cost
(Com ponentf Assem bly J


$0.00
$0.00 '
$0.00
$0.00
$0.00
$0.00

$0.16
$0.11
$0.08
$0.11 !
$0.04
$0.02 '
$0.02 '



Marh-up
Total

Notes:
a) Hem-, 1,2, 8 3 mutt all equal same value otherwise there is a
computation error.
a





























I
MAHUFAC PUKING ASSUMPTIUNS
Process Information
Process & Equipment Assumptions



Semi Automated Line with Operator lo
circlip face seal, S#3Press Screen SI
Bracket Hold Down, S# 6Test S Labe
Operator Load and Unload, Single Slat
Linear Transler line leeding 2 Vertica
Body Assembly into Solenoid Body, St
1 Overmofd., ST#5 Transfer to seconda
Automated Rotary Laser weld table w
FixtureSWeld, S#G Cool, S*7 Re-orier
laser Wefd, S#11 Cool, Station 12 Tes
Semi automated load to pallet, siitoma'
Automated component feed and lase
ad and unload. S1#1 , Operator load injector assemb
p and filter, S#4 Install Compression Limiter Oring a
#7 Operator Unload S Pack
y w. face seal., St#2, install
d Oring Injector, S#S, Install
on, tip seal install and size.
njection Press. Both 4 Cavities (2x2). Linear Transfer Line, St#1 Press Needle
#2, insert Coil and Ring Locator and Press Home, St#3 Load into Mold, ST# 4
y overmold.
ith operator load assist and unioad. S* 1 & 2 load pallet, Stf 3 Fixture & Weid, S5
tate, S#8 insert Valve Assembly /Spring and Sleeve, S#9 Install Inlet Tube, S#10
and Pack.
c fixture and pres.:- Opefatoi assistance on load a
nd unload.
weld assembly station (load, fixture & clamp, welcJ#1 , weld#2, unload)
weld assembly station (load, fixture&clamp, weid, unload)

Multi Spindle CNC Turning Machine +• B
Multi Spindle CNC Turning Machine + B
Mufti Spindle CNC Turning Machine + B
Multi Spindle CNC Turning Machine + B
Cold Form Press with automated part
Automated CNC, Feed and Machine, B
Hopper feed to centerless grinding

atch Wash
atch Wash
atch Wash
andling














|























PACKAGING CALCULATIONS:
Packaging Type: Option m Tote, 42 Totes/Pallet
Part Size: 90x55x25 mm
Parts/Layer per tote: 3 x £
Number of Layers per tote: 9
RatWPallrt Investment Amortization


Expendable Packaging in Pirn Co*






	 1 — I—



Projected Operating Pattern
Daysf
Week


5

5
6
5


5




5


<
1


Shifts.



2


2
2
2


2




2


5F
3rE

Illy.;
Shift



10


10
10
10


10




10


:C
r*a

Mrs.;
wk



100


0.
100
100
100



100





1


T
1

Wks.f
Yr



47
47
47
47
47
47
47


47
47
47
47
47
47
His./
Yr



4700
4700
4700
4700
4700
4700
4700

4700
4700
4700
4700
4700
4700
4700

ON
Vrt H



Cost
per
Piece
30.014
c;t«r
$0.00




t
$108.680
Tier Pad
$0.00
ISECl






1


Total •
m v.} alion
Period
o m\ 9.000,000
P."* Diridcr
0 K. 00
ION









Minimum Calculated Cycles Time
Pcs.l Hr. (190% Eff.)


383
383
383
383
383
383
383

383
383
383
383
383
383
383

D


Cycle TimelOperation
"Sec."


9.40
9.40
9.40
9.40
9.40
9.40
9.40

9.40
9.40
9.40
9.40
9.40
9.40
9.40






Months
60
OiTidtc
Pad;
0
b
b

1



Rare
100%
II
atkigi
g P.itt
ft.
30.00
—
Efficiency %



85%
85%
85%
85%
85%
85%
85%

85%
85%
85%
85%
85%
85%
85%





Pcs.1 Hr.
@ Stated Efficiency


451
451
451
451
4S1
451
451

451
451
451
451
451
451
461





Cycle TimerOperation @
Stated Etficiency "Sec/1


7.9S
7.99
7.99
7.99
7.99
7.99
7.99

.99
.99
.99
.99
.99
.99
.99





Project Process Reg
Lean Design Calculation
for Complete Process
Time "Sec."






32
21
13



43
36
53
33









•1
0
mack
$4,1 SO
*2
•g
Price
$100
Total Number of
Pallets/ Racks
26
fids f
Pallet;
R«*
0

	 1 —












if
if
J
y.i:
»3
•9.
Piitt
0.00


I
I
1
Parallel
OperationsJMachine or



7
1

5
12
4
3
2



3






Supplier. Customer
and In-transit
P
Rick
0







and In-transit
Inventor!
2297S7







I
£
f
i
1



2
2
2
1
1
1
1



















Tack Timef Machinery cle
"Seconds"



15
16
16
12
3
7
7.0


33
26
43
10
10















Multiplier, IF Required for
Parallel Processing
(1=Nothina)



6.0
1.0
5.0
8.0
4.0
3.0
2.0




















merit
Number of Equivalent



0
0
0
5
0
0
0


5
5
5
0
5
5














Resulting PiecesfHour



400
450
450
450
450
514
514


491
485
480
360
450
540












Resulting Cycle Timef
Part
"Sec.


7.50
8.00
8.00
8.00
8.00
7.00
7.00


.33
.43
.32
0.00
8.00
6.67












Total Number of Direct
Operators


2.00
1.00
2.00
4.00
1.00
1.00
1.00


0.50,
0.50
0.50
0.50
0.25
0.25












EPA Contract: EP-C-07-069 WAI-3
F.I, Page 16 of 16

-------
                                            APPENDIX G.I
                       MAQS Worksheets (Worksheet Sections A,B,E and F)
                                           Case Study #0101
                                                    Appendix G.1
                                                 Printed: 12/9/2009
Engine Subsystems
Engine Frames, Mountings & Brackets Subsystem
Crank Drive Subsystem
Counter Balance Subsystem
Cylinder Block Subsystem
Cylinder Head Subsystem
Valve Train Subsystem
Timing Drive Subsystem
Accessory Drive Subsystem
Intake Subsystem
Fuel Induction Subsystem
Exhaust Subsystem
Lubrication (Oil Pans/Sumps) Subsystem
Cooling Subsystem
Induction Air Charging Subsystem
Exhaust Gas Re-Circulations Subsystem
Breather Subsystem
Engine Management, Engine Electronic and
Electrical Subsystem
Accessory (e.g. Starter Motor, Power Steering
Pump, Air Conditioning Compressor) Subsystem


MAQS Worksheets
Location within Appendix
G.1
Not Applicable
Appendix G.1 - 03, Pages 1-7
Appendix G.1 - 04, Pages 1-4
Appendix G.1 - 05, Pages 1-8
Appendix G.1 - 06, Pages 1-8
Appendix G.1 - 07, Pages 1-4
Appendix G.1 - 08, Pages 1-2
Not Applicable
Appendix G.1 - 10, Pages 1-2
Appendix G.1 - 11, Pages 1-12
Appendix G.1 - 12, Pages 1-6
Appendix G.1 - 13, Pages 1-11
Appendix G.1 - 14, Pages 1-9
Appendix G.1 - 15, Pages 1-16
Not Applicable
Appendix G.1 - 17, Pages 1-2
Appendix G.1 - 60, Pages 1-5
Appendix G.1 - 70, Pages 1-4

Total Unit Cost =>
Net Incremental
Component/ Assembly Cost
Impact to OEM
$0.00
$0.00
($35.95)
$0.44
$16.55
$10.06
$1.60
$0.00
($12.73)
$107.32
$37.77
$34.46
$41.56
$258.89
$0.00
$4.17
$56.61
$16.95


File:Cost Model Analysis Template 120809.xls
EPA Contract:EP-C-07-069 WA1-3
G.I, Page 1 of 1

-------
                   Appendix G.1 - Subsystem 03
                      Crank Drive Subsystem
                         Case Study #0101
                        MAQS Worksheets
FfeCrank Drives 03,032509.xls
EPA ConlractEP-C-07-069 WA1-3                           Appendix G.1-03,1 ol 7

-------
                                                                                             Manufacturing Assumption and  Quote Summary
                                                                                                                                                                          APPENDIX G.1-03(1of4)
                                                                                                                                                                                     Print Dale:9/1/2009
              Technology Level: Downsized, Turbccharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                  Vehicle Class: Compacl/Economy24 Passenger	
                   Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class;
            System Description: 2007 Mini Cooper s. 1.6L 14,16V DOHC GDI Turbo
        Component Description: Shalt - Crank
       Component Quote Level:
                                                                                          Part Number: 0301-N0101-01
°le|    I
                                         n Quote| X |
                                                                            _OEM Operating Pattern (Weeks/Year):      n
                                                                            _        Annual Engine Volume (CPV):	
                                                                            _             Components per Engine:      1
                                                                            _          Annual Component Volume:    «o,ooo
                                                                            _          Weekly Component Volume:     9,57<
                                                                                            Estimated Product Life:      10
    OEM Plant Location:     North America
 Supplier Plant Location:     North America
       Shipping Method:        F.O.B
Packaging Specification:
                                                                                                                                                                                                                TBD
GENERAL COMPONENT INFORMATION
1



Tie





Part Description



1 Supplier or OEM Processing


P

Shaft-Crank(ChryslerGema)
Part Number



& Assembly (Full Cos




0301-B0101-01
Purchase Part - Commodity ( Value taken from Purchas













































O



tma




1
GENERAL MANUFACTURING INFORMATION
Primary Process
Description



pping)
Considered for Weight Delta
Only, Assume Fabrication anc
between llini and Chrysler
Crankshaft
"See Note Above"
; Part Database)




































OEM orSuppI
5







OEM



















Material
Specification








MA-Steel-MnVS, Bar


Labor Classification








Not Applicable


Burden
Classification






PP

Not Applicable


MANUFACTURING RATES
Finished Pieces Pe

1






116


'Syndicates Component is Supplied directly to T1 or OEM for
Final or Sub- Assembly.
'SAC'=(Supplier Accounted Costs) Indicates Component is
Supplied directly to T1 or OEM for Final or Sub-Assembly. In
addition component material cost is accounted for in T1 quote
sheet. Thus component cost will only be included for Mark-up


'Alpha-Numeric Character1 = Indicates purchase parts are
brought in by T2/T3 Supplier for Subassembly.










































Number of Opere
0







0



















1
1

=






-39.8,













T1 o





Material
Cost
$/lb
(DB)








$0.73













Labor
Rate
$/Hour
(DB)








$0.00













Burden
Rate
$/Hour








$0.00













OEM Total Manufacturing Cost:
T1 or OEM Mark-Up Rates:
&T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:






MANUFACTURING COSTS
Material
Cost








-$29.06















0.00

Labor/ Part






















$0.00



Burden/
Part








$0.00

















IF
e!
fir

s






-$29.06

















MARK-UP COSTS
End
Item
Scrap
Rate








0.00%














0.70%
-$0.07
-$0.07
SG&A
Rate








0.00%













$0.00
7.00%
-$0.74

Profit
Rate








0.00%














8.00%
-$0.85

ED&T/
R&D
Rate








0.00%













$0.00
0.00%


Total
Mark-up
Rate








0.00%
Supplier
Account
Cost
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

$0.00
$0.00
$0.00
$0.00
$0.00


Total Mark
up

15.70%
-SI .67

Total
Mark-up
Cost








$0.00
Purchase
Price/ Unit
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

$0.00
$0.00
$0.00
$0.00
$0.00







TOTAL COSTS
2.
SL
+ —1
S" ^
W "








-$29.06
Purchase
Price Net, PIA
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

$0.00
$0.00
$0.00
$0.00
$0.00




	 >u.


	 *•
Packaging Cost:
Net Cost Impact to Vehicle:
o
SL
II
1 if

*






-$29.06
Purchase Prici
Net, End Item
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

$0.00
$0.00
$0.00
$0.00
$0.00
1
I


-$10.61


-$12.27
$0.00


TOOLING & INVESTMENT
Tooling Assump
"X1000 "
o

-------
                                                                                             Manufacturing Assumption and Quote Summary
                                                                                                                                 APPENDIX G.1-03,(2of4)
                                                                                                                                            Print Dale:9/1/2009
              Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                  Vehicle Class: Compacl/Economy24 Passenger	
                                   _OEM Operating Pattern (Weeks/Year):_
                   Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class;
            System Description: 2007 Mini Cooper s. 1.6L 14,16V DOHC GDI Turbo
        Component Description: Rod Subassembly - Connecting
       Component Quote Level:         Full Quolel   |
                                                                                           Part Number: 0303-N0101-01
n Quote| X |
                                            Annual Engine Volume (CPV):    <50,ooo
                                                 Components per Engine:      4
                                              Annual Component Volume:   1,800,000
                                              Weekly Component Volume:    38,298
                                                  Estimated Product Life:      10
    OEM Plant Location:     North America
 Supplier Plant Location:     North America
       Shipping Method:
Packaging Specification:
                                                                                                                                                                                                                  NA
GENERAL COMPONENT INFORMATION

1



Tie


1A


1B
2A





2B





Part Description



1 Supplier or OEM Processing


3od Subassembly - Connecting


Rod Subassembly - Connecting
Rod Subassembly - Connecting





Rod Subassembly -Connecting





Part Number



& Assembly (Full Cos


0303-N01 01 -01-01


0303-N0101-01
0303-B01 01-01802





0303-B0101-01S02-M




Purchase Part - Commodity ( Value taken from Purchas

















Bushing -Connecting Rod
















0303-NO,0,-02
















O
!



tma


1


1
'





1




GENERAL MANUFACTURING INFORMATION

Primary Process
Description



pping)
Weight Cost Differential Only,
Fabrication and Machining are
Chrysler Con. Rods.
Mini-Cooper Rod
L7R = 138.5/(85.9/2) = 3.22
«,IIBuShing8Siz,
Chrysler GEMA Rod Weight
Additional Material Reguired
to EgualizeL/R Ratio
GEMA Prod. UR = 2.96,
R = 97/2 = 48.5 SL
=143.75mm
Assuming Mini L7R (3.22).
Hold stroke constant
1=3.22*48.5= 156.17mm
Therefore rod length would
increase by 12.42mm
; Part Database)
1
0
0
0
















MuminumB,™
;Blank 40x30x0.5 mmm)
Mean p = 0.270


















EM or Suppl
%





s


s












s




















Material
Specification






MA-Steel-C70S6, Bar


Not Applicable
MA-Steel-C70S6, Bar





v!A-Steel-C70S6, Bar







Labor Classification






Not Applicable


General Assembly
Not Applicable





Not Applicable







Burden
Classification






Not Applicable


Mech. Assembly, MC
Not Applicable





Not Applicable






MANUFACTURING RATES
5"
4
ed Pieces Pe

1




450


450
450





450






•Syndicates Component is Supplied directly to T1 or OEM for
Final or Sub- Assembly.

'SAC'=(Supplier Accounted Costs) Indicates Component is
Supplied directly to T1 or OEM for Final or Sub-Assembly. In
1 addition component material cost is accounted for in T1 quote
sheet. Thus component cost will only be included for Mark-up
Calculations.

'Alpha-Numeric Character1 = Indicates purchase parts are
brought in by T2/T3 Supplier for Subassembly.




































•z.
berofOpere
0





0


0
0





0

























s
1
1

=




0.964


0.000
-0.979





-0.032




















T1 o





Material
Cost
$/lb
(DB)






$0.70


$0.00
$0.70





$0.70





















Labor
Rate
$/Hour
(DB)






$0.00


$35.51
$0.00





$0.00





















Burden
Rate
$/Hour
(DB)






$0.00


$125.19
$0.00





$0.00




















OEM Total Manufacturing Cost:
T1 or OEM Mark-Up Rates:
&T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:






MANUFACTURING COSTS

Material
Cost






$0.67


$0.00
-$0.69





-$0.02



















Material




Labor/ Part




































Labor
$0.00



Burden/
Part






$0.00


$0.28
$0.00





$0.00



















Burden



IF


S




$0.67


$0.28
-$0.69





-$0.02



















TMC



MARK-UP COSTS

End
Item
Scrap
Rate






0.00%


0.00%
0.00%





0.00%



















Scrap
0.50%
$0.00


SG&A
Rate






0.00%


0.00%
0.00%





0.00%



















SG&A

$0.04


Profit
Rate






0.00%


0.00%
0.00%





0.00%



















Profit

$0.03


ED&T/
R&D
Rate






0.00%


0.00%
0.00%





0.00%



















ED&T

$0.01


Total
Mark-up
Rate






0.00%


0.00%
0.00%





0.00%




Supplier
Account Cos
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00


Total Mark-
$0.00
$0.09


Total
Mark-up
Cost






$0.00


$0.00
$0.00





$0.00




Purchase
Price/ Unit
$0.33
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00





TOTAL COSTS
2.
+ —i
i ""






$0.67


$0.28
-$0.69





-$0.02




Purchase Price
Net, PIA
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00


m
	 HJL

	 *
Packaging Cost:
Net Cost Impact to Vehicle:
i1
si
Iff

*




$0.67


$0.28
-$0.69





-$0.02




Purchase Price
Net, End Item
$0.33
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
1
I
$0.58
$0.58

$0.67
$0.00


TOOLING &
s
gf
§|
o

-------
                                                                                             Manufacturing Assumption and  Quote Summary
                                                                                                                                                                               APPENDIX G.1-03,(2of4)
                                                                                                                                                                                          Print Date:9/1/2009
              Technology Level: Downsized, Turbccharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                  Vehicle Class: Compact/Economy24 Passenger	
                                                                                 _OEM Operating Pattern (Weeks/Year):_
                   Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class;
            System Description: 2007 Mini Cooper s. 1.6L 14,16V DOHC GDI Turbo
        Component Description: RodSubas:
       Component Quote Level:
    - Connectir
Full Quolel    |
                                                                                          Part Number: 0303-N0101-01
                                              n Quote|  X |
Annual Engine Volume (CPV):    <50,ooo
     Components per Engine:      4
  Annual Component Volume:   1,800,000
  Weekly Component Volume:    38,298
      Estimated Product Life:      10
    OEM Plant Location:
 Supplier Plant Location:
       Shipping Method:
Packaging Specification:
GENERAL COMPONENT INFORMATION

1



Part Description



Part Number


O
1
CT

GENERAL MANUFACTURING INFORMATION

Primary Process
Description



EM or Suppl
2


Material
Specification



Labor Classification



Burden
Classification


MANUFACTURING RATES
5"
4
ed Pieces PC

1
z
berofOper
0

s
1
1
CT
=

Material
Cost
Mb
(DB)



Labor
Rate
$/Hour
(DB)



Burden
Rate
$/Hour
(DB|


MANUFACTURING COSTS

Material
Cost



Labor/ Part



Burden/
Part


i
||
™
|
MARK-UP COSTS

End
Item
Scrap
Rate



SGSA
Rate



Profit
Rate



ED&T/
R&D
Rate



Total
Mark-up
Rate



Total
Mark-up
Cost


TOTAL COSTS
a
| ""


|
s|
&
f
TOOLING &
I
gf
§|
O
'—
0

Total* of Pieces

18,000,000
"S*
$3.00

Months'

60
»™
0

lnRT

5.00%
';*:;:;
$0.00




„;,«,*
0

Pallet'/fTa'cl

$0
^

"pat's,"'
""'

«

Number of

1
--^"g,
""""
$0.00 | 0 | $0.00
Supplier,
S
Requirements
6
=;r
0
Supplier,
S
Requirements
{Paris}
229787


Packaging Cost Total: $0.000
                                                                                                                                                                                             PACKAGING CALCULATIONS:
                                                                                                                                                                                             No Change Required For Packaging.
File:Crank Drives 03,032509.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                Appendix G.1-03,4of7
                                                                                                                                                                                       Form Author: G. Kolwich
                                                                                                                                                                                       (248)373-6000 Ext. 2411

-------
                                                                                             Manufacturing Assumption and  Quote Summary
                                                                                                                                                                                                                          APPENDIX G.1-03,(3of4)
              Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                  Vehicle Class: Compact/Economy 2-1 Passenger
                   Study Case#: N0101(N = New, 01 = Technology Package, 01 = Vehicle Class)
            System Description: 2007 Mini Cooper s. 1.6L n, 16V DOHC GDI Turbo
Component Description: Piston - Engine, Machined
Component Quote Level:   r Full Quote
                                                                                                     Part Number: 03M-N0101-01
                                                      r Modification Quote
                                                                                [^ Differential Quote (Quote Summary includes costing for both Technology Packages)
OEM Operating Pattern (Weeks/Year):
        Annual Engine Volume (CPV):
             Components per Engine:_
          Annual Component Volume:_
          Weekly Component Volume:
               Estimated Product Life:
                                                                                                                                                                                                     Supplier Plant Location: North America
 OEM/T1 Classification: T1 Moderate Assembly Complexity
       Shipping Method: FOB Ship Point	
Packaging Specification:_NA	
GENERAL COMPONENT INFORMATION
1
3

Part Description

Tier 1 Supplier or OEM Processing
1A
1B
1C
2A
2B
2C
'iston - Engine, Cast (Mini Cooper)
'iston - Engine, Machined (Mini Cooper)
'iston - Engine, Machined (Mini Cooper)
iston - Engine, Machined (Chrysler GEMA))


Part Number

& Assembly (Full Cos
0304-N01 01 -01-01
0304-N01 01 -01-01
0304-N0101-01
0304-B0101-01-01


O
?
CT

tma
1
1
1
GENERAL MANUFACTURING INFORMATION
Primary Process
Description

pping)
Consider weight andmaterial
Machining
Note, both the Mini and Chrysler GEMA pistons have anodized top ring
groove and a dry-film skirt coating.





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
























OEM/Supplier
Classification


T2/T3 Internal Supplier
T2/T3 Internal Supplier
T2/T3 Internal Supplier
T2/T3 Internal Supplier
T2/T3 Internal Supplier
T2/T3 Internal Supplier







Material
Specification


Not Applicable
Not Applicable
Not Applicable
Not Applicable


Labor
Classification


Mold/Cast/Sinter Operator
Heat Treat Operator
CMC Operator
Mold/Cast/Sinter Operator
Heat Treat Operator
CMC Operator


Burden
Classification


Diecast, LMC
Heat Treat, SMS, MHC
Rot./Lin. Trans. Machining
Line, TP, PREM.
Diecast, LMC
Heat Treat, SMS, LMC
Line, TP


MANUFACTURING RATES
Z!
^
&
8.
3>
I
|


517
442
480
-514
-420
-480
HIM
am
HIM


'Syndicates Component is Supplied directly o T1 or OEM for Final or
Sub-Assembly.
'SAC'=(Supplier Accounted Costs) Indicates Component is Supplied
directly to T1 or OEM for Final or Sub-Assembly. In addition componen
material cost is accounted for in T1 quote sheet. Thus component cost
will only be included for Mark-up Calculations.
'Alpha-Numeric Character1 = Indicates purchase parts are brought in by
T2T3 Supplier for Subassembly.
























Number of Operators


2
1
1
1
0
0
0







Number of Lines


3
4
2
3
2
2
1
1







TJ
S!
fl
= 3>
ll
	 *
Packaging Cost:
Net Cost Impact to Vehicle:
SL
si
is-
s
£


$1.70
$1.12
$1.21
-$1.71
-$0.35
-$1.12
$0.00
$0.00
$0.00
Purchase Price
Net, End Item
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

$0.85
$0.85


$0.98

TOOLING &
Tooling Assumptions
"X1000 "








$0
NVESTMENT
Investment Assumptions
"X1000 "








$0

FfeCrank Drives 03,032509.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                 Appendix G.1-03,5of7
                             Form Author: G. Kolwich
                             (248)373-6000 Ext. 2411

-------
                                                                                              Manufacturing Assumption and  Quote Summary
                                                                                                                                                                                                                          APPENDIX G.1-03,(3of4)
              Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Cla
                  Vehicle Class: Compact/Economy 2-1 Pa!
                   Study Case#: N0101(N = New, 01 = Technology Package, 01 = Vehicle Class)
            System Description: 2007 Mini Cooper s. 1.6L n, 16V DOHC GDI Turbo
        Component Description: Piston - Engine, Machined
       Component Quote Level:   r Full Quote
r Modification Quote
                                                   	  OEM Operating Pattern (Weeks/Year):
                                                   	          Annual Engine Volume (CPV):
                                                   	               Components per Engine:_
                                                   	            Annual Component Volume:_
                                                   	            Weekly Component Volume:
& Differential Quote(QuoteSummaryincludescosting for both Technology Packages)          Estimated Product Life:
                                                                                                      Part Number: 03M-N0101-01
                                                                                                                                                                                                     Supplier Plant Location: North America
                                                                                                                                                OEM/T1 Classification: T1 Moderate Assembly Complexity
                                                                                                                                                     Shipping Method: FOB Ship Point	
                                                                                                                                              Packaging Specification:_NA	
GENERAL COMPONENT INFORMATION


1
£



Part Description



Part Number



?
o-

GENERAL MANUFACTURING INFORMATION


Primary Process
Description



OEM/Supplier
Classification



Material
Specification



Labor
Classification



Burden
Classification

MANUFACTURING RATES
Z!
~
a.
3>
I
1


1
£
O
12
3
w


dumber of Lines


TJ
fl
= 3>

-------
Engine Assembly 0300
                                                                                               Manufacturing Assumption and Quote Summary
                      APPENDIX G.1-03(4of4)
                                Print Dale:9/1/2009
              Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                  Vehicle Class: Compact/Economy 2-1 Passenger
                   Study Case#: N0101(N = New, 01 = Technology Package, 01 = Vehicle Class)
            System Description: 2007 Mini Cooper s. 1.6L n, 16V DOHC GDI Turbo
Component Description: Engine Assembly of Crank Drive Subsystem Components
Component Quote Level:  T Full Quote          r Modification Quote
                                                                                                            Part Number:  ooo-Noioi-01
                                                                                     & Differential Quote (Quote Summary includes costing for both Technology Pac
OEM Operating Pattern (Weeks/Year):      n
        Annual Engine Volume (CPV):    <50,ooo
             Components per Engine:      1
          Annual Component Volume:    <50,ooo
          Weekly Component Volume:     9,57<
               Estimated Product Life:      10
                                                                                                                                                                                                            OEM Plant Location: North America
                                                                                                                                                                                                         Supplier Plant Location: North America
 OEM/T1 Classification: OEM Engine Assembly
       Shipping Method: FOB Ship Point
Packaging Specification:_NA	
GENERAL COMPONENT INFORMATION
1


Tie




Part Description


Part Number


1 Supplier or OEM Processing & Assembly (Full Cos
1
No impact to engine assembly. Assume wrist pin
retaining clip labor/burden add would be offset by
labor/burden press fit pin design.


O


tma

0


GENERAL MANUFACTURING INFORMATION
Primary Process
Description


pping)





Purchase Part - Commodity ( Value taken from Purchase Part Database)
1A
2A
3A
4A

5A

6A
7A
8A
9A
10A








Shaft - Crank
Rod Subassembly - Connecting
Piston - Engine, Machined
^ing/Clip - Piston Pin Retainer

Pin- Piston

Compression Ring -Piston, Top
Compression Ring -Piston, 2nd
Spacer/Expander/Coil Spring - Oil Ring, Piston
Rail(s) - Oil Ring, Piston
Bearing - Connecting Rod to Crank Shaft








0301-N0101-01
0303-N0101-01
0304-N0101-01
0304-N0101-02

0304-N0101-03

0304-N0101-04
0304-N0101-05
0304-N0101-07
0304-N0101-08
0390-N01 01-01








1
4
4
8

4

4
4
4
4
8
0
0
0








;OEM Mark-up included in Cran



GEMA15Cr3(SAE 5015) Case
Hardened





AISn20MnBase, AISnIONi
Turbo Dl











OEM/Supplier
Classification









shaft Worksheet)
SAC
SAC
s

S

s
s
s
s
s











Material
Specification










Labor
Classification










Burden
Classification










MANUFACTURING RATES
Finished Pieces Per h
1



SSSSS





'Syndicates Component is Supplied directly to T1 or OEM for Final or Sub-
Assembly.

•SAC'=(Supplier Accounted Costs) Indicates Component is Supplied directly to
T1 or OEM for Final or Sub-Assembly. In addition component material cost is 1
accounted for in T1 quote sheet. Thus component cost will only be included for
Mark-up Calculations.

'Alpha-Numeric Character1 = Indicates purchase parts are brought in by T2/T3
Supplier for Subassembly.





































Number of Operato


	 *
Packaging Cost:
Net Cost Impact to Vehicle:
s;
si
I"
5



$0.00



Price Net,
End Item
$0.00
$2.66
$3.92
$0.24

$0.96

$1.42
$0.66
$0.68
$0.22
$1.51
$0.00
$0.00
$0.00
I

$12.27
$12.27




TOOLING &
Tooling Assumptio
"X1000 "
0)




























$0
NVESTMENT
Investment Assumpti
"X1000 "
w




























$0


PACKAGING CALCULATIONS:
Packaging Type: No Changes Required to
Packaging
Part Size:
Parts/Layer
Number of Layers:
Rack/Pallet Investment Amortization


Expendable Packaging in Piece Cost
Packaging Cost Tota

Cost per
Piece

Cost [*r











Total
$0
Tier Pad

$0.00


Lump Sum
Payment
(%]

Tier Pads




Total * of
Pieces

Divider Pads,

$0.00


Number of
Months
60
Divider Pads




Interest
Rate

Other #1

$0.00




Others




I
1
1
$0
Other*!

$0.00

_
ital Number of Pallets/
Racte Required
250
Other*!




nberof Parts per Pallet/
Rack
1
Other #3

$0.00


plier,Customerand In-
transit Inventory
lequirements (Wee Is]

Other *3
Pallet/Rad



equirements [Parts]





FfeCrank Drives 03,032509.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                   Appendix G.1-03, 7 of 7
                             Form Author: G. Kolwich
                             (248)373-6000 Ext. 2411

-------
                   Appendix G.1 - Subsystem 04
                    Counter Balance Subsystem
                         Case Study #0101
                        MAQS Worksheets
File:Counter Balance, 031908.xls
EPA Contract:EP-C-07-069 WA1-3                           Appendix G.1-04,1 of 4

-------
  ilance Shall Subassembly 0401
                                                                                              Manufacturing Assumption and  Quote Summary
                                                                               APPENDIX G.1-04,(1of2)
                                                                                          Print Dale:9/1/2009
              Technology Level:  Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                  Vehicle Class: Compact/Economy 2-1 Pa!
OEM Operating Pattern (Weeks/Year):
                                                                                                                                                                                                          OEM Plant Location: North America
                   Study Case*: Noioi(N = New, 01 =T
                                                        	
            System Description: 2007 Chrysler GEMA,:
                                                              	
Component Description: Balance Shaft Assembly (F
Component Quote Level:   P7 Full Quote
                                                            	
                                                                                                          Part Number: MOI-BOI 01-01
                                                       r Modilication Quote
                                                                                    l"~ Ditterential Quote (Quote Summary includes costing tor both Technology Packages)
Annual Engine Volume (CPV):   <50,ooo
     Components per Engine:      1
  Annual Component Volume:   <50,ooo
  Weekly Component Volume:    9,57<
       Estimated Product Life:     10
                                                                                                                                                                                                       Supplier Plant Location: North America
                                                            OEM/T1 Classification: T1 Moderate Assembly Complexity
                                                                 Shipping Method: FOB Ship Point	
                                                          Packaging Specification:	e	
GENERAL COMPONENT INFORMATION
1



Tie

1A

2A
3A
Pu
1A
1B
2A
2B
3A
3B
3C
3D
3E
4A
4B
4C
4D
4E
5A
5B
Part Description



1 Supplier or OEM Processing



Balance Shaft Long and Short
Final Assembly of Balance Shaft Assembly
chase Part - High Impact Item
Bottom Housing Casting
Bottom Housing Casting
Top Housing Balance Shaft Casting
Top Housing Balance Shaft
Balance Shaft Short Casting
Balance Shaft Short Casting
Balance Shaft Short Machined
Balance Shaft Short Machined
Balance Shaft Short Machined
Balance Shaft Short Casting
Balance Shaft Short Casting
Balance Shaft Short Machined
Balance Shaft Short Machined
Balance Shaft Short Machined
Gear Balance Shaft
Gear Balance Shaft
Part Number



& Assembly (Full Cos

)401-B01 01-11-01

0401-B01 01 -06/07
0401-B01 01-01
Full Cost Mapping)
0401-B01 01 -03-1-1
0401-B0101-03-1
0401-B01 01 -08-1-1
0401-B0101-08-1
0401-B01 01 -06-1-1-1
0401-B01 01 -06-1-1-1
0401-B01 01 -06-1-1
0401-B01 01 -06-1-1
0401-B0101-06
0401-B01 01 -07-1-1-1
0401-B01 01 -07-1-1-1
0401-B01 01 -07-1-1
0401-B01 01 -07-1-1
0401-B0101-07
0401-B01 01 -06-2-1
0401-B01 01 -06-2-1
Purchase Part - Commodity ( Value taken from Purchas
1A
'Ih
3A
4A













Dowel Upper to lower housing alignmert
Bearing Shell Balance Shaft
Bolt Balance Shaft Housing
Cap Shaft Close out













0401-B0101-04
0401-B0101-05
0401-B0101-09
0401-B01 01-10













D
3:


tma

1

2
1

1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
GENERAL MANUFACTURING INFORMATION
Primary Process
Description



pping)


housings, machine bearings.
;r"r:r;,
Assemble Shafts into Houisng

Casting
Machine Casting
Casting
Machine Casting
Casting
-leat Treating
Machine
Grind
Jalance
Casting
Heat Treating
Machine
Grind
Jalance
Machine Blanks Hob Teeth
(Same process for both Gears)
-leat Treating
; Part Database)
2
4
6
2
0
0
0
0
0
0
0
0




























OEM/Supplier
Classification







T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.

T2/T3 Diecast, MSMC
T2/T3 Diecast, MSMC
T2/T3 Diecast, MSMC
T2/T3 Diecast, MSMC
T2/T3 Diecast, MSMC
T2/T3 Heat Treat, MSMC
T2/T3 CNC Turning, MSMC
T2/T3 CNC Turning, MSMC
T2/T3 CNC Turning, MSMC
T2/T3 Diecast, MSMC
T2/T3 Heat Treat, MSMC
T2/T3 CNC Turning, MSMC
T2/T3 CNC Turning, MSMC
T2/T3 CNC Turning, MSMC
T2/T3 CNC Turning, MSMC
T2/T3 Heat Treat, MSMC

S
S
s
s
















Material
Specification





*t Applicable

Not Applicable
Not Applicable

Aluminum-A380, Cast
Not Applicable
Aluminum-A380, Cast
Not Applicable
Nodular Iron, Cast
Not Applicable
Not Applicable
Not Applicable
Not Applicable
Nodular Iron, Cast
Not Applicable
Not Applicable
Not Applicable
Not Applicable
LC-S«,,-,2,SB,,
Not Applicable


Labor
Classification







GeneralAssembly
General Assembly

MoloyCast/Sinter Operator
CNC Operator
MoloyCast/Sinter Operator
CNC Operator
MoloyCast/Sinter Operator
Heat Treat Operator
CNC Operator
CNC Operator
CNC Operator
MoloyCast/Sinter Operator
Heat Treat Operator
CNC Operator
CNC Operator
CNC Operator
CNC Operator
Hea, Treat Operator


Burden
Classification





vlech Assembly, LC, Base

Mech Assembly, LC, Base
Mech Assembly, LC, Base

Diecast, LMC
CNC Machining, LMC
Diecast, LMC
CNC Machining, LMC
Perm. Cast, LMC
Heat Treat, MLS, LMC
CNC Turning, HC
Grinding, SMS, MHC
Balancing, MLS, LMC
Perm. Cast, LMC
Heat Treat, MLS, LMC
CNC Turning, HC
Grinding, SMS, MHC
Balancing, MLS, LMC
Balancing, MLS, LMC
H,,,T,,,,1SMS,LMC


MANUFACTURING RATES
Finished Pieces P<
^
1



240

240
240

112
115
111
114
242
242
113
132
120
226
242
114
142
120
235
360


'Syndicates Componen is Supplied directly to T1 or OEM for Final or Sub-
Assembly.

'SAC'=(Supplier Accounted Costs) Indicates Component is Supplied directly to
T1 or OEM for Final or Sub-Assembly. In addition component material cost is
accounted for in T1 quote sheet. Thus component cost will only be included for
Mark-up Calculations.

'Alpha-Numeric Charac er1 = Indicates purchase parts are brought in by T2/T3
Supplier for Subassembly.


































Number of Oper
0
0)



2

1
4

1
1
1
1
3
1
0.5
0.5
0.5
3
1
0.5
0.5
0.5
2
1





















Number of Lin
%




1

2
1

1
1.5
1
2
1
1
1.5
1.25
1
1
1
2.25
1.3
1
4.5
1





















Parallel Proces
Mutiplier
5"






1
5

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1





















1
1
o-
•



0.000

0.000
0.000

2.351
0.000
2.609
0.000
1.721
0.000
0.000
0.000
0.000
2.242
0.000
0.000
0.000
0.000
0.000
0.000





















Material
Cost
$/lb
(DB)





$0.00

$0.00
$0.00

$1.10
$0.00
$1.10
$0.00
$0.35
$0.00
$0.00
$0.00
$0.00
$0.35
$0.00
$0.00
$0.00
$0.00
$0.62
$0.00
















T1 or




Labor
Rate
$/Hour
(DB)





$35.51

$35.51
$35.51

$43.52
$35.70
$43.52
$35.70
$43.52
$46.52
$35.70
$35.70
$35.70
$43.52
$46.52
$35.70
$35.70
$35.70
$35.70
$46.52
















Burden
Rate
$/Hour
(DB)





$15.00

$15.00
$15.00

$100.05
$25.00
$100.05
$25.00
$100.06
$100.00
$75.00
$65.00
$25.00
$100.06
$100.00
$75.00
$65.00
$25.00
$25.00
$50.00
















Applied
Burden
Rate
$/Hour





$120.00

$30.00
$75.00

$100.05
$37.50
$100.05
$50.00
$100.06
$100.00
$112.50
$31.25
$25.00
$100.06
$100.00
$168.75
$34.50
$25.00
$112.50
$50.00
















OEM Total Manufacturing Cost:
T1 or OEM Mark-Up Rates:
&T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:






MANUFACTURING COSTS
Material
Cost





$0.00

$0.00
$0.00

$2.59
$0.00
$2.87
$0.00
$0.60
$0.00
$0.00
$0.00
$0.00
$0.78
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00















Material


1.53
Labor/ Part





$0.30

$0.15
$0.59

$0.39
$0.31
$0.39
$0.31
$0.54
$0.19
$0.16
$0.13
$0.15
$0.58
$0.19
$0.16
$0.13
$0.15
$0.30
$0.13















Labor
$5.83


Burden/
Part





$0.50

$0.13
$0.31

$0.89
$0.33
$0.90
$0.44
$0.41
$0.41
$1.00
$0.61
$0.21
$0.44
$0.41
$1.48
$0.60
$0.21
$0.48
$0.14















Burden



IF
e!
c1
S



$0.80

$0.27
$0.90

$3.87
$0.64
$4.17
$0.75
$1.56
$0.61
$1.16
$0.75
$0.36
$1.80
$0.61
$1.64
$0.72
$0.36
$0.78
$0.27















TMC



MARK-UP COSTS
End
Item
Scrap
Rate





0.00%

0.00%
0.00%

5.00%
5.00%
5.00%
5.00%
5.00%
0.50%
0.50%
0.50%
0.50%
5.00%
0.50%
0.50%
0.50%
0.50%
0.50%
0.50%















Scrap
0.50%
$0.14

SG&A
Rate
(DB)





0.00%

0.00%
0.00%

650%
6.50%
650%
6.50%
650%
6.50%
6.50%
6.50%
6.50%
650%
6.50%
6.50%
6.50%
6.50%
6.50%
6.50%















SG&A

$1.85

Profit
Rate
(DB)





0.00%

0.00%
0.00%

6.00%
6.00%
6.00%
6.00%
6.00%
6.00%
6.00%
6.00%
6.00%
6.00%
6.00%
6.00%
6.00%
6.00%
6.00%
6.00%















Profit

$1.71

ED&T/
R&D
Rate
(DR)





0.00%

0.00%
0.00%

1 .00%
1.00%
1 .00%
1.00%
1 .00%
1.00%
1 .00%
1.00%
1 .00%
1.00%
1 .00%
1.00%
1 .00%
1.00%
1.00%
1.00%















ED&T

$0.71

Total
Mark-
up
Rate





0.00%

0.00%
0.00%

18.50%
18.50%
18.50%
18.50%
18.50%
14.00%
14.00%
14.00%
14.00%
18.50%
14.00%
14.00%
14.00%
14.00%
14.00%
14.00%
Supplier
Cost
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00


Total
Mark-up

$4.42

Total
Mark-
up
Cost





$0.00

$0.00
$0.00

$0.72
$0.12
$0.77
$0.14
$0.29
$0.08
$0.16
$0.10
$0.05
$0.33
$0.08
$0.23
$0.10
$0.05
$0.11
$0.04
Purchase
Price/ Uni
$0.03
$0.25
$0.06
$0.14
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00





TOTAL COSTS
2.
SL
+ —1
3? ^
W"
R-
£



$0.80

$0.27
$0.90

$4.58
$0.75
$4.94
$0.89
$1.84
$0.69
$1.32
$0.85
$0.41
$2.14
$0.69
$1.86
$0.82
$0.41
$0.89
$0.31
Purchase
Price Net,
PIA
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00


Q
»u

	 *
Packaging Cost:
Net Cost Impact to Vehicle:
SL
si
Iff
£•
5



$0.80

$0.55
$0.90

$4.58
$0.75
$4.94
$0.89
$1.84
$0.69
$1.32
$0.85
$0.41
$2.14
$0.69
$1.86
$0.82
$0.41
$1.79
$0.61
Purchase
Price Net,
End Item
$0.05
$1.00
$0.36
$0.28
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
I
I
$28.54
$28.54




TOOLING &
Tooling Assump
"X1000 "
o"
0)










































$0
NVESTMENT
Investment Assum
"X1000 "
"H.
w










































$0


FfeCounter Balance, 031908.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                 APpendix, G.1-04,2ol4
                                                                                       Form Author: G. Kolwich
                                                                                       (248)373-6000 Ext. 2411

-------
  ilance Shalt Subassembly 0401
                                                                                              Manufacturing Assumption and Quote Summary
                                                                               APPENDIX  G.1-04,(1of2)
                                                                                           Print Date:9/1/2009
              Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                  Vehicle Class: Compact/Economy 2-1 Pa!
OEM Operating Pattern (Weeks/Year):
                                                                                                                                                                                                           OEM Plant Location: North America
                   Study Case*: N0101 (N = New, 01 = T

            System Description: 2007 Chrysler GEMA, 2
                                                               NA, dWT, 173hp
Component Description: Balance Shaft Assembly (F
Component Quote Level:   P7 Full Quote

                                                                                                           Part Number: 0«1-B01 01-01
                                                       r Modilication Quote
                                                                                    r~ Differential Quote (Quote Summary includes costing tor both Technology Packages)
Annual Engine Volume (CPV):   <50,ooo
     Components per Engine:      1
  Annual Component Volume:   <50,ooo
  Weekly Component Volume:    9,57<
       Estimated Product Life:     10
                                                                                                                                                                                                        Supplier Plant Location: North America
                                                            OEM/T1 Classification: T1 Moderate Assembly Complexity
                                                                 Shipping Method: FOB Ship Point	
                                                          Packaging Specification:	e	
GENERAL COMPONENT INFORMATION
1
s

Part Description

Part Number

D
?
CT

GENERAL MANUFACTURING INFORMATION
Primary Process
Description

OEM/Supplier
Classification

Material
Specification

Labor
Classification

Burden
Classification

MANUFACTURING RATES
Finished Pieces Per F
1
Number of Operato

NVESTMENT
Investment Assumpti
"X1000 "
3,
PACKAGING CALCULATIONS:
Consider additional volume as result of Balance
Shaft subassembly:
Packaging Type: Option #2
Part Size: 190x220x1 20
Numberof Layers:? '



Expendable Packaging in Piece Cost
Packaging Cost Tota

Cost per
Piece


Co^r












Total


Tie,parl

$0.00


Lump Sum
Payment
(%]


T,,^S




Total * of
Pieces


DivtoP*,

$0.00


Number of
Months
60

Divirle,parls




Interest
Rate


Other #1

$0.00





Others



8
1
1
$420

Other*!

$0.00

1
Number of Pallets'
Racte Required
250

Other*!



1
erof Parts per Pallet/
Rack
175

OtherK

$0.00

ff I
er,Customerandln-
ransit Inventory
uirements (Weeks)


Other K
Pallet/Rad


? I
ransit Inventory






File:Counter Balance, 031908.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                  APpendix, G.1-04,3 of 4
                                                                                       Form Author: G. Kolwich
                                                                                       (248)373-6000 Ext. 2411

-------
Engine Assembly 04
                                                                                              Manufacturing Assumption and  Quote Summary
                                                                             APPENDIX G.1-04,(2of2)
                                                                                        Print Dale:9/1/2009
                 Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                     Vehicle Class: Compact/Economy 2-1 Pa!
                      Study Case#: N0101(N = New, 01 = Technology Package, 01 = Vehicle Class)
               System Description: 2007 Mini Cooper s. 1.6L n, 16V DOHC GDI Turbo
          Component Description: Engine Assembly of Balance Shaft Assembly
                                                                                                             Part Number:
          Component Quote Level:   p Full Quote       r Modification Quote
                                                                          F~ Differential Quote (Quote Summary includes costing tor both Technology Packages)
OEM Operating Pattern (Weeks/Year):
        Annual Engine Volume (CPV):
             Components per Engine: _
          Annual Component Volume:_
          Weekly Component Volume:
               Estimated Product Life:
                                                                                                                                                                                                             OEM Plant Location: North America
                                                                                                                                                                                                          Supplier Plant Location: North America
 OEM/T1 Classification: OEM Engine Assembly
       Shipping Method: FOB Ship Point
Packaging Specification:_NA	
GENERAL COMPONENT INFORMATION
1


Tie


Part Description


1 Supplier or OEM Processing
Mount Balance Shaft Assembly to Engine

Part Number


& Assembly (Full Cos
0401-B0101-01

O


tma
1

GENERAL MANUFACTURING INFORMATION
Primary Process
Description


pping)
Install Balance Shaft Assembly

Purchase Part - Commodity ( Value taken from Purchase Part Database)
1A
2A


















Bolt - Balance Shaft Assembly Mount to Block
Balance Shaft Assembly ( Part of Oil Pump
Assembly)


















PC 12.9
0401-B0101-01


















4
1
0
0
0
0
0
0
0
0
0
0
0










packaging Included in Cost)






















OEM/Supplier
Classification



OEM Assembly, Mark-up


S
SAC





















Material
Specification



ot Applicable



Labor
Classification



General Assembly-OEM



Burden
Classification



Engine Assembly, OEM



MANUFACTURING RATES
Finished Pieces Per h
1


?1?



'Syndicates Component is Supplied directly to T1 or OEM for Final or Sub-
Assembly.
•SAC'=(Supplier Accounted Costs) Indicates Component is Supplied directly to
T1 or OEM for Final or Sub-Assembly. In addition component material cost is 1
accounted for in T1 quote sheet. Thus component cost will only be included for
Mark-up Calculations.

'Alpha-Numeric Character1 = Indicates purchase parts are brought in by T2/T3
Supplier for Subassembly.












































Number of Operato
ta


1

























Number of Lines



1

























Parallel Processin
Mutiplier



1

























1
I
•


0.000

























Material
Cost
S/lb
(DB)



$0.00



















T1 or





Labor
Rate
$/Hour
(DB)



$83.31



















Burden
Rate
$/Hour
(DB)



$150.21



















Applied
Burden
Rate
$/Hour



$150.21



















OEM Total Manufacturing Cost:
T1 or OEM Mark-Up Rates:
&T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:






MANUFACTURING COSTS
Material
Cost



$0.00






















1. 83
Labor/ Part



$0.39



















$0.39


$0.39
Burden/
Part



$0.71























IF
e!
S


$1.10























MARK-UP COSTS
End
Item
Scrap
Rate
(DB)



0.00%




















0.00%
$0.00

SG&A
Rate
(DB)



0.00%




















0.00%


Profit
Rate
(DB)



0.00%




















0.00%


ED&T/
R&D
Rate
(DB)



0.00%




















0.00%
SO.OO

Total
Mark-
up
Rate



0.00%

Supplier
Account
Cost
$0.00
$33.01
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00


Total
Mark-up

0.00%
$0.00

Total
Mark-
up
Cost



$0.00

Price/ Uni
$0.46
$33.01
$000
$000
$000
$000
$000
$000
$000
$000
$000
$000
$0.00







TOTAL COSTS
2.
SL
+ —1
3? M
I"
£


$1.10

Price Net,
PIA
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00




	 >\1


	 >
Packaging Cost:
Net Cost Impact to Vehicle:
SL
si
I"
5


$1.10

Price Net,
End Item
$1.83
$33.01
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
I
I


$35.95





TOOLING &
Tooling Assumptio
"X1000 "
0)

























$0
NVESTMENT
Investment Assumpti
"X1000 "
w

























$0


PACKAGING CALCULATIONS:
Packaging Type:
Part Size:
Parts/Layer
Number of Layers:
Rack/Pallet Investment Amortization


Expendable Packaging in Piece Cost
Packaging CostTota


Cost per
Piece





$0.00












Total
Amount

$0



$0.00


Lump Sum










Pieces





$0.00



Months

60







Rate


Other #1
Packaging

$0.00






Others

Pallet/Rack


£
1
1
a
$0
Other*!
Packaging

$0.00
_
g-l
SF 1
•i 3.

250
Other*!

Pallet/Rack

=
1

3rd
3
1
Other #3

Price Per
$0.00
f
in

*H
I3I

Other *3

Pallet/Rack

%
fifH

111
As a





$0.000
FfeCounter Balance, 031908.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                  Appendix G.1-04,4of4
                                                                                    Form Author: G. Kolwich
                                                                                    (248)373-6000 Ext. 2411

-------
                   Appendix G.1 - Subsystem 05
                     Cylinder Block Subsystem
                         Case Study #0101
                        MAQS Worksheets
FfeCylinder Block 06,032509.xls
EPA ConlractEP-C-07-069 WA1-3                           Appendix G.1-05,1 ol (

-------
Cylinder Block 0501
                                                                                             Manufacturing Assumption and  Quote Summary
                                                                                                                                                                                   APPENDIX G.1-05,(1of5)
                                                                                                                                                                                              Print Dale:9/2/2009
              Technology Level: Downsized, Tuibochaiged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                  Vehicle Class: Compacl/Economy24 Passenger	
                   Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class;
            System Description: 2007 Mini Cooper s. 1.6L 14,16V DOHC GDI Turbo
        Component Description:
       Component Quote Level:
ler Block Assembly - Machined w. Studs, Plugs, etc.
     Full Quote]   I
                                                      Part Number: 0501-N0101-01
                                                   n Quote| X |
_OEM Operating Pattern (Weeks/Year):_
_        Annual Engine Volume (CPV):_
_             Components per Engine:_
_          Annual Component Volume:_
_          Weekly Component Volume:_
                Estimated Product Life:
                                                                                                                                            OEM Plant Location:
                                                                                                                                         Supplier Plant Location:
                                                                                                                                              Shipping Method:
                                                                                                                                        Packaging Specification:
GENERAL COMPONENT INFORMATION
1
S

Tie
1A
1B
1C
Pu
1A
Part Description

1 Supplier or OEM Processing
Cylinder Block Subassembly - Machined
w/o Studs/Plugs, etc
Cylinder Block Subassembly - Machined
w/o Studs/Plugs, etc
Cylinder Block Subassembly - Cast
Part Number

& Assembly (Full Cos
0501-N0101-01 (Mini Cooper)
0501-B01 01 -01 (Chrysler GEMA)
0501-N0101-03
O
?
CT

tma
1
Timing Chain Cover Adds 3.98 Ibs to Chrysler GEMA Head,
Block, Girdle. Divided by coverage contribution:
Head 130/450 = 28.9% or 1.15lbs
Block = 235/450 = 52.2% or 2.08 Ibs
Girdle = 85/450 = 18.9%or0.75
Mini Cooper has integrated Cover in Head/Block/Bead Pla e

chase Part - High Impact Item
Cylinder Liners -Cast Iron

Full Cost Mapping)

0

4
GENERAL MANUFACTURING INFORMATION
Primary Process
Description

pping)
Upper cylinder block
Machining operation adds for
liners = (33.655+ 2.08)

Ibs/liner, Chrysler GEMA
Engine = 2.44lbs/liner
Purchase Part - Commodity ( Value taken from Purchase Part Database)
























OEM or Supplier


OEM
OEM
OEM

OEM


Material
Specification


Not Applicable
Not Applicable

Nodular Iron, Cast


Labor Classification


CMC Operator -OEM
CMC Operator-OEM
No Applicable
\
Burden
Class! fi cat on


CMC Milling, LS, HC
CMC Milling, LS, HC
Not Applicable
/
Assume casting speed for Chrysler
and Mini Cooper Block will be
approximately the same. Thus no
additional Labor or Burden costs were
accounted for.


No Applicable


Not Applicable
Assume processing speed for
Chrysler and Mini Cooper liners
will be approximately the same.
Thus no additional Labor or
Burden costs were accounted







MANUFACTURING RATES
Finished Pieces Per Hour


135
-288
~NA~

~NA~


•Syndicates Component is Supplied directly to T1 or OEM for
Final or Sub- Assembly.
'SAC'=(Supplier Accounted Costs) Indicates Component is
Supplied directly to T1 or OEM for Final or Sub-Assembly. In
addition component material cost is accounted for in T1 quote
sheet. Thus component cost will only be included for Mark-up
Calculations.
'Alpha-Numeric Character1 = Indicates purchase parts are




























Number of Operators


0.25
0.25
0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0







s
1
I
CT


0.000
0.000

-0.540
0.000
0.000
0.000
0.000
0.000
0.000




T1 o


Material
Cost
$/lb
(DB)


$0.00
$0.00
$1.10
IN/
IN/
IN/
IN/
IN/
IN/
IN/
IN/

$0.35
IN/A
IN/A
IN/A
IN/A
IN/A
IN/A




Labor
Rate
$/Hour
(DB)


$68.07
$68.07
$0.00
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A

$0.00
N/A
N/A
N/A
N/A
N/A
N/A




Burden
Rate
$/Hour
(DB)


$250.00
$250.00
$0.00
IN/A
IN/A
IN/A
IN/A
IN/A
IN/A
IN/A
IN/A

$0.00
IN/A
IN/A
IN/A
IN/A
IN/A
IN/A




OEM Total Manufacturing Cost:
T1 or OEM Mark-Up Rates:
&T1 or OEM Mark-Up Values:
Base Cost mpact to Vehicle:



MANUFACTURING COSTS
Material
Cost


$0.00
$0.00
-$7.20
N/
N/
N/
N/
N/
N/
N/

-$0.19
IN/A
IN/A
IN/A
IN/A
IN/A
IN/A



Material
0.00
7.96
Labor/ Part


$0.13
-$0.06
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A

N/A
N/A
N/A
N/A
N/A
N/A



Labor
$0.07
$0.07
Burden/
Part


$1.86
-$0.87
$0.00
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A

$0.00
N/A
N/A
N/A
N/A
N/A
N/A



Burden


IF
$
SL
H
CD


-$0.93
-$7.20
IN/A
IN/A
IN/A
IN/A
IN/A
IN/A
IN/A
IN/A

-$0.19
IN/A
IN/A
IN/A
IN/A
IN/A
IN/A



TMC


MARK-UP COSTS
End
Item
Scrap
Rate


0.00%
0.00%
5.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%

0.30%
0.30%
0.30%
0.30%
0.30%
0.30%
0.30%



Scrap
-$0.05

SG&A
Rate


0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%

6.00%
6.00%
6.00%
6.00%
6.00%
6.00%
6.00%



SG&A
7.00%
-$0.51

Profit
Rate


0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%

4.00%
4.00%
4.00%
4.00%
4.00%
4.00%
4.00%



Profit
-$0.59

ED&T/
R&D
Rate


0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%

0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%



ED&T
0.00%
$0.00

Total
Mark-
up
Rate


0.00%
0.00%
5.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%

10.30%
10.30%
10.30%
10.30%
10.30%
10.30%
10.30%
Supplier
Account
Cost
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

Total
Mark-up
-$1.15

Total
Mark-
up
Cost


$0.00
$0.00
-$0.36
IN/A
IN/A
IN/A
IN/A
IN/A
IN/A
IN/A
IN/A

-$0.02
IN/A
IN/A
IN/A
IN/A
IN/A
IN/A
Purchase
Price/ Uni
$0.00
$000
$000
$000
$000
$000
$000
$000
$000
$000
$0.00



TOTAL COSTS
2.
SL
+ —1
3? ^
I"
-c


$1.98
-$0.93
-$7.56
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A

-$0.21
N/A
N/A
N/A
N/A
N/A
N/A
Price Net,
PIA
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

c
	 n_
	 >
Packaging Cost:
Net Cost Impact to Vehicle:
SL
si
is-
s
*


$1.98
-$0.93
-$7.56
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

-$0.83
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
Price Net,
End Item
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

-$7.34
-$7.34



TOOLING &
Tooling Assumptions
"X1000 "











NVESTMENT
Investment Assumptions
"X1000 "










$0

FfeCylinder Block 05,032509.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                Appendix G.1-05,2of8
                                                                                                                                                                                           Form Author: G. Kolwich
                                                                                                                                                                                           (248)373-6000 Ext. 2411

-------
Cylinder Block 0501
                                                                                             Manufacturing Assumption and  Quote Summary
                                                                                                                                                                                    APPENDIX G.1-05,(1of5)
                                                                                                                                                                                               Print Date:9/2/2009
              Technology Level: Downsized, Turbccharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                  Vehicle Class: Compact/Economy24 Passenger	
                   Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class;
            System Description: 2007 Mini Cooper s. 1.6L 14,16V DOHC GDI Turbo
        Component Description:
       Component Quote Level:
ler Block Assembly - Machined w. Studs, Plugs, etc.
     Full Quote]    I
                                                      Part Number: 0501-N0101-01
                                                   n Quote| X |
_OEM Operating Pattern (Weeks/Year):_
_        Annual Engine Volume (CPV):_
_             Components per Engine:_
_          Annual Component Volume:_
_          Weekly Component Volume:_
                Estimated Product Life:
                                                                                                                                            OEM Plant Location:
                                                                                                                                         Supplier Plant Location:
                                                                                                                                               Shipping Method:
                                                                                                                                        Packaging Specification:
GENERAL COMPONENT INFORMATION

S





Part Description




Part Number





CT

GENERAL MANUFACTURING INFORMATION


Primary Process
Description



s
3
1
5



Material
Specification




Labor Classification




Burden
Classification


MANUFACTURING RATES
5'
£
1
T

1
z
1
S"
o
O
•g
0
ta
s
i
1
5=
"

Material
Cost
Mb
IDB)



Labor
Rate
$/Hour
IDB)



Burden
Rate
$/Hour
IDB)


MANUFACTURING COSTS


Material
Cost




Labor/ Part




Burden/
Part


S
?-i
ll

|
MARK-UP COSTS

End
Item
Scrap
Rate




SGSA
Rate




Profit
Rate




R&D
Rate



Total
Mark-
up
Rate



Total
Mark-
up
Cost


TOTAL COSTS
a

| ""

'
^
S
B£
s
f
TOOLING &

x.s
§i

0)
NVESTMENT
1

s, 1

1


Rack/Pallet Investment Amortization:


Expendable Packaging in Piece Cost:
Packaging Cost Total:



Costper












$o
Tier Pad

$0.00




Tier Pads






Divider Pads,

$0.00



60
Divider Pads

0




Other,

$0.00




Other*

0



$0
Other,

$0.00

Tota,


Othe,^

0



1
0,he,«

$0.00

os ±;
ts (Weeks}

0,he,«

0

os;±;
Repiremer
ts {Paris}





                                                                                                                                                                                         PACKAGING CALCULATIONS:
File:Cylinder Block 05,032509.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                Appendix G.1-05,3of8
                                                                                                                                                                                           Form Author: G. Kolwich
                                                                                                                                                                                           (248)373-6000 Ext. 2411

-------
                                                                                   Manufacturing Assumption and  Quote Summary
                  Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                      Vehicle Class: Compact/Economy 2-4 Passenger	
                       Study Case*: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class)
                System Description: 2007 Mini Cooper S. 1.6L14,16V DOHC GDI Turbo
            Component Description: Bed Plate Assembly- Machined w. Studs, Plugs, i
           Component Quote Level:
                                                                                                Part Number: 0503-N0101-01
Full Quote]    |
                                       Modification Quote
                                                                                   _OEM Operating Pattern (Weeks/Year):     "?
                                                                                            Annual Engine Volume (CPV):   "50,ooo
                                                                                                 Components per Engine:      1
                                                                                              Annual Component Volume:   450,000
                                                                                              Weekly Component Volume:    9,574
                                                                                                   Estimated Product Life:     10
                APPENDIX G.1-05, (2of5)
                           Print Date:9/2/2009
    OEM Plant Location:    North America
 Supplier Plant Location:    North America
       Shipping Method:
Packaging Specification:
                                                                                                                                                                                                                   F.O.B
                                                                                                                                                                                                                    NA
GENERAL COMPONENT INFORMATION

5
|
*


Tie
41.1













Pur
1A









Part Description



1 Supplier or OEM Processin
Bed Plate Subassembty - Cast



Part Number




1
•a
%
i


3 & Assembly (Full Cost m
0503-N0101-02

Mini Cooper Bed Plate integrated Bearing Cap Weight = 18.01
Ibs
Chrysler Girdle has non integrated bearing caps
Weight of Girdle =17.423+ Cover Contribution 0.75 -Oil Filter
Inlet 0.25 Ibs = 17.923
Weight of Caps =0.94/bs/Cap
Ratio of Cap/(Cap-t-Girdle) = 20.8%

Therefore for Mini Cooper assumption is that 20.8% of
Bedplate weight are for Bearing Caps, Thus the following
calculations are made:
Weight of Base Bed Plate Material = 79.2%x18.01 = 14.26 Ibs
Weight of Bearing Caps = 20.8%x1 8.01 = 3.75 Ibs



chase Part - High Impact Item
Baaring Cap -Bolt Through -!„,«,, St9Sl








Full Cost Mapping)
0503-N0101-03







1














5
0
0
0
0
0
0

GENERAL MANUFACTURING INFORMATION


Primary Process
Description



pping)
Bed Plate casting














Main Bearing Caps, Cast








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















































































































O
5
W'



OEM














S






























Material
Specification




Aluminum-A380,














Nodular Iron, Cast












Labor Classification




Not Applicable
\
Burden
Classification


Not Applicable
/
Assume casting speed for
Chrysler and Mini Cooper Bed
Plate will be approximately same.
Trius no additional Labor or
Burden costs were accounted











Not Applicable


























Not Applicable

Assume casting speed for
Chrysler and Mini Cooper
Bearing Caps will be
approximately the same. Trius
no additional Labor or Burden














MANUFACTURING RATES
Z!
3.
3!
1
!
i


~NA~
#DIV/C
#DIV/C
#DIV/C
#DIV/C
#DIV/C
#DIV/C
#DIV/C
#DIV/C
#DIV/C
#DIV/C
#DIV/C
#DIV/C
#DIV/C
#DIV/C
#DIV/C
#DIV/C

"NA"
TJiWO
SDIV/C
SDIV/C
SDIV/C
SDIV/C
SDIV/C




"Syndicates Component is Supplied directly to T1 or OEM for
Final or Sub-Assembly.



"SAC"=( Supplier Accounted Costs) Indicates Component is
Supplied directly to T1 or OEM for Final or Sub- Assembly
In
addition component material cost is accounted for in T1 quote
sheet. Trius component cost will only be included for Mark-up

1




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
















|


















|
O
1
™


0















































I
1
f



-3.663
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000

-0.190
0.000
0.000
0.000
0.000
0.000
0.000


























Material
Cost
$/lb




$1.10
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A

$0.35
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A


























Labor
Rate
$/Hour




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

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


























Burden
Rate
$/Hour




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

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

























MANUFACTURING COSTS


Material
Cost




-$4.03
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A

-$0.07
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A



























Labor/ Part




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

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



























Burden/
Part




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

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

























S
L
|l
g
i


-$4.03
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A

-$0.07
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A

























MARK-UP COSTS

End
Item
Scrap
Rate



5.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%

5.00%
0.30%
0.30%
0.30%
0.30%
0.30%
0.30%



























SG&A
Rate




0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%

6.00%
6.00%
6.00%
6.00%
6.00%
6.00%
6.00%



























Profit
Rate




0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%

4.00%
4.00%
4.00%
4.00%
4.00%
4.00%
4.00%


























ED&T/
R&D
Rate




0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%

0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%


























Total
Mark-
up
Rate



5.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%

15.00%
10.30%
10.30%
10.30%
10.30%
10.30%
10.30%

Supplier
Account
Cost

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

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

Total
Mark-
up
Cost



-$0.20
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A

-$0.01
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A


Price/ Unit

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

$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
TOTAL COSTS

1
II
1 "
*


-$4.23
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A

-$0.08
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A

Purchase
Price Net,
PIA

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

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

1
^ —1
~% °
l"
•<"


-$4.23
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

-$0.38
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

Purchase
Price Net,
End Item

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

$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
TOOLING & INVESTMENT

I
jS

o'
3

















































—
= to
If

i

















































FileCylinder Block 05,032509 .xls
EPA Contract: EP-C-07-069WA1-3
                                                                                                      Appendix G.1-05,4o
                                                                                                                                                              Form Author: G.Kolwich
                                                                                                                                                              (248)373-6000 Ext. 2411

-------
                                                                                   Manufacturing Assumption and  Quote Summary
                  Technology Level:  Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                      Vehicle Class:  Compact/Economy 2-4 Passenger	
                       Study Case*: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class)
                System Description:  2007 Mini Cooper S. 1.6L14,16V DOHC GDI Turbo
            Component Description: Bed Plate Assembly- Machined w. Studs, Plugs, i
            Component Quote Level:
                                                                                                 Part Number: 0503-N0101-01
Full Quote]   |
                                        Modification Quote
                                                                                    _OEM Operating Pattern (Weeks/Year):      "?
                                                                                             Annual Engine Volume (CPV):    "50,ooo
                                                                                                  Components per Engine:      1
                                                                                               Annual Component Volume:    450,000
                                                                                               Weekly Component Volume:     9,574
                                                                                                    Estimated Product Life:      10
                APPENDIX G.1-05, (2of5)
                           Print Date:9/2/2009
    OEM Plant Location:     North America
 Supplier Plant Location:     North America
       Shipping Method:        F.O.B
Packaging Specification:         NA
GENERAL COMPONENT INFORMATION


!










Part Description










Part Number









3
?
>
z

0








GENERAL MANUFACTURING INFORMATION


Primary Process
Description












0
EM or Supp
m












Material
Specification













Labor Classification













Burden
Classification











MANUFACTURING RATES
-n
3.
3!
1

1










W
a.
o
•8
IT
n










5
i!
1
•8
5





T1o






Material
Cost
S/lb








Labor
Rate
$/Hour








Burden
Rate
$/Hour






OEM Total Manufacturing Cost:
T1 or OEM Mark-Up Rates:
ST1 or OEM Mark-Up Values:
Base Cost Impact




o Vehicle:


MANUFACTURING COSTS


Material
Cost




Material

-$4.36
0.00



Labor/ Part




Labor

$0.00

$0.00


Burden/
Part




Burden




S
1
||
+ "
g
1


TMC

-$4.36


MARK-UP COSTS


End
Item
Scrap
Rate




Scrap

0.70%
-$0.03



SG&A
Rate




SG&A

7.00%
-$0.32



Profit
Rate




Prolit

-$0.01
8.00%
-$0.37



ED&T/
R&D
Rate




EDST

$0.00
0.00%
$0.00



Total
Mark-
up
Rate


$0.00

Total
Linkup
1 5.70%
-$0.72



Total
Mark-
up
Cost


$0.00





TOTAL COSTS

1
Total 2 =
1+ Total tt
3-
i
$0.00

C

*L

	 *•
Packaging Cost:
Net Cost Impact to Vehicle:

§
to
B
1
i

$

-$



1
U


00

.61

-$4.61


-$5.34
$0.00
-$5.34

TOOLING & INVESTMENT

I
-I
1 &
8 £
o'
3






$0
—
1
x= §
It
•g.
1






$0




Packaging Calculations


Rack/Pallet Investment Amortization:
Expendable Packaging in Piece Cost:
Packaging Cost Total:


Cost per
Piece



Cost per
Pece
$0.00
$0.000











Total
Amount


$0
Tier Pad
Price Per
$1.00



LumpSum
Payrrent(%)


0.00%
Tier Pads
Pallet/Rack
0



Total) of Pieces


4,500,000
Divider Pads,
Price Per
$3.00



Number of
Months


60
Divider Pads
Pallet/Rack
0



Interest
Rate



OtherfU
Packaging
Price Per
$0.00







OtherfU
Pads
Pallet/Rack
0



Cost per
Pallet /Rack


$0
Otherf)2
Packaging
Price Per
$0.00


Total
Nuirtoerof
Pallets/
Racks
Required

57447
Otherf)2
Pads
Pallet/Rack
0



Nuirtoerof
Parts per
Pallet/ Rack


1
Otherf)3
Price Per'
$0.00

Supplier,
Customer
and In-
transit
Inventory

ts (Weeks)
6
Otherf)3
Pads
Pallet/Rack
0

Supplier,
Customer
and In-
transit
Inventory

t (Parts)
57447



                                                                                                                                                                                                  Negligible Affect To Packaging
FileCylinder Block 05,032509 .xls
EPAContract: EP-C-07-069WA1-3
                                                                                                       Appendix 6.1-05,5 of 8
                                                                                                                                                               Form Author: G.Kolwich
                                                                                                                                                               (248)373-6000 Ext. 2411

-------
Piston Cooling 0504
                                                                                     Manufacturing Assumption and  Quote Summary
                  Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                       Vehicle Class: Compact/Economy 2-4 Passenger	
                        Study Case*: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class)
                 System Description: 2007 Mini Cooper S. 1.6L14,16V DOHC GDI Turbo
            Component Description: Squirter - Oil, Piston Cooler & Retainer
            Component Quote Level:
                                                                                                  Part Number: 0504-N0101-01/02
Modification Quote
                                            _OEM Operating  Pattern (Weeks/Year):     "?
                                                      Annual Engine Volume (CPV):   «o,ooo
                                                           Components per Engine:     4
                                                        Annual Component Volume:   1,800,000
                                                       Weekly Component Volume:    38,298
                                                            Estimated Product Life:     10
                 APPENDIX G.1-05, (3of5)
                            Print Date:9/2/2009
    OEM Plant Location:     North America
 Supplier Plant Location:     North America
       Shipping Method:         F.O.B
Packaging Specification:     Cardboard Boxes
GENERAL COMPONENT INFORMATION
!

Part Description

Purchase Part - Low Impact Item
1A
2A
Bolt -Piston Cooler Valve/Retainer
Squirter- Oil, Piston Cooler
Part Number

QTY Per Assembly

GENERAL MANUFACTURING INFORMATION
Primary Process
Description

OEM or Supplier

Material
Specification


Labor Classification


Burden
Classification


Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)
0504-N0101-02
0504-N0101-01
1
1
Purchase Part Cos! Est. Break
Purchase Part Cos! Est. Break
Purchase Part - Commodity ( Value taken from Purchase Part Database)
























s







Purchased Paris
Purchased Paris







General Assembly
General Assembly







Mech.Assembly.LC
Mech.Assembly.LC







MANUFACTURING RATES
Finished Pieces Per Hour


206
240







Number of Operators


0.5
0.5







SL
c
f


0.350
0.300




T1o


Material
Cost
$/lb


$1.00
$1.00




Labor
Rate
$/Hour


$35.51
$35.51




Burden
Rate
$/Hour


$100.19
$100.19




OEM Tola Manufacturing Cost:
T1 or OEM Mark-Up Rates:
C) &T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:



MANUFACTURING COSTS
Material
Cost


$0.35
$0.30



Material
$0.65
0.00

Labor/ Part


$0.09
$0.07



Labor
$0.16
$0.16
Burden/
Part


$0.49
$0.42



Burden
$0.90

Total 1 =
Material + Labor + Burden


$0.92
$0.79



TMC
$1.71

MARK-UP COSTS
End
Item
Scrap
Rate


0.30%
0.30%



Scrap
$0.01
0.30%
$0.01

SG&A
Rate


6.00%
6.00%



SG&A
$0.10
6.00%
$0.11

Profit
Rate


4.00%
4.00%



Profit
$0.07
4.00%
$0.08

ED&T/
R&D
Rate


0.00%
0.00%



ED&T
0.00%
$0.00

Total
Mark-
up
Rate


10.30%
10.30%
Supplier
Account
Cost


Total
Mark-up
$0.18
1 0.30%
$0.19

Total
Mark-
up
Cost


$0.10
$0.08
Purchase
Price/ Unit




TOTAL COSTS
Total 2 =
Totall + Total Mark-up


$1.02
$0.87
Purchase
Price Net,
PIA


LI
	 fr-Ll
	 *•
Packaging Cost:
Net Cost Impac to Vehicle:
Total 3 =
Total 2 * Qty per Ass'y


$1.02
$0.87
Purchase
Price Net,
End Item


$


.89
$1.89


$2.10

TOOLING &
Tooling Assumptions
"X1000 "








$0
NVESTMENT
Investment Assumptions
"X1000 "








$0



Packaging Calculations


Rack/Pallet Investment Amortization:
Expendable Packaging in Piece Cost:
Packaging Cost Total:


Cost per
Piece


$0.000
Cost per
Pece
$0.01
$0.010











Total
Amount


$0
Tier Pad
Price Per
$0.00



LumpSum
Payment {%]


0.00%
Tier Pads
Pallet/Rack
0



Total) of Pieces


18,000,000
Divider Pads,
Price Per
$0.00



Nuirtoerof
Months


60
Divider Pads
Pallet/Rack
0



Interest
Rate



Otherffl
Packaging
Price Per
$2.50







Otherffl
Pads
Pallet/Rack




Cost per
Pallet /Rack


$0
Otherf)2
Packaging
Price Per
$0.00


Total
Numberof
Pallets/
Racks
Required

460
Otherf)2
Pads
Pallet/Rack
0



Numberof
Parts per
Pallet/ Rack


500
Otherf)3
Packaging,
Price Per
$0.00

Supplier,
Customer
and In-
Requiremei
ts {Weeks]
6
Otherf)3
Pads
Pallet/Rack
0

Supplier,
Customer
andln-
Requiremei
fc {Parts]




                                                                                                                                                                                                    PACKAGING CALCULAIONS:
                                                                                                                                                                                                    Use $0.005 additional cost for both
                                                                                                                                                                                                    squirter and bolt/check valve.
                                                                                                                                                                                                    Assume 250 parts/box, $2.50/Box,
File:Cylinder Block 05,032509 .xls
EPA Contract: EP-C-07-069WA1-3
                                                                                                           jendixG.1-05,60(8
                                                                                                                          Form Author: G.Kolwich
                                                                                                                         (248)373-6000 Ext. 2411

-------
Bearing Elements 0590
                                                                                    Manufacturing Assumption and Quote Summary
                    Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                         Vehicle Class: Compact/Economy 2-4 Passenger	
                         Study Case*: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class)
                  System Description: 2007 Mini Cooper S. 1.6L14,16V DOHC GDI Turbo
              Component Description: Bearings & Thrust Shims - Crankshaft,
              Component Quote Level:
                                                                                                   Part Number: 0590-N0101-01/02/03
Full Quote]   |
                                        Modification Quote
                                                                                    _OEM Operating Pattern (Weeks/Year):
                                                                                             Annual Engine Volume (CPV):
                                                                                                  Components per Engine:
                                                                                               Annual Component Volume:
                                                                                               Weekly Component Volume:
                                                                                                    Estimated Product Life:
          APPENDIX G.1-05, (4of5)
                      Print Date:9/2/2009
    OEM Plant Location:     North America
 Supplier Plant Location:     North America
       Shipping Method:        F.o.B
Packaging Specification:         NA

  Treat as Set, 5 Upper, 5 Lower, 2 Thrust   I	
  Shims	
GENERAL COMPONENT INFORMATION


I






Part Description






Part Number





3
?
>

Z


GENERAL MANUFACTURING INFORMATION


Primary Process
Description




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













Bearing - Crankshaft, 1/2 Bearing (Top)
Bearing/Shim - Crankshaft Thrust
Bearing - Crankshaft, 1/2 Bearing (Bottom)











0590-N0101-01
0590-N0101-02
0590-N0101-03











5
2
5
0




0

























0
s
5

to



S
S
S
















Material
Specification
















Labor Classification








Burden
Classification






MANUFACTURING RATES
-n
3.
3!
1


1



"Syndicates Component is Supplied directly to T1 or OEM for
Final or Sub-Assembly.

"SAC"=( Supplier Accounted Costs) Indicates Component is
Supplied directly to T1 or OEM for Final or Sub- Assembly. In
addition component material cost is accounted for in T1 quote
sheet. Thus component cost will only be ncluded for Mark-up
Calculations.


































w
a
o
H

FT
it



















S
i!
c

sf














T1o






Material
Cost
$/lb


















Labor
Rate
$/Hour


















Burden
Rate
$/Hour
















OEM Tola Manufacturing Cost:
T1 or OEM Mark-Up Rates:
C) &T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:






MANUFACTURING COSTS


Material
Cost















Material
(2.13
0.00



Labor; Part















Labor
$0.00

$0.00


Burden/
Part















Burden
$0.00


S
1
||

g
i












TMC
$2.13


MARK-UP COSTS


End
Item
Scrap















Scrap
$0.00
0.00%
$0.00



SG&A
Rate















SG&A
0.00%
$0.00



Profit
Rate















Profit
0.00%
$0.00



ED&T/
R&D
Rate















ED&T
0.00%
$0.00



Total
Mark-up
Rate




Supplier
Account Cost
$0.00
$0.00
$0.00
$0.00




$0.00


Total Mark-
$0.00
0.00%
$0.00



Total
Mark-up
Cost




Purchase
Price/ Unit
0.19
0.12
0.18
0.00
0.00
0.00
0.00
0.00
$0.00





TOTAL COSTS

1
if
S M

3-
±

Purchase
Price Net, PIA
$0.0
$0.0
$0.0
$0.0




$0.0


n
»L

	 *•
Packaging Cost:
Net Cost Impact to Vehicle:

1


Jf
"S "


£


Purchase
Price Net, End
Item
$0.97
$0.24
$0.92
$0.00




$0.00


$


2.13
$2.13


$2.13
$0.00
$2.13

TOOLING & INVESTMENT

I
j£
2. >
§ 1

o'
3















$0
—
1
x= S
11

•g.
1















$0



Packaging Calculations

Rack/Pallet Investment Amortization:
Expendable Packaging in Piece Cost:
Packaging Cost Total:

Cost per
Piece

$0.000
Cost per
Pece

$0.000








Total
Amount

$0
Tier Pad
Price Per
$1.00


LumpSum
Payment {%]

0.00%
Tier Pads
Pallet/Rack
0


Total) of Pieces

4,500,000
Divider Pads,
Price Per
$3.00


Number of
Months

60
Divider Pads
Pallet/Rack
0


Rate


Otherffl
Packaging
Price Per
$0.00





Otherffl
Pads
Pallet/Rack
0


Cost per
Pallet /Rack

$0
Otherf)2
Packaging
Price Per
$0.00


Nunfcerof
Pallets/
Racks

57447
Otherf)2
Pads
Pallet/Rack
0


Nunfcerof
Pallet/ Rack

1
Otherf)3
Packaging,
Price Per
$0.00

Supplier,
Customerand
In-transit
Inventory
{Weeks]
6
Otherf)3 Pads
Pallet/Rack
0

Supplier,
Customerand
In-transit
Inventory
{Parts]
57447



                                                                                                                                                                                                        No Impact to Packaging
FileCylinder Block 05,032509 .xls
EPAContract: EP-C-07-069WA1-3
                                                                                                       Appendix 6.1-05,7 of 8
                                                                                                                                                              Form Author: G.Kolwich
                                                                                                                                                              (248)373-6000 Ext. 2411

-------
EngineAssembly-05-
                                                                                         Manufacturing Assumption and  Quote Summary
                   Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                        Vehicle Class: Compact/Economy 2-4 Passenger
_OEM Operating Pattern (Weeks/Year):_
                         Study Case*: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class)
                 System Description: 2007 Mini Cooper S. 1.6L14,16V DOHC GDI Turbo
Component Description: OEM Assembly of Cylinder Block Components to Engine
Component Quote Level:          Full Quote|~X~|
                                                                                                       Part Number:
                                                                                            Modification Quote
          Annual Engine Volume (CPV):    "50,ooo
               Components per Engine:       1
            Annual Component Volume:    450,000
            Weekly Component Volume:     9,574
                 Estimated Product Life:      10
                                                                                                                                                                                                       APPENDIX G.1-05, (5of5)
                                                                                                                                                                                                                   Print Date:9/2/2009
                                                                                                                                                                                          OEM Plant Location:      North America
                                                                                                                                                                                       Supplier Plant Location:      North America
                                                                                                                                                                                             Shipping  Method:         F.o.B
                                                                                                                                                                                      Packaging Specification:
                                                                                                                                                                                                                                    NA
GENERAL COMPONENT INFORMATION


I




Tie




Part Description




1 Supplier or OEM Processin
Squirter - Oil, Piston Cooler - Assembly
Squirter - Oil, Piston Cooler - Assembly


Part Number




3 & Assembly (Full Co
0504-N0101-01
0504-N0101-01

3
?
>

2


st m
4
4
GENERAL MANUFACTURING INFORMATION


Primary Process
Description




pping)
Engine Assembly
Engine Assembly
Purchase Part - Commodity ( Value taken from Purchase Part Database)














Squirter - Oil, Piston Cooler & Bolt -
Piston Cooler Valve/ Retainer
Bearing Set (Upper/Lower/Thrust Shim)











0504-N01 01 -01/02
0590-N01 01 -01/02/03











4
1















(UPGRADE SET)














0
5





OEM
OEM


SAC
SAC















Material
Specification





Not Applicable
Not Applicable



Labor Classification





General Assembly-OEM
General Assembly-OEM



Burden
Classification





Mech. Assembly, HC
Mech. Assembly, HC

MANUFACTURING RATES
-n
3.
3!
1

-«
i


800
1440

"Syndicates Component is Supplied directly to T1 or OEM for
Final or Sub-Assembly.
"SAC"=(Suppl er Accounted Costs) Indicates Component is
Supplied directly to T1 or OEM for Final or Sub- Assembly, n
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 brough
in hi; T9/T1 Qi







nnliar fnr Qiihaccamhlu






















W
S.
O
iff

?T
55


1
1


















i
i!
c

5f



0.000
0.000













Material
Cost
$/lb





$0.00
$0.00













Labor
Rate
$/Hour





$83.31
$83.31













Burden
Rate
$/Hour





$150.19
$150.19











T1 or OEM Tola Manufacturing Cost:





T1 or OEM Mark-Up Rates:
C) &T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:






MANUFACTURING COSTS


Material
Cost





$0.00
$0.00









Material







Labor/ Part





$0.10
$0.06









Labor

$0.65


$0.65


Burden/
Part





$0.19
$0.10









Burden

$1.17


$1.17
_l
i
=* Si
|l

r-
?


$0.29
$0.16









TMC





MARK-UP COSTS


End
Item
Scrap
Rate




0.00%
0.00%









Scrap


0.70%
$0.09



SG&A
Rate





0.00%
0.00%









SG&A


7.00%
$0.86



Profit
Rate





0.00%
0.00%









Profit


8.00%
$0.99



ED&T/
R&D
Rate





0.00%
0.00%









ED&T


0.00%
$0.00



Total
Mark-
up
Rate




0.00%
0.00%
Supplier
Cost

$8.38
$2.13








1 5.70%
$1.94



Total
Mark-up
Cost





$0.00
$0.00
Purchase
Price/ Unit

$2.10
$2.13










TOTAL COSTS

s
i!
i "
3-
£


$0.29
$0.16
Purchase

$0.00
$0.00







	 >L.


	 >•
Packaging Cost:
Net Cost Impact to Vehicle:
1
It
1 "


$1.17
$0.65
Purchase
Price Net,
End tern

$E

38
$2.13





$1






.33

$12.33




$3.75
$0.00
$3.75

TOOLING &

I
-I
1 S
8 S

O
3


















$0
NVESTMENT
—
1
x= S
§ >
= 1

•g.
o


















$0


                                      Pallet Options
                                      Option1:48"(122cm)x45"(114cm)x34"(86cm)
                                      Investment $200 US funds (Mike S.)
                                      Assume Plastic Returnables Last 5 Years

                                      Option2: Vacuum Form Pack Made from 1/4" HOPE (Approx. Same Pallet
                                      size as Option »1.  (Mike S. 020909)
                                      Investment $20K for tool
                                      Piece Price, Pallet Base $100/Base
                                      Piece Price, Her Pad $40/Pad

                                      Cardboard Her Pads for Option 1 Pallets $1.00/Pad (Mike S.)
                                      Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)


Packaging Calculations


Rack/Pallet Investment Amortization:
Expendable Packaging in Piece Cost:
Packaging Cost Total:


Cost per
Piece


$0.000
Cost per
Pece

$0.000











Total
Amount


$0
Tier Pad
Price Per
$0.00



LumpSum


0.00%
Tier Pads
Pallet/Rack
0



Total) of Pieces


4,500,000
Divider Pads,
Price Per
$0.00



Nuirtoerof
Months


60
Divider Pads
Pallet/Rack
0



Interest
Rate



Otherffl
Packaging
Price Per
$0.00







Otherffl
Pads
Pallet/Rack
0



Cost per
Pallet /Rack


$0
Otherf)2
Packaging
Price Per
$0.00



Pallets/
Racks
Required

57447
Otherf)2
Pads
Pallet/Rack
0



Pallet/ Rack


1
Otherf)3
Packaging,
Price Per
$0.00

Supplier,

transit
Inventory
Ftequiremei
ts {Weeks]
6
Otherf)3
Pads
Pallet/Rack
0

Supplier,

In-transit
Inventory


57447



                                                                     No Additional Packaging Affects
File:Cylinder Block 05,032509 .xls
EPAContract: EP-C-07-069WA1-3
                                                                                                                jendix G.1-05,80(8
                                                                                 Form Author: G.Kolwich
                                                                                 (248)373-6000 Ext. 2411

-------
                   Appendix G.1 - Subsystem 06
                     Cylinder Head Subsystem
                         Case Study #0101
                        MAQS Worksheets
File:0
EPA CBnlractEP-C-07-069 WA1-3                         Appendix G.1-06,1 ol 8

-------
Cylinder Head 0601
                                                                                    Manufacturing Assumption and  Quote Summary
                  Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                       Vehicle Class: Compact/Economy 2-4 Passenger	
                       Study Case*: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class)
                System Description: 2007 Mini Cooper S. 1.6L14,16V DOHC GDI Turbo
            Component Description: Cylind
            Component Quote Level:
ir Head Assembly - Machined w. Studs, Plugs, etc.
                                                                                                 Part Number: 0601-N0101-01
    Full Quote]   |
                                            Modification Quote
_OEM Operating Pattern (Weeks/Year):     "?
         Annual Engine Volume (CPV):    "50,ooo
              Components per Engine:      1
           Annual Component Volume:    450,000
           Weekly Component Volume:    9,574
                Estimated Product Life:     10
                                                                                                                                                            APPENDIX G.1-06,(1of5)
                                                                                                                                                                        Print Date:9/2/2009
                                                                                                                                                OEM Plant Location:     North America
                                                                                                                                             Supplier Plant Location:
                                                                                                                                                   Shipping Method:
                                                                                                                                            Packaging Specification:
   North America
      F.O.B
   Return able w.
Expendable Separators
GENERAL COMPONENT INFORMATION


5,
|




Tie
1A



1B


1C


1D













Part Description




1 Supplier or OEM Processin
Cylinder Head - Machined w/o. Studs,
Valves, etc.



Cylinder Head - Heat Treat

Cylinder Head Subassembly- Cast

Mini Cooper
Cylinder Head Subassembly- Cast

Chrysler
Part Number

3 & Assembly (Full Co
0601-N0101-01



0601 -N01 01 -02


0601-N0101-02-01


0601-N0101-02-01

Mini Cooper Head = 30.33- (M8x60 studs x 1 5 )
0.69 - Back Support Cap 0.61 = 29.03lbs

Chrysler GEMA Head = 30.64 - (Valve Guides
Intake and Exhaust) 0.53 - (2 MS StudsxSO) 0.12
and (2 M1 0 Studs x60) 0.15 + (T ming Chain
Cover Contribution) 1 .15 = 29.84


























O
3
?
>
£
2


st m
1



1


1


1










GENERAL MANUFACTURING INFORMATION



Primary Process
Description




pping)
assembly Stest

T6 Heat Treat, only consider
solution step (guench and
artificial age for T6 and T5
same cost impact)

IV '

.
IV '











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



















































































O
5
~o
m



OEM



OEM


OEM


OEM

































Material
Specification





Not Applicable



Not Applicable


Aluminum-356-T6,Cast

Aluminum-A319-T5,













Labor Classification


CNC Operator-OEM






Heat eat Operator-OEM


Not/


Not/









pplicable


pplicable

Burden
Classification


CNC Milling, LS,HC







Heat Treat, MLS, MHC


Not Applicable


Not Applicable

Assume casting speed for
Chrysler and Mini Cooper Heads
will be approxima ely the same.
Thus no additional Labor or
Burden costs were accounted for.


















MANUFACTURING RATES
Z!
3.
!
•
.
3
1
T
£
I
3




8



8


8


8
3



1


9


9
urn






urn



"Syndicates Component is Supplied directly to T1 or OEM for
Final or Sub-Assembly.





"SAC"=( Supplier Accounted Costs) Indicates Component is
Supplied directly to T1 or OEM for Final or Sub- Assembly. In
addition componen ma
erial cost is accounted for in T1 quote
sheet. Thus componen cost will only be incuded for Mark-up
Calculations.








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












I












.























W

s.
o
•g

g-
55


0.25



0.25


0


0
0
0
0
0
0
0
0
0
0

























_,.
SL
c
(5
if



0.000



0.000


29.01


-30.99
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000

























Material
Cost
$/lb





$0.00



$0.00


$1.20


$1.15
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A

























Labor
Rate
$/Hour





$68.07



$137.35


$0.00


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

























Burden
Rate
$/Hour





$250.00



$250.00


$0.00


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























MANUFACTURING COSTS
Material
Cost


$0.00






$3


-V






Labor/ Part





$0.21






Burden/
Part





$3.03



S
(D
i
|l
+ M
c1
i


$3.24



5% Added Scrap Cost For A356


4.81


5.64
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A




$0.00


$0.00
#N/
#N/
#N/
#N/
#N/
#N/
#N/
#N/
#N/
























$0.00


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























"^
$34.81


-$35.64
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A























MARK-UP COSTS


End
Item
Scrap
Rate




0.00%



0.00%

*•
5.00%


0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%


























SG&A
Rate





0.00%



0.00%


0.00%


0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%


























Profit
Rate





0.00%



0.00%


0.00%


0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%


























ED&T/
R&D
Rate





0.00%



0.00%


0.00%


0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%

























Total
Mark-
up
Rate




0.00%



0.00%


5.00%


0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%

Supplier
Cost
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

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


Total
Mark-
up
Cost




$0.00



$0.00


$1.74


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


Price/ Unit
$000
$0.00
$000
$000
$000
$000
$000

$0.00
$000
$000
$0.00
$0.00
$0.00
TOTAL COSTS

1
SL
I M
i "

£


$3.24



$3.50


$36.55


-$35.64
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A


PriSrPIA
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00 $0.00
$0.00 $0.00
$0.00 $0.00 I $0.00
$0.00 $0.00 I $0.00
$0.00 $0.00 I $0.00
$0.00 | $0.00 | $0.00

—1
" -1
st
•g "

i



$3.24



$3.50


$36.55


-$35.64
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

Purchase
Price Net,
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
TOOLING &

s1
s.
2. >
§ i
= .5
o'
3


tooling for
cap assembly









































NVESTMENT
—
S
1
§ >
= 1

•g.
i


Reguire
cap assembly










































File:Cylinder Head 06,032009-2.xls
EPA Contract: EP-C-07-069WA1-3
                                                                                                       Appendix 6.1-06,2 of 8
                                                                                                                                                                     Form Author: G.Kolwich
                                                                                                                                                                    (248)373-6000 Ext. 2411

-------
Cylinder Head 0601
                                                                                    Manufacturing Assumption and  Quote Summary
                  Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                      Vehicle Class: Compact/Economy 2-4 Passenger	
                       Study Case*: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class)
                System Description: 2007 Mini Cooper S. 1.6L14,16V DOHC GDI Turbo
            Component Description: Cylinder Head Assembly - Machined w. Studs, Plugs, etc.
            Component Quote Level:
                                                                                                 Part Number: 0601-N0101-01
Full Quote]   |
                                        Modification Quote
                                                                                    _OEM Operating Pattern (Weeks/Year):     "?
                                                                                             Annual Engine Volume (CPV):   "50,ooo
                                                                                                  Components per Engine:      1
                                                                                               Annual Component Volume:   450,000
                                                                                               Weekly Component Volume:    9,574
                                                                                                    Estimated Product Life:     10
                 APPENDIX G.1-06,(1of5)
                            Print Dale:9/2/2009
    OEM Plant Location:     North America
 Supplier Plant Location:
       Shipping Method:
Packaging Specification:
   North America
      F.O.B
   Return able w.
Expendable Separators
GENERAL COMPONENT INFORMATION


I










Part Description










Part Number










TY Per Ass
I
2









GENERAL MANUFACTURING INFORMATION


Primary Process
Description













s
5
•o












Material
Specification













Labor Classification













Burden
Classification











MANUFACTURING RATES
-n
3.
3!
1


1









r?
mber of Op

FT
it









jg
i!
c

§ 1
^
o'
3





$0
NVESTMENT
—
g
= §
Li «.
§ >
1

•g.
1





$0




Packaging Calculations


Rack/Pallet Investment Amortization:
Expendable Packaging in Piece Cost:
Packaging Cost Total:


Cost per
Piece


$0.000
Cost per
Pece
$0.00
$0.000











Total
Amount


$0
Tier Pad
Price Per
$0.00



LumpSum
Payment {%]


0.00%
Tier Pads
Pallet/Rack
0



Total) of Pieces


4,500,000
Divider Pads,
Price Per
$0.00



Number of
Months


60
Divider Pads
Pallet/Rack
0



Rate



Otherffl
Packaging
Price Per
$0.00







Otherffl
Pads
Pallet/Rack
0



Cost per
Pallet /Rack


$0
Otherf)2
Packaging
Price Per
$0.00


Total
Nuirtoerof
Pallets/
Racks
Required

0
Otherf)2
Pads
Pallet/Rack
0



Nuirtoerof
Parts per
Pallet/ Rack


1
Otherf)3
Packaging,
Price Per
$0.00

Supplier,
Customer
and In-
Inventory
Requiremei
ts {Weeks]
0
Otherf)3
Pads
Pallet/Rack
0

Supplier,
Customer
andln-
Inventory
Requiremei
fc {Parts]
0



File:Cylinder Head 06,032009-2.xls
EPAContract: EP-C-07-069WA1-3
                                                                                                          >endixG.1-06,3o(8
                                                                                                                                                                Form Author: G.Kolwich
                                                                                                                                                                (248)373-6000 Ext. 2411

-------
                                                                                   Manufacturing Assumption and  Quote Summary
                                                                                                                                                              APPENDIX 6.1-06, (20(5)
                                                                                                                                                                   Print Dale:9/2/2009
                  Technology Level:  Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                      Vehicle Class:  Compact/Economy 2-4 Passenger	
                       Study Case*: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class)
                System Description:  2007 Mini Cooper S. 1.6L14,16V DOHC GDI Turbo
            Component Description:  Seal - Intake Valve, Seal - Exhaust Valve,
            Component Quote Level:
                                                                                                Part Number: 0602-N0101-03/04
Full Quote]   |
                                        Modification Quote
_OEM Operating Pattern (Weeks/Year):      "?
         Annual Engine Volume (CPV):    "50,ooo
              Components per Engine:      8 SETS
           Annual Component Volume:    3,600,000
           Weekly Component Volume:    76,596
                Estimated Product Life:      10
                                                                                                                                          OEM Plant Location:
                                                                                                                                       Supplier Plant Location:
                                                                                                                                             Shipping Method:
                                                                                                                                       Packaging Specification:
GENERAL COMPONENT INFORMATION

S
1






Part Description






Part Number





1
?
>
£
2


GENERAL MANUFACTURING INFORMATION


Primary Process
Description




Purchase Part - Commodity ( Value taken from Purchase Part Database)
1A
2A













Seat - Intake Valve
Seat - Exhaust Valve













0602-N0101-03
0602-N0101-04













8
8
















i::i::

















o
5
•o




S
S


















Material
Specification








Labor Classification








Burden
Classification






MANUFACTURING RATES
Z!
|
3!
1


i




1
a
o


S



"Syndicates Component is Supplied directly to T1 or OEM for
Final or Sub- Assembly.
"SAC"=(Supplier Accounted Costs) Indicates Component is
Supplied directly to T1 or OEM for Final or Sub-Assembly. In
addition component material cost is accounted for in T1 quote
sheet. Thus component cost will only be included for Mark-up
Calculations.

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




















































!
c
(5
5f















T1o
ISA




Material
Cost
$/lb


















Labor
Rate
$/Hour


















Burden
Rate
$/Hour

















OEM Tola Manufacturing Cost:
T1 or OEM Mark-Up Rates:
C) &T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:






MANUFACTURING COSTS
Material
Cost















Labor/ Part








Burden/
Part






i
i
tt
+ "
c1
i



MARK-UP COSTS

End
Item
Scrap
Rate







SG&A
Rate






Absolute Cost for Premium Valve Seats
Intake Valve, COM0 1 207 => $0.1 8/Valve
Exhaust Valve, AR20 => $0.25/Valve
Benchmark data from Munro on Baseline Intake
and Exhaust Vave Seat $0.1 6 and $0.22









Material
$0.34
0.0

$0.34







Labor
$0.00

$0.00





Burden
$0.00







TMC








Scrap
$0.00
0.00%
$0.00






SG&A
0.00%
$0.00



Profit
Rate

















Profit
$0.00
0.00%
$0.00



R&D

















ED&T
0.00%
$0.00


Total
Mark-
up
Rate



Supplier
Cost
flit*.
$0.00>
$0.00
$0.00
$0.00
$0.00

Total
Mark-
up
Cost



Purchase
Price/ Unit
$0.02
$0.03
$0.00
$0.00
$0.00
$0.00
TOTAL COSTS

1
1 ^
^ "
s-
^

Purchase
Price Net, PIA
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

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

$0.00 $0.00 $0.00


Total
Mark-up
0.00%
$0.00








c
*L

	 >
Packaging Cost:
Net Cost Impac to Vehicle:

10
a
*
£



1
"



Pric
En
hase
$0.14
$0.20
$0.00
$0.00
$0.00
$0.00


$
.00
$0.00
$0.00
$

$0.00


$


.34
$0.34



$0.00
$0.34

TOOLING &

I
2. >
§ i
.5
o'
3
















$0
NVESTMENT
5-
1
2. 3.
§ >
1

•g.
1
















$0




Packaging Calculations


Rack/Pallet Investment Amortization:
Expendable Packaging in Piece Cost:
Packaging Cost Total:


Cost per
Piece


$0.000
Cost per
Pece
$0.00
$0.000











Total
Amount


$0
Tier Pad
Price Per
$0.00



LumpSum
Payment {%]


0.00%
Tier Pads
Pallet/Rack
0



Total) of Pieces


36,000,000
Divider Pads,
Price Per
$0.00



Nuirtoerof
Months


60
Divider Pads
Pallet/Rack
0



Interest
Rate



Otherffl
Packaging
Price Per
$0.00







Otherffl
Pads
Pallet/Rack
0



Cost per
Pallet /Rack


$0
Otherf)2
Packaging
Price Per
$0.00


Total
Numberof
Pallets/
Racks
Required

0
Otherf)2
Pads
Pallet/Rack
0



Numberof
Parts per
Pallet/ Rack


1
Otherf)3
Packaging,
Price Per
$0.00

Supplier,
Customer
and In-
Requiremei
ts {Weeks]
0
Otherf)3
Pads
Pallet/Rack
0

Supplier,
Customer
andln-
Requiremei
fc {Parts]
0



File:Cylinder Head 06,032009-2.xls
EPA Contract: EP-C-07-069WA1-3
                                                                                                         >endixG.1-06,4o(8
                                                                                                                                                               Form Author: G.Kolwich
                                                                                                                                                               (248)373-6000 Ext. 2411

-------
Bearing Caps 0606
                                                                                     Manufacturing Assumption and  Quote Summary
                  Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                       Vehicle Class: Compact/Economy 2-4 Passenger
                                            _OEM Operating Pattern (Weeks/Year):	«_
                        Study Case*: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class)
                System Description: 2007 Mini Cooper S. 1.6L14,16V DOHC GDI Turbo
            Component Description: Cap, Head (Fuel Pump & Vacuum Mount)
            Component Quote Level:          Full Quote|~X~|
                                                                                                  Part Number: oeoe-Noioi-03
Modification Quotef
Annual Engine Volume (CPV):    "50,ooo
     Components per Engine:      1
  Annual Component Volume:    450,000
  Weekly Component Volume:     9,574
       Estimated Product Life:      10
    OEM Plant Location:
 Supplier Plant Location:
       Shipping Method:
Packaging Specification:
                                                                                                                 APPENDIX G.1-06, (3of5)
                                                                                                                             Print Date:9/2/2009
                                                                                                                             North America
                                                                                                                                                                                                                    North America
                                                                                                                                                                                                                       ROB
GENERAL COMPONENT INFORMATION
!

Tie
1A
1B



Part Description

1 Supplier or OEM Processin
Cap, Head (Fuel Pump & Vacuum
Mount)
Cap, Head (Fuel Pump & Vacuum
Mount)



Part Number

3 & Assembly (Full Co
0606-N01 01 -03-01
0606-N01 01 -03-02



QTY Per Assembly

st m
1
1





GENERAL MANUFACTURING INFORMATION
Primary Process
Description

pping)
3ie casting





OEM or Supplier


s
s





Material
Specification


Not Applicable
Aluminum-A380,Cast







Labor Classification


Mold/Cast/Sinter Operator
Mold/Cast/Sinter Operator







Burden
Classification


Diecast.LMC
Diecast.LMC







MANUFACTURING RATES
Finished Pieces Per Hour


240
240





Number of Operators


0.5
0.5





SL
c
f


0.000
0.610


T1o


Material
Cost
$/lb


$0.00
$1.10


Labor
Rate
$/Hour


$43.52
$43.52


Burden
Rate
$/Hour


$100.05
$100.05


OEM Tola Manufacturing Cost:
T1 or OEM Mark-Up Rates:
&T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:



MANUFACTURING COSTS
Material
Cost


$0.00
$0.67

Material
$0.67
0.00

Labor/ Part


$0.09
$0.09

Labor
$0.18
$0.18
Burden/
Part


$0.42
$0.42

Burden
$0.83

Total 1 =
Material + Labor + Burden


$0.51
$1.18

TMC


MARK-UP COSTS
End
Item
Scrap
Rate


0.00%
0.00%

Scrap
$0.00
0.50%
$0.01

SG&A
Rate


0.00%
0.00%

SG&A
6.50%
$0.11

Profit
Rate


0.00%
0.00%

Profit
6.00%
$0.10

ED&T/
R&D
Rate


0.00%
0.00%

ED&T
2.50%
$0.04

Total
Mark-
up
Rate


0.00%
0.00%

Total
Mark-up
1 5.50%
$0.26

Total
Mark-
up
Cost


$0.00
$0.00



TOTAL COSTS
Total 2 =
Totall + Total Mark-up


$0.51
$1.18

C
	 fc-L
	 *•
Packaging Cost:
Net Cost Impac to Vehicle:
Total 3 =
Total 2 * Qty per Ass'y


$
$

$
.51
.18

.69
$1.69
$1.95
$0.03
$1.98

TOOLING &
Tooling Assumptions
"X1000 "






$0
NVESTMENT
Investment Assumptions
"X1000 "






$0



Packaging Calculations


Rack/Pallet Investment Amortization:
Expendable Packaging in Piece Cost:
Packaging Cost Total:


Cost per
Piece


$0.032
Cost per
Pece
$0.00
$0.032











Total
Amount


$64,079
Tier Pad
Price Per
$0.00



LumpSum
Payment {%]


0.00%
Tier Pads
Pallet/Rack
0



Total) of Pieces


2,250,000
Divider Pads,
Price Per
$0.00



Nuirtoerof
Months


60
Divider Pads
Pallet/Rack
0



Interest
Rate



Otherffl
Packaging
Price Per
$0.00







Otherffl
Pads
Pallet/Rack
0



Cost per
Pallet /Rack


$5,140
Otherf)2
Packaging
Price Per
$0.00


Total
Numberof
Pallets/
Racks
Required

12
Otherf)2
Pads
Pallet/Rack
0



Numberof
Parts per
Pallet/ Rack


4608
Otherf)3
Packaging,
Price Per
$0.00

Supplier,
Customer
and In-
Requiremei
ts {Weeks]
6
Otherf)3
Pads
Pallet/Rack
0

Supplier,
Customer
andln-
Requiremei
fc {Parts]
57447



                                                                                                                                                                                                    PACKAGING CALCULATIONS:
                                                                                                                                                                                                      lion #3 Packaging with returnable
                                                                                                                                                                                                    dividers.

                                                                                                                                                                                                    Part Size: 250x 30x45

                                                                                                                                                                                                    Parts per layer: 1 rows of 16
                                                                                                                                                                                                    Number of layers: 6
                                                                                                                                                                                                    Number of partaTote = 96
File:Cylinder Head 06,032009-2.xls
EPAContract: EP-C-07-069WA1-3
                                                                                                        AppnedixG.1-06,5of8
                                                                                                                          Form Author: G.Kolwich
                                                                                                                         (248)373-6000 Ext. 2411

-------
Sealing Elements 0685
                                                                                    Manufacturing Assumption and  Quote Summary
                  Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                      Vehicle Class: Compact/Economy 2-4 Passenger	
                       Study Case*: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class)
                System Description: 2007 Mini Cooper S. 1.6L14,16V DOHC GDI Turbo
            Component Description: Gasket - Cylinder Head to Block
            Component Quote Level:         Full Quote)   |
                                                                                                 Part Number: 0685-N0101-01
Modification Quote
                                            _OEM Operating Pattern (Weeks/Year):      "?
                                                     Annual Engine Volume (CPV):    "50,ooo
                                                          Components per Engine:      1
                                                       Annual Component Volume:    450,000
                                                       Weekly Component Volume:     9,574
                                                            Estimated Product Life:      10
    OEM Plant Location:
 Supplier Plant Location:
       Shipping Method:
Packaging Specification:
                                                                                                                APPENDIX G.1-06, (4of5)
                                                                                                                           Print Date:9/2/2009
                                                                                                                           North America
   North America
      F.O.B
   Return able w.
Expendable Separators
GENERAL COMPONENT INFORMATION
!
*


Part Description



Part Number



QTYPerAss
1
~°

GENERAL MANUFACTURING INFORMATION
Primary Process
Description



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




















Gasket - Cylinder Head to Block



















0685-N0101-01



















1






















Change from 2 to 3 layer
gasket






















O
5
W'



s






















Material
Specification





Labor Classification





Burden
Classification





MANUFACTURING RATES
Finished Pieces
3
g



"Syndicates Component is Supplied directly to T1 or OEM for
Final or Sub-Assembly.

"SAC"=( Supplier Accounted Costs) Indica es Component is
Supplied directly oT1 or OEM for Final or Sub-Assembly. In
addition component material cost is accounted for in T1 quote
sheet. Trius 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.







































Number of Op
3
1

























SL
c






















T1o




Material
Cost
$/lb
(DB)





















Labor
Rate
$/Hour






















Burden
Rate
$/Hour






















OEMTota Manufacturing Cost:
T1 or OEM Mark-Up Rates:
C) &T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:






MANUFACTURING COSTS
Material
Cost




















Material

$1.46


Labor/ Part




















Labor

$0.00

$0.00
Burden/
Part




















Burden

$0.00


h
i "
i


















TMC

$1.46


MARK-UP COSTS
End
Item
Scrap
Rate



















Scrap

$0.00
0.00%
$0.00

SG&A
Rate




















SG&A

0.00%
$0.00

Profit
Rate




















Profit

0.00%
$0.00

ED&T/
R&D




















ED&T

0.00%
$0.00

Total
Mark-
up
Rate


Supplier
Cost
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00


Total

0.00%
$0.00

Total
Mark-
up
Cost


Purchase
Price/ Unit
$1.46
0.00
000
000
000
000
000
0.00
000
000
0.00
0.00
0.00
000






TOTAL COSTS
Total 2
Total 1 + Total
1
1

Purchase
Price Net, PIA
$0.00
$0.0
$0.0
$0.0
$0.0
$0.0
$0.0
$0.0
$0.0
$0.0
$0.0
$0.0
$0.0
$0.0


E

>L

	 >
Packaging Cost:
Net Cost Impac to Vehicle:
—1
ro
s
>
w_
1



Pric
En
hase
$1.46
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$


$

.00


.46

$1.46


$1.46
$0.00
$1.46

TOOLING &
Tooling Assun
"X1000

3






















$0
NVESTMENT
Investment Ass
"X1000
-!
i






















$0




Packaging Calculations


Rack/Pallet Investment Amortization:
Expendable Packaging in Piece Cost:
Packaging Cost Total:


Cost per
Piece


$0.000
Cost per
Pece
$0.00
$0.000











Total
Amount


$0
Tier Pad
Price Per
$0.00



LumpSum
Payment {%]


0.00%
Tier Pads
Pallet/Rack
0



Total) of Pieces


4,500,000
Divider Pads,
Price Per
$0.00



Nuirtoerof
Months


60
Divider Pads
Pallet/Rack
0



Interest
Rate



Otherffl
Packaging
Price Per
$0.00







Otherffl
Pads
Pallet/Rack
0



Cost per
Pallet /Rack


$0
Otherf)2
Packaging
Price Per
$0.00


Total
Numberof
Pallets/
Racks
Required

57447
Otherf)2
Pads
Pallet/Rack
0



Numberof
Parts per
Pallet/ Rack


1
Otherf)3
Packaging,
Price Per
$0.00

Supplier,
Customer
and In-
Requiremei
ts {Weeks]
6
Otherf)3
Pads
Pallet/Rack
0

Supplier,
Customer
andln-
Requiremei
fc {Parts]
57447



File:Cylinder Head 06,032009-2.xls
EPA Contract: EP-C-07-069WA1-3
                                                                                                         jendixG.1-06,60(8
                                                                                                                        Form Author: G.Kolwich
                                                                                                                        (248)373-6000 Ext. 2411

-------
Engine Assembly-06--
                                                                                   Manufacturing Assumption and Quote Summary
                  Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                      Vehicle Class: Compact/Economy 2-4 Passenger	
                       Study Case*: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class)
                System Description: 2007 Mini Cooper S. 1.6L14,16V DOHC GDI Turbo
            Component Description: OEM Assembly of Cylinder Head Components to Engine
            Component Quote Level:
                                                                                                Part Number: NA
Full Quote]    |
                                        Modification Quote
                                                                                   _OEM Operating Pattern (Weeks/Year):      "?
                                                                                            Annual Engine Volume (CPV):    "50,ooo
                                                                                                 Components per Engine:      1
                                                                                              Annual Component Volume:    450,000
                                                                                              Weekly Component Volume:     9,574
                                                                                                   Estimated Product Life:      10
                APPENDIX G.1-06, (5of5)
                            Print Date:9/2/2009
    OEM Plant Location:     North America
 Supplier Plant Location:     North America
       Shipping Method:        F.O.B
Packaging Specification:         NA
GENERAL COMPONENT INFORMATION
!

Tie
1A
1B
Part Description

1 Supplier or OEM Processin
Cap, Head (Fuel Pump & Vacuum Mou
Cap, Head Fuel Pump&VacuumMount)
Part Number

3 & Assembly (Full Co
0606-N01 01 -03-01
0606-N01 01 -03-01
QTY Per Assembly

st m
1
GENERAL MANUFACTURING INFORMATION
Primary Process
Description

pping)
Head and cam assembly
OEM or Supplier


OEM
OEM
Material
Specification


Not Applicable
Not Applicable
Labor Classification


Not Applicable
Not Applicable
Burden
Classification


Not Applicabl
Not Applicable
NOTES:
Did not add any additional costs to add Cap, Head (Fuel Pump & Vacuum
Mount). Assumption is additional labors burden would be negligible in
having existing au omated process.
Machining for 0/S face of Cap, Head (Fuel Pump & Vacuum Mount)
covered as part of Cylinder Head Machining.

Purchase Part - Commodity ( Value taken from Purchase Part Database)
1A
2A
3A
4A
5A



Seat - Intake/Exhaust Valves
Cap, Head (Fuel Pump & Vacuum
Mount)
Gasket - Cylinder Head to Block
Bolt -Manifold, Exhaust
0602-N0101-03
0606-N01 01 -03-01
0680-N0101-01
0685-N0101-01
0680-N0101-10
Stainless Steel Exhaust Manifold Hanger Studs:
Upgrade to Stainless:
Estimated base stud $0.35 and Stainless stud
$0.70
310/316 (Studs on Mini are Magnetic)
41 0 series good for high temp fastener application
not recommended for use w. Aluminum due to
Galvanic Action








8
1
4
1
10
0
0
0
0
0
0
0
0
0





Material difference
Added Part
Added Part
Modified Part







SAC
SAC
S
SAC
S












3


MANUFACTURING RATES
Finished Pieces Per Hour


150
217
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm


"Syndicates Component is Supplied directly to T1 or OEM for
Final or Sub-Assembly.
"SAC"=( Supplier Accounted Costs) Indicates Component is
Supplied directly to T1 or OEM for Final or Sub- Assembly. In
addition component material cost is accounted for in T1 quote
sheet. Thus component cost will only be included for Mark-up
Calculations.
"Alpha-Numeric Character" = Indicates purchase parts are
brought in by T2/T3 Supplier for Subassembly.
























Number of Operators


0
0.25







SL
c
f


0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000




T1o


Material
Cost
$/lb


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




Labor
Rate
$/Hour


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




Burden
Rate
$/Hour


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




OEM Tola Manufacturing Cost:
T1 or OEM Mark-Up Rates:
&T1 or OEM Mark-Up Values:
Base Cost Impact


o Vehicle:

MANUFACTURING COSTS
Material
Cost


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



Material
$10.11

Labor/ Part


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



Labor
$0.00
$0.00
Burden/
Part


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



Burden
$0.00

Total 1 =
Material + Labor + Burden


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



TMC
$10.11

MARK-UP COSTS
End
Item
Scrap
Rate


0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%



Scrap
$0.00
0.00%
$0.00

SG&A
Rate


0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%



SG&A
0.00%
$0.00

Profit
Rate


0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%



Profit
0.00%
$0.00

ED&T/
R&D
Rate


0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%



ED&T
0.00%
$0.00

Total
Mark-
up
Rate


0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
Supplier
Cost
$2.75
$1.98
$0.00
$1.46
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

Total
Mark-up
0.00%
$0.00

Total
Mark-
up
Cost


$0.00
$0.00
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
Purchase
Price/ Unit
$0.34
$1.98
$0.08
$1.46
$0.36
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00



TOTAL COSTS
Total 2 =
Totall + Total Mark-up


$0.00
$0.00
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
Prl^lA
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

c
	 ^L
	 *•
Packaging Cost:
Net Cost Impac to Vehicle:
Total 3 =
Total 2 * Qty per Ass'y


$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
Pll
Pric
En
e Net,
$2.75
$1.98
$0.32
$1.46
$3.60
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

$1

0.11
$10.11
$3.92
$0.00


TOOLING &
Tooling Assumptions
"X1000 "


Require
tooling for cap
assembly





$0
NVESTMENT
Investment Assumptions
"X1000 "


Require
investment for
cap assembly





$0

FileCylinder Head 06,032009-2.xls
EPA Contract: EP-C-07-069WA1-3
                                                                                                      Appendix 6.1-06,7 of 8
                                                                                                                                                               Form Author: G.Kolwich
                                                                                                                                                              (248)373-6000 Ext. 2411

-------
Engine Assembly-06--
                                                                                   Manufacturing Assumption and Quote Summary
Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
    Vehicle Class: Compact/Economy 2-4 Passenger	
                       Study Case*: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class)
                System Description: 2007 Mini Cooper S. 1.6L14,16V DOHC GDI Turbo
            Component Description: OEM Assembly of Cylinder Head Components to Engine
            Component Quote Level:
                                                                                                Part Number: NA
Full Quote]    |
                                       Modification Quote
                                                                                   _OEM Operating Pattern (Weeks/Year):      "?
                                                                                            Annual Engine Volume (CPV):    "50,ooo
                                                                                                 Components per Engine:      1
                                                                                              Annual Component Volume:    450,000
                                                                                              Weekly Component Volume:     9,574
                                                                                                   Estimated Product Life:      10
    OEM Plant Location:
 Supplier Plant Location:
       Shipping Method:
Packaging Specification:
                                                                                                                                                      APPENDIX G.1-06, (5of5)
                                                                                                                                                                  Print Date:9/2/2009
                                                                                                                                                                  North America
                                                                                                                                                                                                                North America
                                                                                                                                                                                                                   F.O.B
GENERAL COMPONENT INFORMATION
!
*

Part Description


Part Number


QTYPerAss
1
"*
GENERAL MANUFACTURING INFORMATION
Primary Process
Description


o
5
W'

Material
Specification


Labor Classification












Burden
Classification



Finished Pieces
Z
g




MANUFACTURING RATES
Number of Op
5
1
SL
c
^





Packaging Calculations






Rack/Pallet Investment Amortization:

Expendable Packaging

n Piece Cost:
Material
Cost
$/lb
(DB)





Cost per



$0.000
Cost per
Pece
$0.00
Labor
Rate
gmour













Burden
Rate
gmour






Total



$0
Tier Pad
Price Per
$0.00
MANUFACTURING COSTS
Material
Cost






LumpSum



0.00%
Tier Pads
Pallet/Rack
0
Labor/ Part






Total) of Pieces



4,500,000
Divider Pads,
Price Per
$0.00
Burden/
Part






Number of



60
Divider Pads
Pallet/Rack
0
h
i "
i









Otherffl
Packaging
Price Per
$0.00
MARK-UP COSTS
End
Item
Scrap
Rate










Otherffl
Pads
Pallet/Rack
0
SG&A
Rate






Cost per



$0
Otherf)2
Packaging
Price Per
$0.00
Profit
Rate





Total
Pallets/
Required


57447
Otherf)2
Pads
Pallet/Rack
0
ED&T/
R&D






Parts per



1
Otherf)3
Packaging,
Price Per
$0.00
Total
Mark-
up
Rate



Supplier,
Customer
transit
Requiremen
ts {Weeks]

6
Otherf)3
Pads
Pallet/Rack
0
Total
Mark-
up
Cost



Supplier,
Customer
transit
Requiremei
fc {Parts]




Packaging Cost Total: $0.000
TOTAL COSTS
Total 2
Total 1 + Total
1
1









—i
g §•

w_
TOOLING &
Tooling Assun
"X1000

3

PACKAGING CALCULATIONS:
Exhaust manifold bolt packaging
no change for material upgrade.


Packaging cost for Cam Cap
bolts a
e included in piece price,
increase in material usage only.



WESTMENT
Investment Ass
"X1000
|
i










File:Cylinder Head 06,032009-2.xls
EPA Contract: EP-C-07-069WA1-3
                                                                                                         jendixG.1-06,80(8
                                                                                                                                                               Form Author: G.Kolwich
                                                                                                                                                              (248)373-6000 Ext. 2411

-------
                   Appendix G.1 - Subsystem 07
                       Valve Train Subsystem
                         Case Study #0101
                         MAQS Worksheets
FfeValve Trains 07,032609.xls
EPA ConlractEP-C-07-069 WA1-3                          Appendix G.1-07,1 ol 4

-------
Valves lnt.0701 8 Exh.0702
                                                                                               Manufacturing Assumption and Quote Summary
                                                                                                                                         APPENDIX G.1-07,(1of3)
                                                                                                                                                      Printed:9/2/2009
                 Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                     Vehicle Class: Compact/Economy 2-1 Pa!
                                                            OEM Operating Pattern (Weeks/Year):
                                                                                                                                                                                                              OEM Plant Location: North America
                      Study Case#: N0101(N = New,  01 = Technology Package, 01 = Vehicle Class)
               System Description: 2007 Mini Cooper s. 1.6L n, 16V DOHC GDI Turbo
          Component Description: Valve - Intake t, Valve - Outlet
          Component Quote Level:    l~ Full Quo
                                                                                                             Part Number: 0701-N0101-01 &0702-N0101-01
                                                           r Modification Quote
17 Differential Quote (Quote Summary includes costing tor both
                                                                    Annual Engine Volume (CPV):   <50,ooo
                                                                         Components per Engine:      8
                                                                      Annual Component Volume:   3,600,000
                                                                      Weekly Component Volume:    76,596
                                                                           Estimated Product Life:      10
                                                                                                                                                                                                           Supplier Plant Location: North America	
                                                                                                                                                                                                           OEM/T1 Classification: "I High Assembly Complexity
       Shipping Method: FOB Ship Point
Packaging Specification:	
GENERAL COMPONENT INFORMATION
1



Part Description



Part Number



D
3:


GENERAL MANUFACTURING INFORMATION
Primary Process
Description




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
























Valve -Inlet


Valve Outlet



















0701-N0101-01


0702N0101 01



















1





0
0
0
0
0
0
0
0
0
0
0








irfetevabeswoudneedtobeiipgraied-
C(rafe"cToTc)nrj's
^xhaust lakes wild need to be upgraded


iieSadiumfilledasYiell. Thsdssign
r±s±t±^



















OEM/Supplier
Classification






s


s





















Material
Specification






Labor
Classification






Burden
Classification






MANUFACTURING RATES
Finished Pieces PC
~*
i




'Syndicates Componen is Supplied directly to T1 or OEM for Final or Sub-
Assembly.
'SAC'=(Supplier Accounted Costs) Indicates Component is Supplied directly to
T1 or OEM for Final or Sub-Assembly. In addition component material cost is
accounted for in T1 quote sheet. Thus component cost will only be included for
Mark-up Calculations.
'Alpha-Numeric Charac er1 = Indicates purchase parts are brought in by T2/T3
Supplier for Subassembly.










































Number of Oper
0
0)





























Number of Lin
S






























Parallel Proces
Multiplier
5"






























1
1
o-
•





























Material
Cost
$/lb
(DB)


























T1 or




Labor
Rate
$/Hour
(DB)


























Burden
Rate
$/Hour
(DB)


























Applied
Burden
Rate
$/Hour


























OEM Total Manufacturing Cost:
T1 or OEM Mark-Up Rates:
&T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:






MANUFACTURING COSTS
Material
Cost

























Material

0.00
1. 08
Labor/ Part

























Labor
$0.00


Burden/
Part

























Burden



IF
e!
c1
S























TMC



MARK-UP COSTS
End
Item
Scrap
Rate

























Scrap

$0.01

SG&A
Rate
(DB)

























SG&A
$0.00
7.00%
$0.03

Profit
Rate
(DB)

























Profit

$0.09

ED&T/
R&D
Rate
(DR)

























ED&T
$0.00
4.00%
$0.04

Total
Mark-
up
Rate




Account
Cost

$0.00





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


Total
Mark-up

$0.21

Total
Mark-
up
Cost




Price/ Uni

$0.11





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





TOTAL COSTS
2.
SL
+ —1
3? ^
W"
R-
£


Price Net,
PIA

$0.00





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


Q
»i>

	 >
Packaging Cost:
Net Cost Impact to Vehicle:
s;
si
is-
oT
5


Price Net,
End Item

$0.11





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

1
$1.08
$1.08




TOOLING &
Tooling Assump
"X1000 "
o"
0)


























$0
NVESTMENT
Investment Assum
"X1000 "
"H.
w





























PACKAGING CALCULATIONS:
Packaging Type: NO IMPACT TO PACKAGING
Part Size:
Parts/Layer
Number of Layers:
Rack/Pallet Investment Amortization
Expendable Packaging in Piece Cost
Packaging CostTota
Piece

csr





£L
$0
;;-x
$0.00
Lump Sum
Payment
(%]

Si
0
Total * of
Pieces

Divider Pads,
$0.00
Number of
Months
60
D;:;ss
0
Interest
Rate

S
$0.00


„;,«,*
0
CostperPalletffiack
$0
Ss
$0.00
I Total Number of Pallets/
Racte Required
250
„;,«,*
0
I Number of Parts per Pallet/
«
1
P,±t'
$0.00
|Supplier,Customerand In-
transit Inventory
Requirements (Wee Is]
6
„;,«,*
0
I Supplier,Customerand In-
transit Inventory
Requirements [Parts]



$0.000
FfeValve Trains 07,032609.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                  Appendix G.1-07,2of4
                                                                                                                                                 Form Author: G. Kolwich
                                                                                                                                                 (248)373-6000 Ext. 2411

-------
                                                                                               Manufacturing Assumption and  Quote Summary
                                                                             APPENDIX G.1-07,(2of3)
                                                                                        Print Dale:9/2/2009
                 Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                     Vehicle Class: Compact/Economy 2-1 Passenger
OEM Operating Pattern (Weeks/Year):
                                                                                                                                                                                                              OEM Plant Location: North America
                      Study Case#: N0101(N = New, 01 = Technology Package, 01 = Vehicle Class)
               System Description: 2007 Mini Cooper s. 1.6L n, 16V DOHC GDI Turbo
        Annual Engine Volume (CPV):    <50,ooo
             Components per Engine: _
                                                                                                                                                                                                           Supplier Plant Location: North America
          Component Description: Camshaft - Intake Machine & Exhaust Machined
                                                                                                              Part Number: 0706-N0101-02 &0706-N0101-11
                                                                                                                                                          Annual Component Volume:    <50,ooo
          Component Quote Level:   r Full Quote
                                                             Moditication Quote
                                                                                   |7 Differential Quote (Quote Summary includes costing for both Technology Packages)
          Weekly Component Volume:    9,57<
               Estimated Product Life:
 OEM/T1 Classification:    rtoderate Assembly Complexity
       Shipping Method:"^Ship Point
Packaging Specification:_NA	
GENERAL COMPONENT INFORMATION
1
3

Tie
1A
2A
3A

Part Description

1 Supplier or OEM Processing
Camshaft - Exhaust Machined (MINI)
Camshaft - Intake Machined (MINI)

Part Number

& Assembly (Full Cos
0706-N0101-11
0706-B0101-02
0706-B0101-11
Purchase Part - Commodity ( Value taken from Purchas












D
?
CT

tma
1
1
GENERAL MANUFACTURING INFORMATION
Primary Process
Description

pping)

SrSS:r"
VeghtDer^enMini^Chr^r

; Part Database)
0
0
0
0
0
0
0
0
0
0
0
0
0











OEM/Supplier
Classification


T1 Assembly, Mark-up Applied
© Bottom.
© Bottom.
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.







Material
Specification


odularlron, Cast
odularlron, Cast
odularlron, Cast
odularlron, Cast


Labor
Classification


Not Applicable
Not Applicable
Not Applicable
Not Applicable


Burden
Classification


Not Applicable
Not Applicable
Not Applicable
Not Applicable


MANUFACTURING RATES
Finished Pieces Per Hour


113
113
113
113


'Syndicates Componen is Supplied directly to T1 or OEM for Final or Sub-
Assembly.
'SAC'=(Supplier Accounted Costs) Indicates Component is Supplied directly to
T1 or OEM for Final or Sub-Assembly. In addition component material cost is
accounted for in T1 quote sheet. Thus component cost will only be included for
Mark-up Calculations.
'Alpha-Numeric Charac er1 = Indicates purchase parts are brought in by T2/T3
Supplier for Subassembly.
























Number of Operators


1
1







Number of Lines


1
1
1
1







Parallel Processing
Mutiplier


1
1
1
1







s
1
I
CT


4.256
-4.260
-4.630







Material
Cost
$/lb
(DB)


$0.35
$0.35
$0.35
$0.35




T1 or


Labor
Rate
$/Hour
(DB)


$0.00
$0.00
$0.00
$0.00




Burden
Rate
$/Hour
(DB)


$0.00
$0.00
$0.00
$0.00




Applied
Burden
Rate
$/Hour


$0.00
$0.00
$0.00
$0.00




OEM Total Manufacturing Cost:
T1 or OEM Mark-Up Rates:
&T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:



MANUFACTURING COSTS
Material
Cost


$1.36
$1.49
-$1.49
-$1.62



Material
0.00
-$0.26
Labor/ Part






Labor
$0.00
$0.00
Burden/
Part


$0.00
$0.00
$0.00
$0.00



Burden


IF
$
SL
H
CD


$1.36
$1.49
-$1.49
-$1.62



TMC


MARK-UP COSTS
End
Item
Scrap
Rate
(DB)


0.00%
0.00%
0.00%
0.00%



Scrap
-$0.01

SG&A
Rate
(DB)


0.00%
0.00%
0.00%
0.00%



SG&A
6.50%
-$0.02

Profit
Rate
(DB)


0.00%
0.00%
0.00%
0.00%



Profit
-$0.02

ED&T/
R&D
Rate
(DB)


0.00%
0.00%
0.00%
0.00%



ED&T
2.50%
-$0.01

Total
Mark-
up
Rate


0.00%
0.00%
0.00%
0.00%
Supplier
Cost
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

Total
Mark-up
20.00%
-$0.05

Total
Mark-
up
Cost


$0.00
$0.00
$0.00
$0.00
Purchase
Price/ Uni
$000
$000
$000
$000
$000
$000
$000
$000
$000
$000
$0.00
$0.00
$0.00



TOTAL COSTS
2.
SL
+ —1
3? ^
I"
-c


$1.36
$1.49
-$1.49
-$1.62
Purchase
Price Net,
PIA
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

Q
	 m
	 >
Packaging Cost:
Net Cost Impact to Vehicle:
SL
si
Iff
£•
£


$1.36
$1.49
-$1.49
-$1.62
Purchase
Price Net,
End Item
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
1
-$0.26
-$0.26



TOOLING &
Tooling Assumptions
"X1000 "








$0
NVESTMENT
Investment Assumptions
"X1000 "








$0

PACKAGING CALCULATIONS:
Packaaina TvDe: WO IMPACT TO PACKAGING
Part Size:
Parts/Layer
Number of Layers:

Rack/Pallet Investment Amortization



Expendable Packaging in Piece Cost
Packaging CostTota


Cost per
Piece






$0.00













Total
Amount


$0



$0.00


Lump Sum
(%]










Pieces






$0.00



Months


60







Rate



Other #1
Packaging

$0.00







Others

Pallet/Rack


£
t
1
a

$0
Other*!
Packaging

$0.00

g,|
&i
•i 3.

e
250
Other*!

Pallet/Rack

=
1

ii
s
I
1
OtherK

Price Per
$0.00
f
til

l| f
I1!
7

Other *3

Pallet/Rack

%
fifH

111
I"3 i






$0.000
FfeValve Trains 07,032609.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                   Appendix G.1-07,3of4
                                                                                     Form Author: G. Kolwich
                                                                                     (248)373-6000 Ext. 2411

-------
Engine Assembly 0700
                                                                                               Manufacturing Assumption and  Quote Summary
                   APPENDIX G.1-07,(3of3)
                              Print Date:9/2/2009
                 Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                     Vehicle Class: Compact/Economy 2-1 Passenger
                      Study Case#: N0101(N = New, 01 = Technology Package, 01 = Vehicle Class)
               System Description: 2007 Mini Cooper s. 1.6L n, 16V DOHC GDI Turbo
          Component Description: Engine Assembly Impact from upgraded Valve Train components
                                                                                                              Part Number: 0700
          Component Quote Level:   |- Fu|| Quote      r Modification Quote     F7 Differential Quote (Quote Summary includes costing tor both Technology Packages)
OEM Operating Pattern (Weeks/Year):
        Annual Engine Volume (CPV):
             Components per Engine: _
          Annual Component Volume:_
          Weekly Component Volume:
               Estimated Product Life:
                                                                                                                                                                                                              OEM Plant Location: North America
                                                                                                                                                                                                           Supplier Plant Location: North America
 OEM/T1 Classification: OEM Engine Assembly
       Shipping Method: FOB Ship Point
Packaging Specification:_NA	
GENERAL COMPONENT INFORMATION
1


Tie



Part Description


Part Number



1 Supplier or OEM Processing & Assembly (Full Cos
1
No engine assembly cost impact as a result of
valve train upgrades.





O


tma

0

GENERAL MANUFACTURING INFORMATION
Primary Process
Description


pping)




Purchase Part - Commodity ( Value taken from Purchase Part Database)
1A
'Ih
















Valves Intake and Exhaust
Camshafts Exhaust & Intake
















Delta (Mini$-Ch
Delta (Mini$-Ch












ysler$)
ysler$)















8
1
0
0
0
0
0
0
0
0
0
0
0




























OEM/Supplier
Classification








SAC
SAC



















Material
Specification









Labor
Classification









Burden
Classification









MANUFACTURING RATES
Finished Pieces Per h
1



SSSSS




•Syndicates Componen is Supplied directly to T1 or OEM for Final or Sub-
Assembly.

'SAC'=(Supplier Accounted Costs) Indicates Component is Supplied directly to
T1 or OEM for Final or Sub-Assembly. In addition component material cost is
accounted for in T1 quote sheet. Thus component cost will only be included for
Mark-up Calculations.

'Alpha-Numeric Charac er1 = Indicates purchase parts are brought in by T2/T3
Supplier for Subassembly.



































Number of Operato
ta



0
























Number of Lines




1
























Parallel Processin
Multiplier




1
























1
I
•



0.000
























Material
Cost
S/lb
(DB)




SN/A



















T1 or




Labor
Rate
$/Hour
(DB)




SN/A



















Burden
Rate
ffHour
(DB)




SN/A



















Applied
Burden
Rate
$/Hour




SN/A



















OEM Total Manufacturing Cost:
T1 or OEM Mark-Up Rates:
&T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:






MANUFACTURING COSTS
Material
Cost




SN/A


















Material


1.00
Labor/ Part




SN/A


















Labor
$0.00


Burden/
Part




SN/A


















Burden



IF
e!
S



SN/A


















TMC



MARK-UP COSTS
End
Item
Scrap
Rate
(DB)




SN/A


















Scrap
0.00%
$0.00

SG&A
Rate
(DB)




SN/A


















SG&A

$0.00

Profit
Rate
(DB)




SN/A


















Profit
0.00%
$0.00

ED&T/
R&D
Rate
(DB)




SN/A


















ED&T

$0.00

Total
Mark-
up
Rate




SN/A


Cost
$10.37
($0.31)
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00


Total
Mark-up
0.00%
$0.00

Total
Mark-
up
Cost




SN/A


Price/ Uni
$1.30
($0.31)
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00





TOTAL COSTS
2.
SL
+ —1
3? ^
I"
£



SN/A


Price Net,
PIA
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00


Q
»u

	 *
Packaging Cost:
Net Cost Impact to Vehicle:
SL
si
I"
5



$0.00


Price Net,
End Item
$10.37
-$0.31
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
I
I
$10.06
$10.06




TOOLING &
Tooling Assumptio
"X1000 "
0)

























$0
NVESTMENT
Investment Assumpti
"X1000 "
w

























$0


PACKAGING CALCULATIONS:
Packaging Type:
Part Size:
Parts/Layer
Number of Layers:
Rack/Pallet Investment Amortization


Expendable Packaging in Piece Cost
Packaging Cost Tota

Cost per
Piece

Cost per











Total
$0
Tier Pad

$0.00


Lump Sum
Payment
(%]
0.00%
Tier Pads

0


Total * of
Pieces

Divider Pads,

$0.00


Number of
Months
60
Divider Pads

0


Interest
Rate

0,he,,1
Price Per
$0.00




Other*
Pallet/Rack
0


Dost per Pallet /Rack
$0
Othe,^
Price Per
$0.00


tal Number of Pallets/
Racks Required
250
Others
Pallet/Rack
0

^
nber of Parts per Pallet/
Rack
1
0,he,«
Price Per
$0.00

o>
11!
IJ|
6
OtherB
Pallet/Rack
0

£
flf
I5i
?
57447




FfeValve Trains 07,032609.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                   Appendix G.1-07,4of4
                          Form Author: G. Kolwich
                          (248)373-6000 Ext. 2411

-------
                   Appendix G.1 - Subsystem 08
                      Timing Drive Subsystem
                         Case Study #0101
                        MAQS Worksheets
File:Timing Drives 08 O32608.xls
EPA Contract:EP-C-07-069 WA1-3                           Appendix G.1-08,1 of 2

-------
Timing Wheels 0801
                                                                                              Manufacturing Assumption and Quote Summary
                 Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                     Vehicle Class: Compact/Economy 2-1 Pa!
                      Study Case#: N0101(N = New, 01 = Technology Package, 01 = Vehicle Class)
               System Description: 2007 Mini Cooper s. 1.6L n, 16V DOHC GDI Turbo
          Component Description: Sprocket - Crankshaft, Timing Drive
          Component Quote Level:   r Full Quote
                                                                                                             Part Number: 0801-N0101-01
F Modification Quote
                         f~ Differential Quote (Quote Summary includes costing tor both Technology Packages)
                                                                                    OEM Operating Pattern (Weeks/Year):
                                                                                            Annual Engine Volume (CPV):
                                                                                                 Components per Engine: _
                                                                                              Annual Component Volume:_
                                                                                              Weekly Component Volume:
                                                                                                   Estimated Product Life:
                                                                                                                                                                APPENDIX G.1-08,(1of1)
                                                                                                                                                                            Print Date:9/2/2009

                                                                                                                                                  OEM Plant Location: North America
                                                                                                                                                                                                          Supplier Plant Location: North America
 OEM/T1 Classification: T1 Low Assembly Complexity
       Shipping Method: FOB Ship Point	
Packaging Specification:	
GENERAL COMPONENT INFORMATION
1
S


Part Description


Part Number


D
?
CT


GENERAL MANUFACTURING INFORMATION
Primary Process
Description


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












Sprocket - Crankshaft, Timing Drive











0801-N0101-01











1
0
0
0
0
0
0
0
0
0
0
0
0







ups included)













OEM/Supplier
Classification



s













Material
Specification




Labor
Classification




Burden
Classification




MANUFACTURING RATES
Finished Pieces Per h
1



'Syndicates Componen is Supplied directly to T1 or OEM for Final or Sub-

'SAC'=(Supplier Accounted Costs) Indicates Component is Supplied directly to
T1 or OEM for Final or Sub-Assembly. In addition component material cost is
accounted for in T1 quote sheet. Thus component cost will only be included for
Mark-up Calculations.
'Alpha-Numeric Charac er1 = Indicates purchase parts are brought in by T2/T3
Supplier for Subassembly.



































Number of Operato
\1


	 *
Packaging Cost:
Net Cost Impact to Vehicle:
SL
si
Iff
£•
£-

Purchase
Price Net,
End Item
$1.60
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
1
$1.60
$1.60





TOOLING &
Tooling Assumptio
"X1000 "
0)














$0
NVESTMENT
Investment Assumpti
"X1000 "
w














$0

PACKAGING CALCULATIONS:
Packaging Type: No Change to Packaging
Part Size:
Parts/Layer
Number of Layers:
Rack/Pallet Investment Amortization


Expendable Packaging in Piece Cost
Packaging Cost Tota

Cost per
Piece

Cost per











Total
$o
Tier Pad

$0.00


Lump Sum
Payment
(%]

Tier Pads




Total * of
Pieces

Divider Pads,

$0.00


Number of
Months
60
Divider Pads




Interest
Rate

Other #1

$0.00




Others




I
1
1
$0
Other*!

$0.00

_
ital Number of Pallets/
Racks Required
250
Other*!




nberof Parts per Pallet/
Rack
1
Other #3

$0.00


plier,Customerand In-
transit Inventory
lequirements (Weeks)

Other K
Pallet/Rad


"
equirements [Parts]





FfeTiming Drives 08 O32608.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                  Appendix G.1-08,2of2
                                                                                                                                                                         Form Author: G. Kolwich
                                                                                                                                                                         (248)373-6000 Ext. 2411

-------
                   Appendix G.1 - Subsystem 10
                         Intake Subsystem
                         Case Study #0101
                         MAQS Worksheets
File:lntake Systems 10 032609.xls
EPA Contract:EP-C-07-069 WA1-3                           Appendix G.1-10,1 of 2

-------
Intake Manifold 1001
                                                                                               Manufacturing Assumption and Quote Summary
                                                                                                                                                                                                            APPENDIX G.1-10(1of1)
                                                                                                                                                                                                                       Print Date:9/2/2009
Technology Level:  Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                     Vehicle Class: Compact/Economy 2-1 Pa!
                                                                                                                                               OEM Operating Pattern (Weeks/Year):
                                                                                                                                                                                                              OEM Plant Location: North America
                      Study Case#: N0101(N = New, 01 = Technology Package, 01 = Vehicle Class)
               System Description: 2007 Mini Cooper s. 1.6L n, 16V DOHC GDI Turbo
          Component Description:   ilfold Assembly - Intake
          Component Quote Level:   l~ Full Quote
                                                                                                             Part Number:  001-N0101-01
                                          F Modification Quote
                                                                    17 Ditterential Quote (Quote Summary includes costing tor both Technology Packages)
                                                                                                                                       Annual Engine Volume (CPV):   <50,ooo
                                                                                                                                            Components per Engine:      1
                                                                                                                                         Annual Component Volume:   <50,ooo
                                                                                                                                         Weekly Component Volume:    9,57<
                                                                                                                                              Estimated Product Life:     10
                                                                                                                                                                                                           Supplier Plant Location: North Americ
                                                                                                                                                                                                           OEM/T1 Classification:
                                                                                                                                                                                                                                          te Assembly Complexity
                                                                                                                                                                                                                 Shipping Method: FOB Ship Point
                                                                                                                                                                                                          Packaging Specification: Vacuum Form Beturnal
GENERAL COMPONENT INFORMATION
1

Tie
1A
1B
1A



Part Description

1 Supplier or OEM Processing
Manifold -Intake, Bottom Half (Mini)
Manifold - Intake, Bottom Half (Chrysler)
Manifold - Intake, Top Half (Chrysler)
Part Number

& Assembly (Full Co
001-N01 01 -01-07
001-N01 01 -01-06
001-B0101-01-07
1001-B01 01 -01-06
Equipment, Tooling and Fixturing for friction welding top and
bottom sections of intake manifold together would be less
expensive for Mini versus GEMA. However since time and
burden rate differences would be minor, we have not included the
difference as a line code in the quote.








D

tma
1
1
0
1
1
0
0
0
0
0
0





GENERAL MANUFACTURING INFORMATION
Primary Process
Description

pping)
Injection Molding
Injection Molding
Injection Molding





OEM/Supplier
Classification


T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.





Material
Specification


Nyion6-30GF, Inject.
Nyion6-30GF, Inject.
Nyion6-30GF, Inject.





Labor
Classification


MoloyCast/Sinter Operator
MoloyCast/Sinter Operator
MoloyCast/Sinter Operator
MoloyCast/Sinter Operator





Burden
Classification


Inject. Mold, MLS
Inject. Mold, MLS
Inject. Mold, MLS
Inject. Mold, MLS





MANUFACTURING RATES
Finished Pieces Per Hour


254
267
SSSSS
-226
-255
»»
»»
»»
»»





Number of Operators


0.5
0.5
0
0.5
0.5
0
0
0
0
0
0





Number of Lines


1
1
1
1
1





Parallel Processing
Multiplier


1
1
1
1
1





1
I


1.408
0.949
0.000
-5.036
-3.380
0.000
0.000
0.000
0.000
0.000
0.000





Material
Cost
$/lb
(DB)


$1.76
$1.76
SN/A
$1.76
$1.76
SN/A
SN/A
SN/A


T1 or


Labor
Rate
$/Hour
(DB)


$43.52
$43.52
SN/A
$43.52
$43.52
N/A
N/A
N/A


Burden
Rate
$/Hour
(DB)


$150.01
$150.01
SN/A
$150.01
$150.01
N/
N/
N/


Applied
Burden
Rate
$/Hour


$150.01
$150.01
SN/A
$150.01
$150.01
SN/A
SN/A
SN/A


OEM Total Manufacturing Cost:
T1 or OEM Mark-Up Rates:
&T1 or OEM Mark-Up Values:
Base Cost mpact to Vehicle:



MANUFACTURING COSTS
Material
Cost


$2.48
$1.67
SN/A
-$3.86
-$5.95
SN/A
SN/A
SN/A

Material

0.66
Labor/ Part


$0.09
$0.08
SN/A
-$0.10
-$0.09
N/
N/
N/

Labor
-$0.01

Burden/
Part


$0.59
$0.56
SN/A
-$0.67
-$0.59
N/A
N/A
N/A

Burden


IF
e!


$3.15
$2.31
SN/A
-$9.62
-$6.62
SN/A
SN/A
SN/A

TMC


MARK-UP COSTS
End
Item
Scrap
Rate
(DB)


0.00%
0.00%
SN/A
0.00%
0.00%
N/A
N/A
N/A

Scrap
0.50%
-$0.05

SG&A
Rate
(DB)


0.00%
000%
SN/A
0.00%
0.00%
SN/A
SN/A
SN/A

SG&A


Profit
Rate
(DB)


0.00%
0.00%
SN/A
0.00%
0.00%
N/A
N/A
N/A

Profit


ED&T/
R&D
Rate
(DB)


0.00%
0.00%
SN/A
0.00%
0.00%
SN/A
SN/A
SN/A

ED&T


Total
Mark-
up
Rate


0.00%
0.00%
SN/A
0.00%
0.00%
N/A
N/A
N/A

Total
Mark-up


Total
Mark-
up
Cost


$0.00
$0.00
SN/A
$0.00
$0.00
SN/A
SN/A
SN/A



TOTAL COSTS
2.
SL
+ —i


$3.15
$2.31
SN/A
-$9.62
-$6.62
N/
N/
N/

Q

	 *
Packaging Cost:
Net Cost Impact to Vehicle:
SL
s|


$3.15
$2.31
$0.00
-$9.62
-$6.62
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
1
410.78
-$10.78



TOOLING &
Tooling Assumptions
"X1000 "







NVESTMENT
Investment Assumptions
"X1000 "






$0

PACKAGING CALCULATIONS:
Packaging Type: Option #2
Part Size: 370x280x1 70
Parts/Layer 4x3 =12
Number of Layers: 5

PACKAGING CALCULATIONS:
CHRYSLER GEMA INTAKE MANIFOLD - £0 36
Packaging Type: Option #2
Part Size: 370x380x225
Parts/Layer 3x3
Number of Layers:3

Rack/Pallet Investment Amortization:


Expendable Packaging in Piece Cost:
Packaging Cost Total:
Cost per
Piece

Cost [*r









Total

Tier Pad

$0.00

Lump Sum
Payment
(%]

Tier Pads



Total * of
Pieces

Divider Pads,

$0.00

Number of
Months
60
Divider Pads



Interest
Rate

Other #1

$0.00



Others



1
1
1
$340
Other*!

$0.00

1 Total Number of Pallets/
Racte Required
2128
Other*!



I Number of Parts per Pallet/
Rack
27
OtherK

$0.00

I Supplier,Customerand In-
transit Inventory
Requirements (Wee Is]

Other *3
Pallet/Rad


I transit Inventory
Requirements [Parts]





File:lnlake Systems 10 032609.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                  Appendix G.1-10,2of2
                                                                                                                                                                                                                    Form Author: G. Kolwich
                                                                                                                                                                                                                    (248)373-6000 Ext. 2411

-------
                   Appendix G.1 - Subsystem 11
                     Fuel Induction Subsystem
                         Case Study #0101
                         MAQS Worksheets
File:Fuel Induction 11 O32709.xls
EPAContract:EP-C-07-069WA1-3                           Appendix G.1-11,1 of 12

-------
                                                                                             Manufacturing Assumption and  Quote Summary
                                                                                                                                                               APPENDIX G.1-11,(1of7)
                                                                                                                                                                          Print Date:9/2/2009
                Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                     Vehicle Class: Compact/Economy 2-1 Pa!
                      Study Case#: N0101(N = New, 01 = Technology Package, 01 = Vehicle Class)
               System Description: 2007 Mini Cooper s. 1.6L n, 16V DOHC GDI Turbo
          Component Description: Fuel Rail - High Pressure
          Component Quote Level:   I* Full Quote
                                                                                                            Part Number: 1101-N0101-02
r Modification
                         r~ Differential Quote (Quote Summary includes
                                                                                   OEM Operating Pattern (Weeks/Year):     n
                                                                                           Annual Engine Volume (CPV):	
                                                                                                Components per Engine:     1
                                                                                             Annual Component Volume:   <50,ooo
                                                                                             Weekly Component Volume:    9,57<
                                                                                                  Estimated Product Life:     10
                                                                                                                                                                                                           OEM Plant Location: North America
                                                                                                                                                                                                        Supplier Plant Location: North Americ
                                                                                                                                                                                                         OEM/T1 Classification:
                                                                                                                                                                                                                                      	
                                                                                                                                                                                                              Shipping Method: FOB Ship Point
                                                                                                                                                                                                        Packaging Specification: Returnable w. Expendable Separators
GENERAL COMPONENT INFORMATION
1


Tie

Pu
1A
2A
3A
4A
4B
5A
Part Description


1 Supplier or OEM Processing
Fuel Rail High Pressure
chase Part - High Impact Item
Tube -Injector Rail
Threaded Plug Rail Inlet
Boss High Pressure Sensor
Cup Injector Port
Cup Injector Port
Bracket Rail Mounting
Part Number


& Assembly (Full Cos
101-N0101-02
Full Cost Mapping)
101-N01 01 -02-06
101-N01 01 -02-05
101-N01 01 -02-03
101-N01 01 -02-01
1101-N01 01 -02-01-1
1101-N01 01 -02-02
O


tma
1

1
1
1
4
4
2
GENERAL MANUFACTURING INFORMATION
Primary Process
Description


pping)
Assembly, Braze S Test

Turn S cross Drill
Machines Tap
Machines Tap
Plating
Machines Cross Drill
Stamping
Purchase Part - Commodity ( Value taken from Purchase Part Database)


2A











High Pressure Fuel Sensor Assembly











1101-N0101-03











1
0













3ressure Sensor












OEM/Supplier
Classification



T1 Assembly, Mark-up Applied
© Bottom.

T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.



S












Material
Specification



Not Applicable

S-Steel-304, Tube
S-Steel-304, Bar
S-Steel-304, Bar
Plating, Fuel Rail
S-Steel-304, Bar
S-Steel-304, Coil

Labor
Classification



GeneralAssembly

CMC Operator
CMC Operator
CMC Operator
P,,,inc,C,,,inaOp,,,,,,
CMC Operator
Cut/Punch/Forming Operator

Burden
Classification



Mech Assembly, LC, Base

CMC Turning, MC
CMC Turning, MC
CMC Turning, LMC
Plate/Finish, SMS, MHC
CMC Turning, HC
Stamp/Form, SMS, LMC

MANUFACTURING RATES
Finished Pieces Per h
1


288

1
1
10
13
164
720
4
10
610

'Syndicates Component is Supplied directly to T1 or OEM for Final or Sub-
Assembly.

'SAC'=(Supplier Accounted Costs) Indicates Component is Supplied directly o
T1 or OEM for Final or Sub-Assembly. In addition component material cost s
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.

































Number of Operato
U

	 *
Packaging Cost:
Net Cost Impact to Vehicle:
SL
s|
5


$0.89

$1.34
$0.84
$1.16
$1.08
$4.81
$0.88
Price Net,
End Item


$7.50
$0.00





$18.59
$18.59



$20.76
TOOLING &
Tooling Assumptio
"X1000 "
0)























$0
NVESTMENT
Investment Assumpti
"X1000 "
w























$0


PACKAGING CALCULATIONS:
Packaging Type: Option #3, Tote w. Vacuum Form
Pack
Part Size: 300x55x1 00mm
Parts/Layer 8
Number of Layers:3
Rack/Pallet Investment Amortization


Expendable Packaging in Piece Cost
Packaging Cost Tota

Cost per
Piece

Cost [*,











Total

Tie, Pad

$0.00


Lump Sum
Payment
(%]

Tie, Pads




Total * of
Pieces

Divide, Pads,

$0.00


Number of
Months
60
Divide, Pads




Interest
Rate

Other #1

$0.00




Othetfl




I
1
1
$2,740


$0.00

_
ital Number of Pallets/
Racte Required
50





nberof Parts per Pallet/
Rack
1152


$0.00


plier,Customerand In-
transit Inventory
lequirements (Wee Is]

OthetB




equire merits [Parts]





FfeFuel Induction 11032709.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                Appendix G.1-11,2ol12
                                                                                                                                                                       Form Author: G. Kolwich
                                                                                                                                                                       (248)373-6000 Ext. 2411

-------
lnjeclor-1104-R5
                                                                                              Manufacturing Assumption and  Quote Summary
                 Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                     Vehicle Class: Compact/Economy 2-1 Pa!
                      Study Case#: N0101(N = New, 01 = Technology Package, 01 = Vehicle Class)
               System Description: 2007 Mini Cooper s. 1.6L n, 16V DOHC GDI Turbo
          Component Description: Fuel Injector Assembly-Solenoid, 7 Hole
          Component Quote Level:   I*  Full Quote
                                                                                                             Part Number: UM-NOI01-01
F Modification Quot
                         l~~ Differential Quote (Quote Summary includes
                                                                                    OEM Operating Pattern (Weeks/Year):      n
                                                                                            Annual Engine Volume (CPV):    «o,ooo
                                                                                                  Components per Engine:      <
                                                                                               Annual Component Volume:   1,800,000
                                                                                              Weekly Component Volume:    38,298
                                                                                                   Estimated  Product Life:      10
                                                                                                                                                                 APPENDIX G.1-11,(2of7)
                                                                                                                                                                            Print Date:9/2/2009

                                                                                                                                                   OEM Plant Location: North America
                                                                                                                                                                                                          Supplier Plant Location: North America
  OEM/T1 Classification: T1 High Assembly Complexity
       Shipping Method: FOB Ship Point	
Packaging Specification:	;rnal Dunna;
GENERAL COMPONENT INFORMATION
1
3


Part Description


Tier 1 Supplier or OEM Processing
1A
2A
3A
4A
5A
6,
7A

Fuel Injector Assembly
Seal Injector Tip
Solenoid Booy preassembled
Needle Body Assembly
Needle Assembly
Needle Injector
Metering Valve assembly

Purchase Part - High Impact Item
1A
2A
3A
4A
5A
6A
7A
7B
8A
8A
8A
9A
10A
11A
11B
12A
13A
Body Injector Solenoid
Sleeve winding to inlet separator
Sleeve Fuel Inlet
Body needle
Inlet Tube
Spring Seat Lower
Needle valve
Ball Needle seat
Ball Needle seat
Ball Needle seat
Metering Valve
Plate Metering Valve
Tp-lnjector
Tp -Injector
=aceseal Injector to head
Backet Injector hold-down
Part Number


D
?
CT


& Assembly (Full Cost ma
04-N0101-01
04-N01 01 -01-30
04-N01 01 -01-10
104-N01 01 -01-50
104-N01 01 -01-11
104-N01 01 -01-13
104-N01 01 -01-16

Full Cost Mapping)
104-N01 01 -01-20
104-N01 01 -01-27
104-N01 01 -01-28
104-N0101-01-9
104-N01 01 -01-21
104-N01 01 -01-24
104-N01 01 -01-24-01
104-N01 01 -01-23
104-N01 01 -01-23
104-N01 01 -01-23
104-N01 01 -01-18
104-N01 01 -01-19
104-N01 01 -01-08
104-N01 01 -01-08-01
104-N01 01 -01-4-1
104-N0101-01-2
1
1
1
1
1
1
1
*

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
*
GENERAL MANUFACTURING INFORMATION
Primary Process
Description


pping)
Final Assembly
Oermoldseal ©Injector Tip
Laser weld internal valve body
Assembles Press Sleeve
Laser Weld Ball and Seat to
Needle
Laser Weld Plate to Valve


Machine Booy
vlachineand Roll Splines
Machine
vlachineand Roll Splines
Cut and Flare
vlachine
Machine Heat Treat
EDM Mounting Pocket
Grind/Lap/Wash
Cold Hea*Machine/Heat Treat
vlachined
Stamping
:DM Micro Popping
Metal Injection Molding
3owder Metal
Stamping
OEM/Supplier
Classification



T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.


T2/T3CNC Turning, MSMC
T2/T3 CNC Turning, MSMC
T2/T3CNC Turning, MSMC
T2/T3 CNC Turning, MSMC
T2/T3Hydro/CNCForm, SSLC
T2/T3 CNC Turning, MSMC
T2/T3 CNC Turning, MSMC
T2/T3 CNC Turning, MSMC
T2/T3 CNC Turning, MSMC
T2/T3 CNC Turning, MSMC
T2/T3 CNC Turning, MSMC
T2/T3 Stamp/Form, MSMC
T2/T3 CNC Turning, MSMC
T2/T3 Powder Metal, LSHC
T2/T3 Powder Metal, SSLC
T2/T3 Stamp/Form, MSMC
Material
Specification



Not Applicable
Nyion-HT, Inject.
Nylon66-40FMR, Inject.
Not Applicable
Not Applicable
Not Applicable
Not Applicable


S-Steel-440C, Bar
S-Steel-440C, Bar
S-Steel-440C, Bar
S-Steel-440C, Bar
S-Steel-304, Tube
S-Steel-440C, Bar
S-Steel-440C, Bar
Not Applicable
Not Applicable
S-Steel-440C, Bar
S-Steel-440C, Bar
S-Steel-304, Coil
Not Applicable
S-Steel-440-MIM
PM-SMF-SS410
HC-Steel-4130, Coil
Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembl





Purchase Part - Commodity ( Value taken from Purchase Part Database)
1A
2A
3A
4A
5A
6A
7A
8A
9A



Solenoid Windings
Sleeve Screen Stop
0-Ring Injector to rail seal



1104-N01 01 -01-22
104-N01 01 -01-15
104-N01 01 -01-25
104-N0101-01-5
104-N0101-01-1



1
1
1
1
1
1
1
1
1
*
0
0
0









S
S
S
S







Labor
Classification



Electromechanical Assembly
Electromechanical Assembly
Electromechanical Assembly
Electromechanical Assembly
Electromechanical Assembly
Electromechanical Assembly


CNC Operator
CNC Operator
CNC Operator
CNC Operator
Forging Operator
CNC Operator
CNC Operator
CNC Operator
CNC Operator
CNC Operator
CNC Operator
CNC Operator
Cut/Punch/Forming Operator
CNC Operator
MoloyCast/Sinter Operator
Mold/Cast/Sinter Operator
Cut/PunclVForming Operator
Process)



Burden
Classification



Mech Assembly, LC, Base
Mech Assembly, MC, Base
Mech Assembly, MC, Base
Mech Assembly, MC, Base
Mech Assembly, MC, Base
Mech Assembly, MC, Base


CNC Turning, MC
CNC Turning, MC
CNC Turning, MC
CNC Turning, MC
Cold Forge, LMC
CNC Turning, MC
CNC Turning, MC
CNC Turning, MC
CNC Turning, MC
CNC Turning, MC
Cold Forge, LMC
CNC Turning, MC
Stamp/Form, SMS, LMC
CNC Milling, MHC
Powder Metal, MHC
Powder Metal, LMC
Stamp/Form, SMS, LMC




MANUFACTURING RATES
Finished Pieces Per h
1


480
450
450
450
450
514
514
SSSSS

500
491
485
460
360
450
540
540
720
540
720
470
766
480
480
1440
600
am




'Syndicates Component is Supplied directly to T1 or OEM for Final or Sub-
Assembly.
•SAC'=(Supplier Accounted Costs) Indicates Component is Supplied directly to
T1 or OEM for Final or Sub-Assembly. In addition component material cost is 1
accounted for in T1 quote sheet. Thus component cost will only be included for
Mark-up Calculations.
'Alpha-Numeric Character1 = Indicates purchase parts are brought in by T2/T3
Supplier for Subassembly.










Number of Operato
0)


2
1
2
4
1
1
1
0

0.5
0.5
0.5
0.5
0.5
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.5
1
0.5
0.5
0










Number of Lines



1
1
1
1.5
1
1
1
1

5
4.5
3.5
5.5
1
1.5
1.5
1.5
1
1.5
1
3
1
2
1
1
1
1









Parallel Processin
Multiplier



6
1
5
4
3
2
1

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1









S
1
I
CT
"


0.000
0.005
0.030
0.000
0.000
0.000
0.000
0.000

0.140
0.074
0.041
0.043
0.010
0.0002
0.000
0.002
0.000
0.000
0.0003
0.005
0.0002
0.000
0.002
0.005
0.078
0.000









Material
Cost
$/lb
(DB)



$0.00
$4.00
$1.54
$0.00
$0.00
$0.00
$0.00
SN/A

$4.56
$4.56
$4.56
$4.56
$1.65
$4.56
$0.00
$4.56
$0.00
$0.00
$4.56
$4.56
$1.64
$0.00
$13.68
$4.92
$0.78










Labor
Rate
$/Hour
(DB)



$37.35
$37.35
$37.35
$37.35
$37.35
$37.35
$37.35
SN/A

$35.70
$35.70
$35.70
$35.70
$38.52
$35.70
$35.70
$35.70
$35.70
$35.70
$35.70
$35.70
$42.18
$35.70
$43.52
$43.52
$42.18










Burden
Rate
$/Hour
(DB)



$15.00
$30.00
$45.00
$30.00
$30.00
$30.00
$30.00
SN/A

$45.00
$45.00
$45.00
$45.00
$100.09
$45.00
$45.00
$45.00
$45.00
$45.00
$100.09
$45.00
100.10
150.15
150.14
100.14
100.10










Applied
Burden
Rate
$/Hour



$90.00
$30.00
$225.00
$360.00
$120.00
$90.00
$60.00
SN/A

$225.00
$202.50
$157.50
$247.50
$100.09
$67.50
$67.50
$67.50
$45.00
$67.50
$100.09
$135.00
$100.10
$300.30
$150.14
$100.14
$100.10










MANUFACTURING COSTS
Material
Cost



$0.00
$0.02
$0.05
$0.00
$0.00


SN/A

$0.64
$0.34
$0.19
$0.20
$0.02
$0.00
$0.00
$0.01
$0.00
$0.00
$0.00
$0.02
$0.00
$0.00
$0.03
$0.02
$0.06










Labor/ Part



$0.16
$0.08
$0.17
$0.33
$0.08
$0.07
$0.07
SN/A

$0.04
$0.04
$0.04
$0.04
$0.05
$0.02
$0.02
$0.02
$0.01
$0.02
$0.01
$0.02
$0.01
$0.04
$0.09
$0.02
$0.04










Burden/
Part



$0.19
$0.07
$0.50
$0.80
$0.27
$0.18
$0.12
SN/A

$0.45
$0.41
$0.33
$0.54
$0.28
$0.15
$0.13
$0.13
$0.06
$0.13
$0.14
$0.29
$0.13
$0.63
$0.31
$0.07
$0.17










IF
e!
+ _|
Ss
?"
+ "
3


$0.34
$0.17
$0.71
$1.13
$0.35
$0.25
$0.19
SN/A

$1.12
$0.79
$0.55
$0.77
$0.35
$0.17
$0.14
$0.15
$0.07
$0.14
$0.15
$0.33
$0.14
$0.66
$0.43
$0.11
$0.26










MARK-UP COSTS
End
Item
Scrap
Rate
(DB)



0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
SN/A

0.50%
0.50%
0.50%
0.50%
0.30%
0.50%
0.50%
0.50%
0.50%
0.50%
0.50%
0.50%
0.50%
0.50%
0.70%
0.30%
0.50%










SG&A
Rate
(DB)



0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
SN/A

6.50%
6.50%
6.50%
6.50%
6.00%
6.50%
6.50%
6.50%
6.50%
6.50%
6.50%
6.50%
6.50%
6.50%
7.00%
6.00%
6.50%










Profit
Rate
(DB)



0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
SN/A

6.00%
6.00%
6.00%
6.00%
4.00%
6.00%
6.00%
6.00%
6.00%
6.00%
6.00%
6.00%
6.00%
6.00%
8.00%
4.00%
6.00%










ED&T/
R&D
Rate
(DB)



0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
SN/A

1.00%
1.00%
1.00%
1.00%
0.00%
1.00%
1.00%
1.00%
1.00%
1.00%
1.00%
1.00%
1.00%
1.00%
2.00%
0.00%
1.00%










Total
Mark-
up
Rate



0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
SN/A

14.00%
14.00%
14.00%
14.00%
10.30%
14.00%
14.00%
14.00%
14.00%
14.00%
14.00%
14.00%
14.00%
14.00%
17.70%
10.30%
14.00%



Supplier
Account
Cost
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

Total
Mark-
up
Cost



$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
SN/A

$0.16
$0.11
$0.08
$0.11
$0.04
$0.02
$0.02
$0.02
$0.01
$0.02
$0.02
$0.05
$0.02
$0.09
$0.08
$0.01
$0.04



Price/ Unil
$0.25
$0.08
$0.01
$0.03
$0.01
$0.05
$0.02
$0.03
$0.09
$0.00
$0.00
$0.00
$0.00

TOTAL COSTS
2.
SL
^ °
S" ^
I "
-c


$0.34
$0.17
$0.71
$1.13
$0.35
$0.25
$0.19
SN/A

$1.28
$0.90
$0.63
$0.88
$0.38
$0.19
$0.16
$0.17
$0.09
$0.16
$0.17
$0.38
$0.17
$0.76
$0.51
$0.12
$0.30



Purchase
Price Net,
PIA
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

SL
II
^?
£•
£-


$0.34
$0.17
$0.71
$1.13
$0.35
$0.25
$0.19
$0.00

$1.28
$0.90
$0.63
$0.88
$0.38
$0.19
$0.16
$0.17
$0.09
$0.16
$0.17
$0.38
$0.17
$0.76
$0.51
$0.12
$0.30
$0.00


Purchase
Price Net,
End Hem
$0.25
$0.08
$0.01
$0.03
$0.01
$0.05
$0.02
$0.03
$0.09
$0.00
$0.00
$0.00
$0.00
I
-i-
TOOLINGS INVESTMENT
Tooling Assumptio
"X1000 "
0)

































Investment Assumpti
"X1000 "
3

































FfeFuel Induction 11032709.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                 Appendix G.1-11,Sol 12
                                                                                                                                                                         Form Author: G. Kolwich
                                                                                                                                                                         (248)373-6000 Ext. 2411

-------
lnjeclor-1104-R5
                                                                                               Manufacturing Assumption and Quote Summary
                 Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                     Vehicle Class: Compact/Economy 2-1 Passenger
                      Study Case#: N0101(N = New,  01 = Technology Package, 01 = Vehicle Class)
               System Description: 2007 Mini Cooper s. 1.6L n, 16V DOHC GDI Turbo
Component Description: Fuel Injector Assembly-Solenoid, 7 Hole
Component Quote Level:   I* Full Quote
                                                                                                              Part Number: UM-NOI01-01
                                                           F Modification Quot
                                                                                    l~~ Differential Quote (Quote Summary includes
OEM Operating Pattern (Weeks/Year):_
        Annual Engine Volume (CPV):_
             Components per Engine:_
          Annual Component Volume:_
          Weekly Component Volume:_
               Estimated Product Lite:
                                                                                                                                                                                                                   APPENDIX G.1-11,(2of7)
                                                                                                                                                                                                                              Print Date:9/2/2009

                                                                                                                                                                                                    OEM Plant Location: North America
                                                                                                                                                                                                           Supplier Plant Location: North America
                                                                                                                                                                                                  OEM/T1 Classification: T1 High Assembly Complexity
                                                                                                                                                                                                       Shipping Method: FOB Ship Point
                                                                                                                                                                                                           Packaging Specification: Returnable Container t, Internal Dunnage
GENERAL COMPONENT INFORMATION

1





Part Description





Part Number













GENERAL MANUFACTURING INFORMATION

Primary Process
Description








OEM/Supplier
Classification








Material
Specification








Labor
Classification








Burden
Classification







MANUFACTURING RATES
5"
hed Pieces Per h
i






z
mberofOperato
ta







dumber of Lines







TJ
rallel Processin
Multiplier







s
I
I
•







Material
Cost
$/lb
(DB)


T1 or





Labor
Rate
$/Hour
(DB)



Burden
Rate
$/Hour
(DB)



Applied
Burden
Rate
$/Hour


OEM Total Manufacturing Cost:
T1 or OEM Mark-Up Rates:
&T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:






MANUFACTURING COSTS

Material
Cost

Material

0.00
:.16

Labor/ Part

Labor
$1.47

$1.47

Burden/
Part

Burden



IF
SL
|
TMC



MARK-UP COSTS

End
Item
Scrap
Rate
(DB)

Scrap
0.70%
$0.08


SG&A
Rate
(DB)

SG&A

$0.77


Profit
Rate
(DB)

Profit
8.00%
$0.88


ED&T/
R&D
Rate
(DB)

ED&T




Total
Mark-
up
Rate

Total
Mark-up




Total
Mark-
up
Cost




TOTAL COSTS
2.
I ""
f
E
»l>

	 *
Packaging Cost:
Net Cost Impact to Vehicle:
3
SL
II
i"
f
$10.95
$10.95




TOOLINGS INVESTMENT

If
•^
0)



$0
1
stment Assumpti
"X1000 "
Z



$0


PACKAGING CALCULATIONS:
Packaging Type: Option #3 Tote, 42 Totes/Pallet
Part Size: 90x55x25 mm
Parts/Layer per tote: 3x8
Number of Layers per tote: 9
Rack/Pallet Investment Amortization


Expendable Packaging in Piece Cost
Packaging CostTota

Piece

Cost [*r
"""

$0.014








"

,„„
""""
$0.00


Lump Sum
Payment
(%]


'""""*



Total! of
Pieces/
Amortization
Period


""""
$0.00


Number of
Service Months
60

""'""
0


Interest
Rate

Othsrfl

$0.00









8
I
1
$4,180
Other*!

$0.00


tal Number of Pallets/
Racks Required
26




?
mber of Parts per Pallet
Rack
9072
Other «

$0.00

f
transit Inventory
equipments [Weeks]
6

P.IMR.ck


^
plier,Customerand In-
transit Inventory
Requirements (Parts)





File:Fuel Induction 11032709.xls
EPA Contract EP-C-07-069 WA1-3
                                                                                                                  Appendix G.1-11,4ol12
                                                                                                                                                                                                                           Form Author: G. Kolwich
                                                                                                                                                                                                                           (248)373-6000 Ext. 2411

-------
HP-Fuel Pump 1107-R5
                                                                                              Manufacturing Assumption and  Quote Summary
                                                                                                                                                                 APPENDIX G.1-11,(3of7)
                                                                                                                                                                            Print Date:9/2/2009
                 Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                     Vehicle Class: Compact/Economy 2-1 Pa!
                      Study Case#: N0101(N = New, 01 = Technology Package, 01 = Vehicle Class)
               System Description: 2007 Mini Cooper s. 1.6L n, 16V DOHC GDI Turbo
          Component Description: Fuel Pump-High Pressure w. Vol.Control Valve (Driven-Off Intake Cam;
          Component Quote Level:   I* Full Quote
                                                                                                             Part Number: 1107-N0101-01
r Modilicatio
                         l~~ Differential Quote (Quote Summary includes
                                                                                    OEM Operating Pattern (Weeks/Year):
                                                                                            Annual Engine Volume (CPV):
                                                                                                 Components per Engine: _
                                                                                              Annual Component Volume:_
                                                                                              Weekly Component Volume:
                                                                                                   Estimated Product Life:
                                                                                                                                                                                                             OEM Plant Location: North America
                                                                                                                                                                                                          Supplier Plant Location: North Americ
                                                                                                                                                                                                           OEM/T1 Classification:
                                                                                                                                                                                                                                        	
                                                                                                                                                                                                                Shipping Method:  FOB Ship Point
                                                                                                                                                                                                         Packaging Specification:  Returnable w. Expendable Separators
GENERAL COMPONENT INFORMATION
1
£


Part Description


Tier 1 Supplier or OEM Processing
1A
2A
3A
4A
5A
Fuel Pump - High Pressure w. Vol. Control
Swash PI ale Drive Assembly
B,,,,,pi»nc,,i,»
Bellow Retainer
Shaft Drive Adapter
Purchase Part - High Impact Item
1A
1B
1C
2A
2B
3A
4A
5A
6A
7A
8A
9A
10A
11A
12A
12B
13A
13A
14A
14B

15A
15B
17A
17B
18A
18B
19A
19B
19C
20A
Housing Fuel Pump
Housing Fuel Pump
H,usingFu,IPump
Bar Stock - Check Valve Assembly
Check Valve Assembly
Retainer Check Valve Assembly
Plate -Check Valve
Seat -Check Valve Plate
Retainer Check Valve
Bellow piston cavity
Spring Seat
Top Seat and Sealing Flange
Bellow Retainer
Piston High pressure pump
Cap Piston contactto swash plate
Cap Piston contact to swash plate
Casting: Swash Plate Drive Housing
Swash Plate Drive Housing Machined
Swash Plate Assy - Cast
Swash Plate Assy

Shaft Drive Adapter PM
Shaft Drive Adapter w/out backlash adjuster
Mount Bracket HP fuel Pump
Mount Bracket HP fuel Pump
3p,«- MOM B,,4et-»«h plate refine,
Spacer -Mount Bracket
Di,ph,,gmTempe,,tu,eC,mpen»ting
Top Stamping Diaphragm Temperature
Compensating
Compensating
Fitting Fuel Inlet
Part Number


| QTYPerAssembl}


& Assembly (Full Cost ma
,W-N,,,,-,,
1107-N01 01 -01-09
1107-N01 01 -01-14
1107-N01 01 -01-16
1107-N01 01 -01-09-6
Full Cost Mapping)
1107-N0101-01-25-1
1107-N01 01 -01-25-1
1107-N01 01 -01-25
1107-N01 01 -01-22-1
1107-N01 01 -01-22
1107-N01 01 -01-24-1
1107-N01 01 -01-20
1107-N01 01 -01-21
1107-N01 01 -01-17
1107-N01 01 -01-14-1
1107-N01 01 -01-14-2
1107-N01 01 -01-14-3
1107-N01 01 -01-16-1
1107-N01 01 -01-11
1107-N01 01 -01-10
1107-N01 01 -01-10
1107-N01 01 -01-09-2
1107-N01 01 -01-09-1
1107-N01 01 -01-09-5-3
1107-N0101 -01-09-6-1
1107-N01 01 -01-03
1107-N01 01 -01-03-1
1107-N0101 -01-02
1107-N01 01 -01-02-1
1107-N01 01 -01-08
1107-N01 01 -01-08-1
1107-N01 01 -01-08-2
1107-N01 01 -01-06
1
1
2
2
1

,
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
'
1
GENERAL MANUFACTURING INFORMATION
Primary Process
Description


pping)
Final Assembly Line
SubassemblyLine
Weld Subassembly
fellows Retli'neT"01110
Press Ball, Springs and Insert

Extrude Housing
Machine Housing
Assemble Ball Plugs
Machining
Assemble components
Machining
Machining
Machining
Machining
Cut and Form Tube Stock
Machining
Machining
Machining
Machining
bating
Machining
Mumlnum Diecast
Machine Casting
ron Casting
Machine Casting
Heat Treat
Machining
Ground Flat
:ineblanked
Fineblanked
:ineblanked
Assemble S Test
Forma Stamp
Forma Stamp
Machine
OEM/Supplier
Classification



T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.

T2/T3 Cold Forge, MSMC
T2/T3 CMC Milling, LSHC
T2/T3Mech. Assembly, SSLC
T2/T3 CMC Turning, SSLC
T2/T3Mech. Assembly, SSLC
T2/T3 CMC Turning, SSLC
T2/T3 CMC Turning, SSLC
T2/T3 CMC Turning, SSLC
T2/T3 CMC Turning, SSLC
T2/T3 Hydro/CMC Form,
MSMC
T2/T3 CMC Turning, SSLC
T2/T3 CMC Turning, SSLC
T2/T3 CMC Turning, SSLC
T2/T3 CMC Turning, SSLC
T2/T3 Plate/Finish Mech.,
SSLC
T2/T3 CMC Turning, SSLC
T2/T3 Diecast, SSLC
T2/T3 CMC Turning, MSMC
T2/T3Perm. Cast, MSMC
T2/T3 CMC Turning, MSMC
T2/T3 Plate/Finish Mech.,
SSLC
T2/T3 CMC Turning, MSMC
T2/T3 CMC Milling, SSLC
T2/T3 CMC Milling, SSLC
T2/T3 Fine Blank, SSLC
T2/T3 Fine Blank, SSLC
T2/T3 Fine Blank, SSLC
T2/T3 Mech. Assembly, SSLC
T2/T3 Stamp/Form, SSLC
T2/T3 Stamp/Form, SSLC
T2/T3 CMC Turning, SSLC
Material
Specification



Not Applicable
Not Applicable
Not Applicable
Not Applicable
Not Applicable

Aluminum-7075-T6, Ext.
Not Applicable
Purchased Parts
S-Steel-304, Bar
Purchased Parts
Ni-AI-Bronze-630000, Bar
S-Steel-304, Bar
S-Steel-304, Bar
S-Steel-316,Bar
Titanium-6AL4V, Bar
S-Steel-316, Bar
S-Steel-316, Bar
A-Steel-41XXS, Bar
A-Steel-4140,Bar
Not Applicable
A-Steel-4140, Bar
Aluminum -A380, Cast
Not Applicable
Nodular Iron, Cast
Not Applicable
Not Applicable
Not Applicable
Not Applicable
Not Applicable
MC-Steel-1000S,Coil
Not Applicable
MC-Steel-1000S, Coil
Purchased Parts
LC-Steel-1000S, Coil
LC-Steel-1000S, Coil
S-Steel-304, Bar
Labor
Classification



General Assembly
General Assembly
General Assembly
General Assembly
General Assembly

Extruding/Drawing Operator
CNC Operator
General Assembly
Lathe/Turning Operator
General Assembly
Lathe/Turning Operator
Lathe/Turning Operator
Lathe/Turning Operator
Lathe/Turning Operator
Cut/Punch/Forming Operator
Lathe/Turning Operator
Lathe/Turning Operator
Lathe/Turning Operator
Lathe/Turning Operator
Platino/Coating Operator
Lathe/Turning Operator
MoloyCast/Sinter Operator
MoloyCast/Sinter Operator
MoloyCast/Sinter Operator
CNC Operator
CNC Operator
MoloyCast/Sinter Operator
Cut/Punch/Forming Operator
Cut/Punch/Forming Operator
Cut/Punch/Forming Operator
Cut/Punch/Forming Operator
Cut/Punch/Forming Operator
Cut/Punch/Forming Operator
Cut/Punch/Forming Operator
Lathe/Turning Operator
Burden
Classification



Mech Assembly.HC, Base
Mech Assembly, MC, Base
Mech Assembly, MC, Base
Mech Assembly, MC, Base
Mech Assembly, MC, Base

Cold Forge, MHC
CNC Machining, LMC
Mech Assembly, LC, Base
S-CNC Turning, HC
Mech Assembly, MC, Base
CNC Turning, LC
CNC Turning, LC
S-CNC Turning, MC
S-CNC Turning, HC
Hydro/CNCForm, MLS, MHC
S-CNC Turning, MC
S-CNC Turning, MC
S-CNC Turning, MC
S-CNC Turning, MC
Plate/Finish, SMS, LMC
S-CNC Turning, MC
Diecast, LMC
RTM Turning, HC, PP, Base
Perm. Cast, MHC
RTM Turning, HC, PP, Base
CNC Turning, MC
Powder Metal, LMC
CNC Machining, LMC
Fine blank, LMC
Fine blank, LMC
Fine blank, LMC
Fine blank, LMC
Mech Assembly, LC, Base
S,,mP,F,,m,SMS,LMC
S-P/FP.SMS.LMC
S-CNC Turning, MC
MANUFACTURING RATES
| Finished Pieces Per H
1


360
360
300
600
300

96
121
240
180
277
144
257
250
251
225
235
230
231
225
360
225
286
300
286
360
250
124
632
200
600
391
600
439
300
621
643
123
Number of Operatoi
ta


3
1
2
1
0.5

2
4
1
0.25
1
1
0.5
1
1
1
1
1
2
2
0.5
1
0.5
0.5
3
0.5
0.25
1
0.5
1
0.5
1
0.5
0.5
0.5
Number of Lines



1
1
1
1
1

1
14
1
2
1
2
2
2.5
3
1
3
3
5
4
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1.5
I Parallel Processini
I Multiplier



10
8
4
1
1

1
1
4
1
2
1
2
1
1
1
1
1
1
1.5
1
1.5
1
1
1
1.2
1
1
1
2
1
1
1
1
3
1
1
1
S
1
I
CT
=


0.250
0.000
0.000
0.000
0.000

1.800
0.000
0.110
0.040
0.030
0.075
0.000
0.005
0.050
0.010
0.050
0.110
0.500
0.030
0.000
0.000
0.209
0.000
0.219
0.000
0.000
0.000
0.037
0.000
0.000
1.080
0.000
0.557
0.120
0.042
0.018
0.120
Material
Cost
$/lb
(DB)




$0.00
$0.00
$0.00
$0.00

$3.21
$0.00
$1.00
$1.65
$1.00
$2.44
$1.65
$1.65
$2.44
$34.37
$2.44
$2.44
$0.78
$0.78
$0.00
$0.78
$1.10
$0.00
$0.35
$0.00
$0.00
$0.00
$1.00
$0.00
$0.00
$0.55
$0.00
$0.55
$1.00
$0.45
$0.45
$1.65
Labor
Rate
$/Hour
(DB)




$35.51
$35.51
$35.51
$35.51

$54.35
$35.70
$35.51
$37.60
$35.51
$37.60
$37.60
$37.60
$37.60
$42.18
$37.60
$37.60
$37.60
$37.60
$55.17
$37.60
$43.52
$43.52
$43.52
$35.70
$46.52
$35.70
$43.52
$43.52
$42.18
$42.18
$42.18
$42.18
$42.18
$42.18
$42.18
$37.60
Burden
Rate
$/Hour
(DB)



S45.00
$30.00
$30.00
$30.00
$30.00

$150.09
$25.00
$15.00
$85.00
$30.00
$25.00
$25.00
$55.00
$85.00
$150.12
$55.00
$55.00
$55.00
$55.00
$100.17
$55.00
$100.05
$200.00
$150.06
$200.00
$100.00
$45.00
$100.14
$25.00
$100.13
$100.13
$100.13
$100.13
$15.00
$100.10
$100.10
$55.00
Applied
Burden
Rate
$/Hour



$450.00
$240.00
$120.00
$30.00
$30.00

$150.09
$350.00
$60.00
$170.00
$60.00
$50.00
$100.00
$137.50
$255.00
$150.12
$165.00
$165.00
$275.00
$330.00
$100.17
$165.00
$100.05
$200.00
$150.06
$240.00
$100.00
$45.00
$100.14
$50.00
$100.13
$100.13
$100.13
$100.13
$45.00
$100.10
$100.10
$82.50
MANUFACTURING COSTS
Material
Cost



$0.00
$0.00
$0.00
$0.00
$0.00

$5.78
$0.00
$0.11
$0.07
$0.03
$0.18
$0.00
$0.01
$0.12
$0.34
$0.12
$0.27
$0.39
$0.02
$0.00
$0.00
$0.23
$0.00
$0.08
$0.00
$0.00
$0.00
$0.04
$0.00
$0.00
$0.59
$0.00
$0.31
$0.12
$0.02
$0.01
$0.20
Labor/ Part



$0.30
$0.10
$0.24
$0.06
$0.06

$1.13
$1.18
$0.15
$0.05
$0.13
$0.26
$0.07
$0.15
$0.15
$0.19
$0.16
$0.16
$0.33
$0.33
$0.08
$0.17
$0.08
$0.07
$0.46
$0.05
$0.19
$0.29
$0.07
$0.05
$0.07
$0.05
$0.07
$0.05
$0.14
$0.03
$0.03
$0.15
Burden/
Part



$1.25
$0.67
$0.40
$0.05
$0.10

$1.56
$2.88
$0.25
$0.94
$0.22
$0.35
$0.39
$0.55
$1.02
$0.67
$0.70
$0.72
$1.19
$1.47
$0.28
$0.73
$0.35
$0.67
$0.53
$0.67
$0.40
$0.36
$0.16
$0.25
$0.17
$0.26
$0.17
$0.23
$0.15
$0.16
$0.16
$0.67
IF
$
SL
H
CO
1


$1.55
$0.77
$0.64
$0.11
$0.16

$8.47
$4.06
$0.51
$1.06
$0.37
$0.79
$0.46
$0.71
$1.29
$1.20
$0.98
$1.15
$1.91
$1.82
$0.35
$0.90
$0.66
$0.74
$1.06
$0.72
$0.59
$0.65
$0.26
$0.30
$0.24
$0.90
$0.24
$0.58
$0.41
$0.21
$0.20
$1.02
MARK-UP COSTS
End
Item
Scrap
Rate
(DB)



0.00%
0.00%
0.00%
0.00%
0.00%

0.50%
0.70%
0.30%
0.30%
0.30%
0.30%
0.30%
0.30%
0.30%
5.00%
0.30%
0.30%
0.30%
0.30%
0.30%
0.30%
5.00%
0.50%
5.00%
0.50%
0.30%
0.50%
0.30%
0.30%
0.30%
0.30%
0.30%
0.30%
0.30%
0.30%
0.30%
0.30%
SG&A
Rate
(DB)



0.00%
0.00%
0.00%
0.00%
0.00%

650%
7.00%
6.00%
6.00%
6.00%
6.00%
6.00%
6.00%
6.00%
6.50%
6.00%
6.00%
6.00%
6.00%
6.00%
6.00%
600%
6.50%
650%
6.50%
6.00%
6.50%
600%
6.00%
6.00%
600%
6.00%
600%
6.00%
600%
600%
6.00%
Profit
Rate
(DB)



0.00%
0.00%
0.00%
0.00%
0.00%

6.00%
8.00%
400%
4.00%
400%
400%
4.00%
4.00%
4.00%
6.00%
4.00%
4.00%
4.00%
4.00%
4.00%
4.00%
4.00%
6.00%
6.00%
6.00%
4.00%
6.00%
4.00%
4.00%
4.00%
4.00%
4.00%
4.00%
400%
4.00%
4.00%
400%
ED&T/
R&D
Rate
(DB)



0.00%
0.00%
0.00%
0.00%
0.00%

1.00%
2.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
1 .00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
1 .00%
1 .00%
1.00%
0.00%
1.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
Total
Mark-
up
Rate



0.00%
0.00%
0.00%
0.00%
0.00%

14.00%
17.70%
10.30%
10.30%
10.30%
10.30%
10.30%
10.30%
10.30%
18.50%
10.30%
10.30%
10.30%
10.30%
10.30%
10.30%
15.00%
14.00%
18.50%
14.00%
10.30%
14.00%
10.30%
10.30%
10.30%
10.30%
10.30%
10.30%
10.30%
10.30%
10.30%
10.30%
Total
Mark-
up
Cost



$0.00
$0.00
$0.00
$0.00
$0.00

$1.19
$0.72
$0.05
$0.11
$0.04
$0.08
$0.05
$0.07
$0.13
$0.22
$0.10
$0.12
$0.20
$0.19
$0.04
$0.09
$0.10
$0.10
$0.20
$0.10
$0.06
$0.09
$0.03
$0.03
$0.02
$0.09
$0.02
$0.06
$0.04
$0.02
$0.02
$0.11
TOTAL COSTS
Total 2 =
Total! + Total Mark-
-c


$1.55
$0.77
$0.64
$0.11
$0.16

$9.66
$4.78
$0.56
$1.17
$0.41
$0.87
$0.51
$0.78
$1.42
$1.42
$1.09
$1.27
$2.10
$2.01
$0.39
$0.99
$0.75
$0.84
$1.25
$0.82
$0.65
$0.74
$0.29
$0.34
$0.26
$1.00
$0.26
$0.64
$0.45
$0.24
$0.22
$1.13
SL
sl
Iff
£•
£


$1.55
$0.77
$1.27
$0.22
$0.16

$9.66
$4.78
$0.56
$1.17
$0.41
$0.87
$1.02
$1.56
$2.84
$2.84
$2.17
$2.54
$4.21
$4.02
$0.78
$1.99
$0.75
$0.84
$1.25
$0.82
$0.65
$0.74
$0.29
$0.34
$0.26
$1.00
$0.26
$0.64
$0.45
$0.24
$0.22
$1.13
TOOLINGS NVESTMENT
Tooling Assumptior
"X1000 "
0)




































Investment Assumpti'
"X1000 "
w




































FfeFuel Induction 11032709.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                 Appendix G. 1-11, Sol 12
                                                                                                                                                                         Form Author: G. Kolwich
                                                                                                                                                                         (248)373-6000 Ext. 2411

-------
HP-Fuel Pump 1107-R5
                                                                                              Manufacturing Assumption and  Quote Summary
                                                                                                                                                                 APPENDIX G.1-11,(3of7)
                                                                                                                                                                            Print Dale:9/2/2009
                 Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                     Vehicle Class: Compact/Economy 2-1 Pa!
                      Study Case#: N0101(N = New, 01 = Technology Package, 01 = Vehicle Class)
               System Description: 2007 Mini Cooper s. 1.6L n, 16V DOHC GDI Turbo
          Component Description: Fuel Pump-High Pressure w. Vol.Control Valve (Driven-Off Intake Cam;
          Component Quote Level:   I* Full Quote
                                                                                                             Part Number: 1107-N0101-01
r Modilicatio
                         l~~ Differential Quote (Quote Summary includes
                                                                                    OEM Operating Pattern (Weeks/Year):
                                                                                            Annual Engine Volume (CPV):
                                                                                                 Components per Engine:
                                                                                              Annual Component Volume:
                                                                                              Weekly Component Volume:
                                                                                                   Estimated Product Life:
                                                                                                                                                                                                             OEM Plant Location: North America
                                                                                                                                                                                                          Supplier Plant Location: North Americ
                                                                                                                                                                                                           OEM/T1 Classification:
                                                                                                                                                                                                                                        	
                                                                                                                                                                                                                Shipping Method:  FOB Ship Point
                                                                                                                                                                                                         Packaging Specification:  Returnable w. Expendable Separators
GENERAL COMPONENT INFORMATION
1
3
Part Description
Part Number
D
?
CT
GENERAL MANUFACTURING INFORMATION
Primary Process
Description
Purchase Part - Commodity ( Value taken from Purchase Part Database)
1A
2A
3A
4A
5
10A
1 A
12A
13A
14A
15A
16A
17A
18A
20A
2 A
22A
23A
23B
25
26



4mm Ball Plug
Seal Fuel Outlet Fitting
Check Ball
Spring Check Ball
Seat Check Ball
Spring Check Valve
Seat Check valve spring
Spring -Check Valve
Spring Bellow return
Pin Guide
0-Ring Bellow OD sealing
Spring HP piston
Seal Swash Plate shaft
Bearing Roller Thrust, Swash Plate
Spring Backlash adjust
Ball Backlash Adjust
Ball Seat/Retainer
0-ringOD Seal to pump housing
Bolt Mount bracket
Oil Swash Plate cavity
Solenoid Fuel Pump Control
Bolt Control Solenoid -fuel pump
Head



NA
NA
1107-N01 01 -01-22-4
107-N01 01 -01-23
107-N01 01 -01-19
Pin Guide
107-N01 01 -01-16-2
107-N01 01 -01-09-4
107-N01 01 -01-09-7
107-N01 01 -01-09-6-3
107-N01 01 -01-09-3
107-N01 01 -01-26
107-N01 01 -01-08-3-1
107-N01 01 -01-07
107-N01 01 -01-05
185-N0101-01



1





3urchase Part
Purchase Part
Purchase Part
Purchase Part
Purchase Part
Purchase Part
Purchase Part
Purchase Part
Purchase Part
Purchase Part
Purchase Part
Purchase Part
Purchase Part
Purchase Part





OEM/Supplier
Classification

B1
B3
B3
S
S
S
S
S
S
S
S
S
B19A
B19A
S
S





Material
Specification


Labor
Classification


Burden
Classification


MANUFACTURING RATES
Finished Pieces Per Hour


'Syndicates Componen is Supplied directly to T1 or OEM for Final or Sub-
Assembly.
'SAC'=(Supplier Accounted Costs) Indicates Component is Supplied directly to
T1 or OEM for Final or Sub-Assembly. In addition component material cost is I
accounted for in T1 quote sheet. Thus component cost will only be included for
Mark-up Calculations.
'Alpha-Numeric Charac er1 = Indicates purchase parts are brought in by T2/T3
Supplier for Subassembly.

























Number of Operators







Number of Lines







Parallel Processing
Multiplier







s
1
I
CT








PACKAGING CALCULATIONS:
Packaging Type: Option #3 Totes
Part Size: 100x100x100
Parts/Layer 4x2
Number of Layers: 3
Rack/Pallet Investment Amortization:
Expendable Packaging in Piece Cost:
Packaging CostTota :
Materia
Cost
$/lb
(DB)




T1 or



Piece
$0.111
csr

Labor
Rate
$/Hour
(DB)




Burden
Rate
$/Hour
(DB)




Applied
Burden
Rate
$/Hour




OEM Total Manufacturing Cost:
T1 or OEM Mark-Up Rates:
&T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:








£L

s:
$0.00


Lump Sum
Payment
(%]

Si
0
MANUFACTURING COSTS
Materia
Cost



Material
0.00
6.99
Labor/ Part



Labor
$8.24

Burden/
Part



Burden


IF
$
SL
H
CD



TMC
$53.55

MARK-UP COSTS
End
Item
Scrap
Rate
(DB)



Scrap
$0.41

SG&A
Rate
(DB)



SG&A
$2.30
7.00%
$4.06

Profit
Rate
(DB)



Profit
$4.65

ED&T/
R&D
Rate
(DB)



ED&T
$0.14
4.00%

Tola
Mark-
up
Rate
Supplier
Account
Cost
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

Total
Mark-up


Total
Mark-
up
Cost
Price/ Uni
$0.01
$0.04
$0.01
$0.01
$0.01
$0.03
$0.06
$0.01
$0.05
$0.02
$0.07
$0.02
$0.06
$0.19
$0.23
$0.65
$0.01
$0.01
$0.01
$0.08
$0.05
$0.20
$0.07
$0.05
$0.08
$10.00
$0.06
$0.08



TOTAL COSTS
2.
SL
+ —i
s? ^
I"
-c
Purchase
Price Net,
PIA
$0.07
$0.04
$0.01
$0.01
$0.01
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.07
$0.05
$0.00
$0.00
$0.00
$0.00

Q
	 ^u
	 *
Packaging Cost:
Net Cost Impact to Vehicle:

Total * of
Pieces

Divider Pads,
$0.00
Number of
Months
60
D;:;ss
0
Interest
Rate

S
$0.00


P..^cK
0
Cost per Pallet /Rack
.< i
l> i
J3.880 | I 1008
Otter*! i:*«r« Oirwr#3
$0.00 | 0 | $0.00
u
il!
!"!
~ =
0
f|f
II!
I9 I
?
-
$0.111
SL
si
is-
s
*
Purchase
Price Net,
End Item
$0.00
$0.00
$0.00
$0.00
$0.00
$0.03
$0.12
$0.02
$0.10
$0.04
$0.14
$0.04
$0.12
$0.19
$0.23
$0.65
$0.02
$0.02
$0.02
$0.08
$0.15
$0.20
$0.00
$0.00
$0.08
$10.00
$0.12
$0.08
I
$58.06
$58.06

$0.11

TOOLING &
Tooling Assumptions
"X1000 "





$0
NVESTMENT
Investment Assumptions
"X1000 "








FfeFuel Induction 11032709.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                 Appendix G.1-11,6ol12
                                                                                                                                                                         Form Author: G. Kolwich
                                                                                                                                                                         (248)373-6000 Ext. 2411

-------
PipeAssembly1170-R5
                                                                                              Manufacturing Assumption and  Quote Summary
                                                                                                                                                                APPENDIX G1-11,(4of7)
                                                                                                                                                                           Print Dale:9/2/2009
                Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                     Vehicle Class: Compact/Economy 2-1 Pa!
                      Study Case#: N0101(N = New, 01 = Technology Package, 01 = Vehicle Class)
               System Description: 2007 Mini Cooper s. 1.6L n, 16V DOHC GDI Turbo
          Component Description: Pipe Assembly - Fuel, High Pressure, Pi
          Component Quote Level:   I* Full Quote
                                                                                                            Part Number: 1170-N0101-01
r Modificatio
                         r~ Differential Quote (Quote Summary includes
                                                                                    OEM Operating Pattern (Weeks/Year):     n
                                                                                           Annual Engine Volume (CPV):	
                                                                                                 Components per Engine:      1
                                                                                             Annual Component Volume:    <50,ooo
                                                                                             Weekly Component Volume:    9,57<
                                                                                                  Estimated Product Life:     10
                                                                                                                                                                                                            OEM Plant Location: North America
                                                                                                                                                                                                        Supplier Plant Location: North Americ
                                                                                                                                                                                                         OEM/T1 Classification:
                                                                                                                                                                                                                                      	
                                                                                                                                                                                                              Shipping Method: FOB Ship Point
                                                                                                                                                                                                        Packaging Specification: Returnable
GENERAL COMPONENT INFORMATION
1
£

Tie
1A
Pu
1A
2A
Part Description

1 Supplier or OEM Processing
Pipe - Fuel, High Pressure, Pump to Rail
chase Part - High Impact Item
Tube Slock HP pumptorail
Tube Nul HP pumpto rail
Part Number

& Assembly (Full Cos
170-N0101-01
Full Cost Mapping)
1170-N01 01 -01-01
1170-N01 01 -01-02
O
?
CT

tma
1

2
GENERAL MANUFACTURING INFORMATION
Primary Process
Description

pping)
Assembly Tube Nuts and Flare

CMC Tube Bending
Purchase Part - Commodity ( Value taken from Purchase Part Database)












0
0
0
0
0
0
0
0
0











OEM/Supplier
Classification


© Bottom.

T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.







Material
Specification


Not Applicable

S-Steel-304, Tube
S-Steel-304, Tube

Labor
Classification


GeneralAssembly

Cul/Punch/Forming Operator
CMC Operator

Burden
Classification


Mech Assembly, LC, Base

Hydro/CMC Form, SMS, LMC
CMC Turning, LC

MANUFACTURING RATES
Finished Pieces Per Hour


225

171
233

'Syndicates Component is Supplied directly to T1 or OEM for Final or Sub-
Assembly.
'SAC'=(Supplier Accounted Costs) Indicates Component is Supplied directly o
T1 or OEM for Final or Sub-Assembly. In addition component material cost s
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.






















Number of Operators


1

0.25
0.5







Number of Lines


1

1
2







Parallel Processing
Multiplier


2

1
1







S
1
I
CT


0.000

o.oeo
0.088







Material
Cost
$/lb
(DB)


$0.00

$1.65
$1.65




T1 or


Labor
Rate
$/Hour
(DB)


$35.51

$42.18
$35.70




Burden
Rate
$/Hour
(DB)


$15.00

$100.12
$25.00




Applied
Burden
Rate
$/Hour


$30.00

$100.12
$50.00




OEM Total Manufacturing Cost:
T1 or OEM Mark-Up Rates:
&T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:



MANUFACTURING COSTS
Material
Cost


$0.00

$0.10
$0.15



Material
0.00
$0.39
Labor/ Part


$0.16

$0.06
$0.06



Labor
$0.34
$0.34
Burden/
Part


$0.13

$0.58
$0.17



Burden


IF
$
SL
H
CD


$0.29

$0.74
$0.38



TMC


MARK-UP COSTS
End
Item
Scrap
Rate
(DB)


0.00%

0.00%
0.00%



Scrap
$0.01

SG&A
Rate
(DB)


0.00%

000%
0.00%



SG&A
6.00%

Profit
Rate
(DB)


0.00%

0.00%
000%



Profit


ED&T/
R&D
Rate
(DB)


0.00%

0.00%
0.00%



ED&T
1.00%

Total
Mark-
up
Rate


0.00%

0.00%
0.00%
Supplier
Cost
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

Total
Mark-up


Total
Mark-
up
Cost


$0.00

$0.00
$0.00
Purchase
Price/ Uni
$000
$000
$000
$000
$000
$000
$000
$000
$000



TOTAL COSTS
2.
SL
+ —1
3? M
I"
-c


$0.29

$0.74
$0.38
Purchase
Price Net,
PIA
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

Q
	 m
	 >
Packaging Cost:
Net Cost Impact to Vehicle:
SL
si
is-
s
*


$0.29

$0.74
$0.76
Purchase
Price Net,
End Item
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

$1.80
$1.80



TOOLING &
Tooling Assumptions
"X1000 "










$0
NVESTMENT
Investment Assumptions
"X1000 "










$0

PACKAGING CALCULATIONS:
Packaging Type: Option #3 Packaging
PartSize:=(1/2*(170*70))*50)=2.975E5mmA3
Tote Volume= 508x300x300=45. 7E6mmA3
Parts/Tote = 150

Rack/Pallet Investment Amortization



Expendable Packaging in Piece Cost
Packaging CostTota


Cost per
Piece






$0.00













Total
Amount


$16,117



$0.00


Lump Sum










Total * of
Pieces






$0.00


Number of
Months


60






Interest
Rate



Other *1
Packaging

$0.00







Other*!

Pallet/Rack


£
I
1
a
"
$2,020
Other*!
Packaging

$0.00
_
g-l
SF 1
•i 3.

1
8
Other*!

Pallet/Rack

=
1

SrS

i
7200
Other #3

Price Per
$0.00
f
in

% 1 1
f 5 »
fi 1

Other *3

Pallet/Rack

%
$n

ill
s^ ™
" =•





$0.008
FfeFuel Induction 11032709.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                 Appendix G.1-11,7ol12
                                                                                                                                                                       Form Author: G. Kolwich
                                                                                                                                                                       (248)373-6000 Ext. 2411

-------
Fuel Rail! 101-GEMA
                                                                                              Manufacturing Assumption and  Quote Summary
                                                                             APPENDIX G.1-11,(5of7)
                                                                                        Print Dale:9/2/2009
                 Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                     Vehicle Class: Compact/Economy 2-1 Passenger
OEM Operating Pattern (Weeks/Year):
                                                                                                                                                                                                            OEM Plant Location: North America
                      Study Case#: B0101(N = New, 01 = Technology Package, 01 = Vehicle Class)
               System Description: 2007 Chrysler GEMA, ULU, 16V DOHC, NA, dWT, 173hp
        Annual Engine Volume (CPV):    <50,ooo
             Components per Engine: _
                                                                                                                                                                                                         Supplier Plant Location: North America	
                                                                                                                                                                                                          OEM/T1 Classification: '• -:.» assembly Complexity
          Component Description: Fuel Rail Assembly
                                                                                                             Part Number: 1101-80101-01
          Component Quote Level:   I*  Full Quote
                                                           r Modification
                                                                                    17 Ditterential Quote (Quote Summary includes
          Annual Component Volume:    <50,ooo
          Weekly Component Volume:     9,57<
               Estimated Product Life:
                                                                                                                                                                                                               Shipping Method: FOB Ship Point
                                                                                                                                                                                                         Packaging Specification: Returnable w. Expendable Separators
                                                                                                                                                                                         10
GENERAL COMPONENT INFORMATION
1
3

Tie
1A
2A
3A
Pu
1A
2A
3A
4A
5A
Part Description

1 Supplier or OEM Processing
Fuel Rail Assembly
Fuel Rail Assembly
Fuel Rail Assembly
chase Part - High Impact Item
Tube Injector Rail
End Cap
Cup Injector Port
Inlet Tube
Part Number

& Assembly (Full Cos
101-B0101-01
101-B0101-01
101-B0101-01
Full Cost Mapping)
101-B0101-01-3
101-B0101-01-4
101-B0101-01-5
101-60101-01-6
1101-B0101-01-7
D
?
S.

tma
1
1
1
0

2
2
1
0
GENERAL MANUFACTURING INFORMATION
Primary Process
Description

pping)
Projection Weld Brackets
Assembly end caps and inlet

Cut to length and back extrude
inlet
Stamp
Stamp
Stamp
BendS Form
Purchase Part - Commodity ( Value taken from Purchase Part Database)












0
0
0
0
0
0
0
0
0
0
0
0
0
0











OEM/Supplier
Classification


T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.

T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.








Material
Specification


ot Applicable
ot Applicable
ot Applicable

-Steel-304, Tube
-Steel-304, Tube



Labor
Classification


GeneralAssembly

Cut/Punch/Forming Operator

Cut/Punch/Forming Operator
Cut/Punch/Forming Operator



Burden
Classification


Mech Assembly, HC, Base
Mech Assembly, LC, Base
Mech Assembly, LC, Base

S,,m,F,,m,SMS,LMC

Hydro/CMC Form, SMS, LMC



MANUFACTURING RATES
Finished Pieces Per Hour


157
257
157
»»S

300
706
735
679
600
»»S


'Syndicates Componen is Supplied directly to T1 or OEM for Final or Sub-
Assembly.
'SAC'=(Supplier Accounted Costs) Indicates Component is Supplied directly to
T1 or OEM for Final or Sub-Assembly. In addition component material cost is
accounted for in T1 quote sheet. Thus component cost will only be included for
Mark-up Calculations.
'Alpha-Numeric Charac er1 = Indicates purchase parts are brought in by T2/T3
Supplier for Subassembly.
























Number of Operators


2
1
2
0

0.5
0.5
0.5
0.5
0







Number of Lines


1
1
1
1

1
1
1
1
1
1







Parallel Processing
Multiplier


1
1
4
1

1
1
1
1
1
1







S
1
I
CT


0.000
0.000
0.000
0.000

0.563
0.011
0.006
0.095
0.029
0.000







Material
Cost
$/lb
(DB)


$0.00
$0.00
$0.00
IN/A

$1.65
$1.64
$1.64
$1.64
$1.65
IN/A




T1 or


Labor
Rate
$/Hour
(DB)


$35.51
$35.51
$35.51
IN/A

$42.18
$42.18
$42.18
$42.18
$42.18
IN/A




Burden
Rate
$/Hour
(DB)


$45.00
$15.00
$15.00
IN/A

$100.10
$100.10
$100.10
$100.10
$100.12
IN/A




Applied
Burden
Rate
$/Hour


$45.00
$15.00
$60.00
IN/A

$100.10
$100.10
$100.10
$100.10
$100.12
IN/A




OEM Total Manufacturing Cost:
T1 or OEM Mark-Up Rates:
&T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:



MANUFACTURING COSTS
Material
Cost


$0.00
$0.00
$0.00
IN/A

$0.93
$0.02
$0.01
$0.16
$0.05
IN/A



Material

1. 36
Labor/ Part


$0.45
$0.14
$0.45
IN/A

$0.14
$0.03
$0.03
$0.03
$0.04
IN/A



Labor
$1.46
$1.46
Burden/
Part


$0.29
$0.06
$0.38
IN/A

$0.33
$0.14
$0.14
$0.15
$0.17
IN/A



Burden


IF
$
SL
H
CD


$0.74
$0.20
$0.84
IN/A

$1.40
$0.19
$0.17
$0.33
$0.25
IN/A



TMC


MARK-UP COSTS
End
Item
Scrap
Rate
(DB)


0.00%
0.00%
0.00%
IN/A

0.00%
0.00%
0.00%
0.00%
0.00%
IN/A



Scrap
0.30%

SG&A
Rate
(DB)


0.00%
0.00%
0.00%
IN/A

000%
000%
000%
000%
000%
IN/A



SG&A


Profit
Rate
(DB)


0.00%
0.00%
0.00%
IN/A

0.00%
0.00%
0.00%
0.00%
0.00%
IN/A



Profit
4.00%

ED&T/
R&D
Rate
(DB)


0.00%
0.00%
0.00%
IN/A

0.00%
0.00%
0.00%
0.00%
0.00%
IN/A



ED&T


Total
Mark-
up
Rate


0.00%
0.00%
0.00%
IN/A

0.00%
0.00%
0.00%
0.00%
0.00%
IN/A
Supplier
Account
Cost
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

Total
Mark-up
11.30%

Total
Mark-
up
Cost


$0.00
$0.00
$0.00
IN/A

$0.00
$0.00
$0.00
$0.00
$0.00
IN/A
Price/ Uni
$000
$000
$000
$000
$000
$000
$000
$000
$000
$000
$000
$000
$000
$000



TOTAL COSTS
2.
SL
+ —1
3? ^
I"
-c


$0.74
$0.20
$0.84
IN/A

$1.40
$0.19
$0.17
$0.33
$0.25
IN/A
Purchase
Price Net,
PIA
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

Q
	 >\1
	 *
Packaging Cost:
Net Cost Impact to Vehicle:
SL
si
is-
&
*


$0.74
$0.20
$0.84
$0.00

$1.40
$0.38
$0.70
$0.67
$0.25
$0.00
Purchase
Price Net,
End Item
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
1
S5.18
$5.18



TOOLING &
Tooling Assumptions
"X1000 "











NVESTMENT
Investment Assumptions
"X1000 "










$0

FfeFuel Induction 11032709.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                 Appendix G. 1-11, Sol 12
                                                                                    Form Author: G. Kolwich
                                                                                    (248)373-6000 Ext. 2411

-------
Fuel Rail! 101-GEMA
                                                                                                      Manufacturing Assumption and  Quote Summary
                                                                                                                                                                              APPENDIX G.1-11,(5of7)
                                                                                                                                                                                          Print Date:9/2/2009
                  Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                       Vehicle Class: Compact/Economy 2-1 Pa!
                        Study Case#: B0101(N = New, 01 = Technology Package, 01 = Vehicle Class)
                System Description: 2007 Chrysler GEMA, ULU, 16V DOHC, NA, dWT, 173hp
           Component Description: Fuel Rail Assembly
           Component Quote Level:   I* Full Quote
                                                                                                                      Part Number: 1101-80101-01
r Modification
                           17 Ditterential Quote (Quote Summary includes
                                                                                           OEM Operating Pattern (Weeks/Year):      n
                                                                                                    Annual Engine Volume (CPV):	
                                                                                                         Components per Engine:      1
                                                                                                      Annual Component Volume:    <50,ooo
                                                                                                      Weekly Component Volume:     9,57<
                                                                                                           Estimated Product Life:      10
                                                                                                                                                                                                                              OEM Plant Location: North America
                                                                                                                                                                                                                          Supplier Plant Location: North Americ
                                                                                                                                                                                                                           OEM/T1 Classification:
                                                                                                                                                                                                                                                          	
                                                                                                                                                                                                                                 Shipping Method: FOB Ship Point
                                                                                                                                                                                                                          Packaging Specification: Returnable w. Expendable Separators
GENERAL COMPONENT INFORMATION
1
S

Part Description

Part Number

D
?
CT

GENERAL MANUFACTURING INFORMATION
Primary Process
Description

OEM/Supplier
Classification

Material
Specification

Labor
Classification

Burden
Classification

MANUFACTURING RATES
Finished Pieces Per F
1
Number of Operato

NVESTMENT
Investment Assumpti
"X1000 "
3,
                                      Pallet Options
                                      Option1:48l(122cm)x45l(114cm)x34l(86cm)
                                      Investment $200 US funds (Mike S.)
                                      Assume Plastic Retumables Last 5 Years

                                      OptionZ: Vacuum Form Pack Made from 1/41 HOPE (Approx. Same Pallet size as Option »1.
                                      (Mike S. 020909)
                                      Investment $20K for tool
                                      Piece Prce, Pallet Base $100/Base
                                      Piece Prfce, Tier Pad $40/Pad

                                      Options: Smaller Totes ApproxZO'lSOammlxIZ'ISOOmmlxIZ'ISOOmm)
                                         age: 8 Layers of 6 on single Pallet Base.
                                      Cost per Tote: $75/Tote
                                          per Base $100/Base

                                      Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)
                                      Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)
                                      ABS Vacuum Form Pads 2.5mm Thick for Option »3 Pallets, $5.00
                                      Returnable Dividers For Option 1 Pallet - 8 Cells (2x4)xHeight of Pallet, =$20.00
PACKAGING CALCULATIONS:
Packaging Type: Option #3
Part Size:
Parts/Layer 1X12
Number of Layers 3
Rack/Pallet Investment Amortization


Expendable Packaging in Piece Cost
Packaging Cost Tota

Cost per
Piece


Pises










Total


Pries Per
$0.00


Lump Sum
Payment
(%]
0.00%

P.IWR.ck
0


Total * of
Pieces


Price Per
$0.00


Number of
Months
60


0


Interest
Rate


,*„„
$0.00




Oh
„„„»,*
0


Dost per Pallet /Rack
$4,180
Oh
,*„„
$0.00


tal Number of Pallets/
Racks Required
33
Oh
„„„»,*
0

?
nber of Parts per Pallet/
Rack
1728
Oh
,*„„
$0.00

£
11!
IJ|
6
.,.„.
„„„»,*
0

|
I5i
?
57447




File:Fuel Induction 11032709.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                           AppendixG. 1-11, 9of 12
                                                                                                                                                                                      Form Author: G. Kolwich
                                                                                                                                                                                      (248)373-6000 Ext. 2411

-------
lnjector-1104-GEMA
                                                                                              Manufacturing Assumption and Quote Summary
                                                                                                                                                                 APPENDIXG.1-11(6of7)
                                                                                                                                                                           Print Dale:9/2/2009
                Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                     Vehicle Class: Compact/Economy 2-1 Pa!
                      Study Case#: N0101(N = New, 01 = Technology Package, 01 = Vehicle Class)
               System Description: 2007 Chrysler GEMA, ULU, 16V DOHC, NA, dWT, 173hp
          Component Description: Fuel Injector Assembly- Low Pressure, 4 Hole
          Component Quote Level:   I* Full Quote
                                                                                                            Part Number: 1104-80101-01
r Modilicatio
                         l~~ Differential Quote (Quote Summary includes
                                                                                    OEM Operating Pattern (Weeks/Year):
                                                                                            Annual Engine Volume (CPV):
                                                                                                 Components per Engine:
                                                                                              Annual Component Volume:
                                                                                             Weekly Component Volume:
                                                                                                  Estimated Product Life:
                                                                                                                                                                                                            OEM Plant Location: North America
                                                                                                                                                                                                         Supplier Plant Location: North Americ
                                                                                                                                                                                                          OEM/T1 Classification:
                                                                                                                                                                                                                                      	
                                                                                                                                                                                                               Shipping Method: FOB Ship Point
                                                                                                                                                                                                        Packaging Specification: Returnable w. Expendable Separators
GENERAL COMPONENT INFORMATION
1
3

Tie
1A
2A
3A
4A
5A
Pu
1A
2A
3A
4A
5A
7A
9A
10A
10B
11A
Part Description

1 Supplier or OEM Processing
Injector Needle Assembly
Needle Body Assembly
Solenoid Body1 Overmold
Final Assembly
chase Part - High Impact Item
Tube Inlet
Inlet Sleeve Adaptor Stamped
Body, Needle
Needle Valve
Bracket Injector Hold down
Injector Tip Housing
Plate -Injector Tip
Plate -Injector Tip
Tip Relief Plate
Part Number

& Assembly (Full Cos
104-B01 01 -01-80
104-B01 01 -01-70
104-B01 01 -01-71
104-B01 01 -01-72
104-B01 01 -01-73
Full Cost Mapping)
104-B01 01 -01-50
104-B01 01 -01-28
104-B01 01 -01-09
104-B01 01 -01-51
104-B01 01 -01-24
104-B01 01 -01-52
104-B01 01 -01-02-01
104-B01 01 -01-02
1104-N01 01 -01-08
1104-N01 01 -01-08-02
1104-N01 01 -01-08-01
1104-B01 01 -01-70
Purchase Part - Commodity ( Value taken from Purchas
1A
2A
3A
4A
5A
7A
10A



Screen, Fuel Inlet
Ball Needle Seat
Solenoid Winding Assembly
0-Ring Injector to Rail Seal
0-Ring Injector to Head
Injector SlipWasher



1104-B01 01 -01-25
1104-B01 01 -01-06
1104-B0101-01-17
104-B01 01 -01-23
104-B01 01 -01-12
104-N01 01 -01-22
104-B01 01 -01-61
104-B01 01 -01-62
104-B01 01 -01-63
104-B01 01 -01-64



D
?
S.

tma
1
1
1
1
1

1
1
1
1
1
1
1
1
1
1
1
1
GENERAL MANUFACTURING INFORMATION
Primary Process
Description

pping)
Assemble Injector Tip
Assemble Injector Needle
Oerm old Solenoid Body

Machine
Stamped
Machine
Machine
Stamped
Stamped'Forged
Machine
Stamp
Heat Treat & Plate
Machine
.aser Injector Holes
; Part Database)
1
1
1
1
1





(Used Pricing from Mini
Injector)





OEM/Supplier
Classification


T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.

T2/T3 CNC Turning, MSMC
T2/T3 Stamp/Form, SSLC
T2/T3 CNC Turning, MSMC
T2/T3 CNC Turning, MSMC
T2/T3 Stamp/Form, SSLC
T2/T3 CNC Turning, MSMC
T2/T3 Stamp/Form, SSLC
T2/T3 Heat Treat, SSLC
T2/T3 CNC Turning, MSMC
T2/T3 CNC Turning, MSMC
T2/T3 CNC Turning, MSMC


S
S
S
S





Material
Specification


Not Applicable
Not Applicable
Not Applicable
*/lon66-40FMR, Inject.
Not Applicable

A-Steel-41XXS, Bar
A-Steel-41XXS, Bar
A-Steel-41XXS, Bar
SPR-Steel, Coil
A-Steel-41XXS, Bar
Not Applicable



Labor
Classification


Eectromechanica, Assembly

CNC Operator
CNC Operator
CNC Operator
Cut/PunclVForming Operator
CNC Operator
Cut/Punch/Forming Operator
Plating/Coating Operator
CNC Operator
Cut/Punch/Forming Operator
CNC Operator



Burden
Classification


Mech Assembly, MC, Base
Mech Assembly, MC, Base
Mech Assembly, MC, Base
Mech Assembly, HC, Base
Mech Assembly, HC, Base

CNC Turning, LC
Stamp/Form, SMS, MHC
S-CNC Turning, LC
S-CNC Turning, LC
Stamp/Form, SMS, LMC
Stamp/Form, SMS, LMC
S-CNC Turning, LC
Stamp/Form, SMS, LMC
Plate/Finish, SMS, LMC
S-CNC Turning, MC
CNC Milling, LMC



MANUFACTURING RATES
Finished Pieces Per Hour


1800
430
430
450
480

471
1200
450
465
720
600
643
1800
1800
450
3600
3600
2057


'Syndicates Componen is Supplied directly to T1 or OEM for Final or Sub-
Assembly.
'SAC'=(Supplier Accounted Costs) Indicates Component is Supplied directly to
T1 or OEM for Final or Sub-Assembly. In addition component material cost is
accounted for in T1 quote sheet. Thus component cost will only be included for
Mark-up Calculations.
'Alpha-Numeric Charac er1 = Indicates purchase parts are brought in by T2/T3
Supplier for Subassembly.
























Number of Operators


0.5
0.5
2
2
2

2
0.5
1
0.5
0.5
0.5
0.25
0.5
1
0.25
0.25
0.25







Number of Lines


1
2
2
2
2

5.5
1
4
1
1
2.5
1
1
4.5
1
1
1







Parallel Processing
Multiplier


4
7
1
6

1
1
1
1
1
1
1
1
1
1
1
1
1







S
1
I
CT


0.000
0.000
0.000
0.030
0.000

0.035
0.023
0.049
0.043
0.005
0.005
0.021
0.001
0.003
0.000
0.000
0.000







Material
Cost
$/lb
(DB)


$0.00
$0.00
$0.00
$1.54
$0.00

$0.78
$0.78
$0.78
$0.78
$0.78
$0.78
$0.78
$0.65
$15.00
$0.78
$0.78
$0.00
$0.78




T1 or


Labor
Rate
$/Hour
(DB)


$35.51
$35.51
$35.51
$37.35
$35.51

$35.70
$42.18
$35.70
$35.70
$42.18
$42.18
$35.70
$42.18
$55.17
$35.70
$42.18
$35.70
$42.18




Burden
Rate
$/Hour
(DB)


$30.00
$30.00
$30.00
$45.00
$45.00

$25.00
$125.10
$35.00
$35.00
$100.10
$100.10
$35.00
$100.10
$100.17
$55.00
$100.10
$125.15
$100.10




Applied
Burden
Rate
$/Hour


$120.00
$180.00
$420.00
$90.00
$540.00

$137.50
$125.10
$140.00
$140.00
$100.10
$100.10
$87.50
$100.10
$100.17
$247.50
$100.10
$125.15
$100.10




OEM Total Manufacturing Cost:
T1 or OEM Mark-Up Rates:
&T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:



MANUFACTURING COSTS
Material
Cost


$0.00
$0.00
$0.00
$0.05
$0.00

$0.03
$0.01
$0.02
$0.04
$0.03
$0.00
$0.00
$0.01
$0.02
$0.00
$0.00
$0.00
$0.00



Material

1. 03
Labor/ Part


$0.01
$0.04
$0.15
$0.17
$0.15

$0.15
$0.02
$0.08
$0.08
$0.03
$0.04
$0.03
$0.01
$0.02
$0.08
$0.00
$0.00
$0.01



Labor
$1.04
$1.04
Burden/
Part


$0.07
$0.38
$0.88
$0.20
$1.13

$0.29
$0.10
$0.31
$0.30
$0.14
$0.17
$0.14
$0.06
$0.06
$0.55
$0.03
$0.03
$0.05



Burden


IF
n
SL
H
CO


$0.08
$0.41
$1.02
$0.41
$1.27

$0.47
$0.13
$0.41
$0.42
$0.20
$0.21
$0.17
$0.07
$0.09
$0.63
$0.03
$0.04
$0.05



TMC


MARK-UP COSTS
End
Item
Scrap
Rate
(DB)


0.00%
0.00%
0.00%
0.00%
0.00%

0.50%
0.30%
0.50%
0.50%
0.30%
0.30%
0.50%
0.30%
0.30%
0.50%
0.50%
0.50%
0.30%



Scrap
$0.05

SG&A
Rate
(DB)


0.00%
0.00%
0.00%
0.00%
0.00%

6.50%
6.00%
6.50%
6.50%
600%
600%
6.50%
600%
6.00%
6.50%
650%
6.50%
600%



SG&A


Profit
Rate
(DB)


0.00%
0.00%
0.00%
000%
0.00%

6.00%
4.00%
6.00%
6.00%
4.00%
4.00%
600%
4.00%
4.00%
6.00%
6.00%
6.00%
4.00%



Profit


ED&T/
R&D
Rate
(DB)


0.00%
0.00%
0.00%
0.00%
0.00%

1.00%
0.00%
1.00%
1 .00%
0.00%
0.00%
1.00%
0.00%
0.00%
1 .00%
1.00%
1 .00%



ED&T


Total
Mark-
up
Rate


0.00%
0.00%
0.00%
0.00%
0.00%

14.00%
10.30%
14.00%
14.00%
10.30%
10.30%
14.00%
10.30%
10.30%
14.00%
14.00%
14.00%
Supplier
Cost
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

Total
Mark-up
19.70%

Total
Mark-
up
Cost


$0.00
$0.00
$0.00
$0.00
$0.00

$0.07
$0.01
$0.06
$0.06
$0.02
$0.02
$0.02
$0.01
$0.01
$0.09
$0.00
$0.01
$0.01
Purchase
Price/ Uni
$0.01
$0.05
$0.02
$0.41
$0.03
$0.15
$0.09
$0.05
$0.02
$0.01



TOTAL COSTS
2.
SL
+ —i
3? M
I"
-c


$0.08
$0.41
$1.02
$0.41
$1.27

$0.54
$0.14
$0.47
$0.47
$0.22
$0.23
$0.19
$0.08
$0.09
$0.72
$0.04
$0.04
$0.06
Purchase
Price Net,
PIA
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

Q
	 m
	 *
Packaging Cost:
Net Cost Impact to Vehicle:
SL
si
is-
S
*


$0.08
$0.41
$1.02
$0.41
$1.27

$0.54
$0.14
$0.47
$0.47
$0.22
$0.23
$0.19
$0.08
$0.09
$0.72
$0.04
$0.04
$0.06
Purchase
Price Net,
End Item
$0.01
$0.05
$0.02
$0.41
$0.03
$0.15
$0.09
$0.05
$0.02
$0.01
I
I
$7.31
$7.31

$0.01
	
TOOLING &
Tooling Assumptions
"X1000 "










$0
NVESTMENT
Investment Assumptions
"X1000 "










$0

FfeFuel Induction 11032709.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                Appendix G.1-11,10of 12
                                                                                                                                                                        Form Author: G. Kolwich
                                                                                                                                                                        (248)373-6000 Ext. 2411

-------
lnjector-1104-GEMA
                                                                                               Manufacturing Assumption and Quote Summary
                                                                                                                                                                  APPENDIXG.1-11(6of7)
                                                                                                                                                                            Print Date:9/2/2009
                 Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                     Vehicle Class: Compact/Economy 2-1 Pa!
                      Study Case#: N0101(N = New, 01 = Technology Package, 01 = Vehicle Class)
               System Description: 2007 Chrysler GEMA, ULU, 16V DOHC, NA, dWT, 173hp
          Component Description: Fuel Injector Assembly- Low Pressure, 4 Hole
          Component Quote Level:   I* Full Quote
                                                                                                             Part Number: 1104-80101-01
r Modilicatio
                         l~~ Differential Quote (Quote Summary includes
                                                                                    OEM Operating Pattern (Weeks/Year):
                                                                                            Annual Engine Volume (CPV):
                                                                                                  Components per Engine:
                                                                                              Annual Component Volume:
                                                                                              Weekly Component Volume:
                                                                                                   Estimated  Product Life:
                                                                                                                                                                                                              OEM Plant Location: North America
Supplier Plant Location: North Americ
 OEM/T1 Classification:
                                                                                                                                                                                                                                            _
                                                                                                                                                                                                                                        Assembly Complexity
                                                                                                                                                                                                                 Shipping Method: FOB Ship Point
                                                                                                                                                                                                          Packaging Specification: Returnable w. Expendable Separators
GENERAL COMPONENT INFORMATION
1
S

Part Description

Part Number

D
?
CT

GENERAL MANUFACTURING INFORMATION
Primary Process
Description

OEM/Supplier
Classification

Material
Specification

Labor
Classification

Burden
Classification

MANUFACTURING RATES
Finished Pieces Per F
1
Number of Operato

NVESTMENT
Investment Assumpti
"X1000 "
3,
PACKAGING CALCULATIONS:
Packaging Type: Option #3 Tote
Part Size: 90x55x25 mm
Parts/Layer 3x8
Number of Layers: 9
Rack/Pallet Investment Amortization:


Expendable Packaging in Piece Cost:
Packaging Cost Total:

Cost per
Piece


Pises










Total


Pries Per
$0.00


Lump Sum
Payment
(%]
0.00%

P.lk*R.ck
0


Total * of
Pieces


Price Per
$0.00


Number of
Months
60


0


Interest
Rate


,*„„
$0.00




Oh
„„„»,*
0


a
i
s
I
$4,420
Oh
,*„„
$0.00

_,
tal Number of Pallets/
Racks Required
22
Oh
„„„»,*
0

?
her of Parts per Pallet
Rack
10368
Oh
,*„„
$0.00


II!
IJ|
6
.,.„.
„„„»,*
0

|
I5i
?





File:Fuel Induction 11032709.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                 Appendix G.1-11,11 of 12
                                                                                                                                                                         Form Author: G. Kolwich
                                                                                                                                                                         (248)373-6000 Ext. 2411

-------
Engine Assembly-1100 R5
                                                                                              Manufacturing Assumption and  Quote Summary
                                                                            APPENDIX G.1-11,(7of7)
                                                                                       Print Dale:9/2/2009
                Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                     Vehicle Class: Compact/Economy 2-1 Passenger
OEM Operating Pattern (Weeks/Year):
                                                                                                                                                                                                            OEM Plant Location: North America
                      Study Case#: N0101(N = New, 01 = Technology Package, 01 = Vehicle Class)
               System Description: 2007 Mini Cooper s. 1.6L n, 16V DOHC GDI Turbo
        Annual Engine Volume (CPV):    <50,ooo
             Components per Engine: _
                                                                                                                                                                                                         Supplier Plant Location: North America
          Component Description: OEM Assembly of Fuel Induction Components to Engim
                                                                                                             Part Number: 1100
          Component Quote Level:   r Full Quote
                                                           r Modification
                                                                                      Ditterential Quote (Quote Summary includes
          Annual Component Volume:    <50,ooo
          Weekly Component Volume:     9,57<
               Estimated Product Life:
 OEM/T1 Classification: OEM Engine Assembly
       Shipping Method: FOB Ship Point
Packaging Specification:_NA	
                                                                                                                                                                                         10
GENERAL COMPONENT INFORMATION
1
3

Tie
1A

Part Description

1 Supplier or OEM Processing
Fuel Rail -High Pressure
Pipe Assembly -Fuel, High Pressure, Pumpto
Part Number

& Assembly (Full Cos
101-N0101-02
107-N0101-01
D
?
S.

tma
1
4
1
GENERAL MANUFACTURING INFORMATION
Primary Process
Description

pping)
Install Fuel Rail to Cylinder
Head (Two Additional
Fasteners Over Base GEMA
Engine)
In stallFuel Injectors to
Cylinder Head, Considered
Wash to Base Engine
Head, 3 Fasteners
Run Down Two Tube Nuts
Purchase Part - Commodity ( Value taken from Purchase Part Database)
1A
3A
4A
5A
7A
8A



Fuel Rail - High Pressure (w. HP Sensor)
Pipe Assembly - Fuel, High Pressure, Pumpto
Fuel Rail Assembly
Fuel Injector Assembly - Low Pressure, 4 Hole
Bolt -Fuel Pump (to head)
Bolt -Fuel Rail (to head)



1101-N0101-02
1107-N0101-01
170-N0101-01
101-B0101-01
104-B0101-01
180-N0101-02



1
4
1
1
0
4
0
3
2





;Mini Cooper)
(Mini Cooper)
(Mini Cooper)
(Mini Cooper)
Chrysler GEMA
Chrysler GEMA





OEM/Supplier
Classification


OEM Assembly, Mark-up
Applied ©Bottom.
OEM Assembly, Mark-up
Applied © Bottom.
OEM Assembly, Mark-up
Applied ©Bottom.
OEM Assembly, Mark-up
Applied © Bottom.

SAC
SAC
SAC





Material
Specification


Not Applicable
Not Applicable
Not Applicable
Not Applicable


Labor
Classification


General Assembly-OEM
Not Applicable
General Assembly-OEM
General Assembly-OEM


Burden
Classification


Engine Assembly, OEM
Not Applicable
Engine Assembly, OEM
Engine Assembly, OEM


MANUFACTURING RATES
Finished Pieces Per Hour


257
451
171
257


•Syndicates Component is Supplied directly to T1 or OEM for Final or Sub-
Assembly.
'SAC'=(Supplier Accounted Costs) Indicates Component is Supplied directly to
T1 or OEM for Final or Sub-Assembly. In addition component material cost is
accounted for in T1 quote sheet. Thus component cost will only be included for
Mark-up Calculations.
'Alpha -Numeric Character1 = Indicates purchase parts are brought in by T2T3
Supplier for Subassembly.

























Number of Operators


1
1







Number of Lines


1
1
1
1







Parallel Processing
Multiplier


1
1
1
1







s
1
I
CT


0.000
0.000
0.000
0.000








PACKAGING CALCULATIONS:
No Packaging Considera ions Required.
Packaging Type:
Part Size:
Parts/Layer
Number of Layers:
Rack/Pallet Investment Amortization:
Expendable Packaging in Piece Cost:
Packaging CostTota :
Materia
Cost
$/lb
(DB)


$0.00
$0.00
$0.00
$0.00




T1 or



Piece

csr
$0.00
Labor
Rate
$/Hour
(DB)


$83.31
$0.00
$83.31
$83.31




Burden
Rate
$/Hour
(DB)


$150.21
$0.00
$150.21
$150.21




Applied
Burden
Rate
$/Hour


$150.21
$0.00
$150.21
$150.21




OEM Total Manufacturing Cost:
T1 or OEM Mark-Up Rates:
&T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:








--
$0
;;-x
$0.00


Lump Sum
Payment
(%]

rBtk

MANUFACTURING COSTS
Materia
Cost


$0.00
$0.00
$0.00
$0.00



Material
(103.99)
$0.15
Labor/ Part


$0.32
$0.49
$0.32



Labor
$1.13
$1.13
Burden/
Part


$0.58
$0.00
$0.88
$0.58



Burden


IF
$
SL
H
CD


$0.91
$0.00
$1.36
$0.91



TMC


MARK-UP COSTS
End
Item
Scrap
Rate
(DB)


0.00%
0.00%
0.00%
0.00%



Scrap
$0.00

SG&A
Rate
(DB)


0.00%
0.00%
0.00%
0.00%



SG&A
0.00%
$0.00

Profit
Rate
(DB)


0.00%
0.00%
0.00%
0.00%



Profit
$0.00

ED&T/
R&D
Rate
(DB)


0.00%
0.00%
0.00%
0.00%



ED&T
0.00%
$0.00

Tola
Mark-
up
Rate


0.00%
0.00%
0.00%
0.00%
Supplier
Account
Cost
$20.76
$52.50
$69.61
$2.01
$0.00
($5.83)
($35.07)
$0.00
$0.00
$0.00

Total
Mark-up
$0.00

Total
Mark-
up
Cost


$0.00
$0.00
$0.00
$0.00
Price/ Uni
$20.76
$13.13
$69.61
$2.01
($5.83)
($8.77)
$0.00
$0.03
$0.03



TOTAL COSTS
2.
SL
+ —i
3? M
I"
-c


$0.91
$0.00
$1.36
$0.91
Price Net,
PIA
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

Q
	 m
	 >
Packaging Cost:
Net Cost Impact to Vehicle:

Total * of
Pieces

"S*
$0.00
Numberof
Months
60
D;:;ss

Interest
Rate

Other #1
Packaging
$0.00


Others

8
1
I
$0
Other*!
Packaging
$0.00
Total Numberof Pallets/
Racks Required
57447
Other*!

Number of Parts per Pallet
Rack
1
Other #3
$0.00
Supplier, Customerand In-
transit Inventory
Requirements [Weeks]
6
Other *3

transit Inventory
Requirements (Parts)



$0.000
SL
si
is-
&
*


$0.91
$0.00
$1.36
$0.91
Price Net,
End Item
$20.76
$52.50
$2.01
$0.00
-$5.83
-$35.07
$0.00
$0.09
$0.06
I

$107.31
$107.31



TOOLING &
Tooling Assumptions
"X1000 "








$0
NVESTMENT
Investment Assumptions
"X1000 "








$0


FfeFuel Induction 11032709.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                 Appendix G.1-11,12of 12
                                                                                    Form Author: G. Kolwich
                                                                                    (248)373-6000 Ext. 2411

-------
                   Appendix G.1 - Subsystem 12
                        Exhaust Subsystem
                         Case Study #0101
                         MAQS Worksheets
FfeExhaust Subsystem 12 033009.xls
EPA ConlractEP-C-07-069 WA1-3                          Appendix G.1-12,1 ol 6

-------
Manifold Exhaust 1201
                                                                                             Manufacturing Assumption and  Quote Summary
                Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                     Vehicle Class: Compact/Economy 2-1 Pa!
                      Study Case#: N0101(N = New, 01 = Technology Package, 01 = Vehicle Class)
               System Description: 2007 Mini Cooper s. 1.6L n, 16V DOHC GDI Turbo
          Component Description: Manifold - Exhaust, Dual Wall
          Component Quote Level:   l~ Full Quote
                                                                                                            Part Number: 201-N0101-01
r Modilicatio
                         17 Differential Quote (Quote Summary includes
                                                                                    OEM Operating Pattern (Weeks/Year):
                                                                                            Annual Engine Volume (CPV):
                                                                                                 Components per Engine: _
                                                                                              Annual Component Volume: _
                                                                                              Weekly Component Volume:
                                                                                                  Estimated Product Life:
                                                                                                                                                                APPENDIX G.1-12(1of4)
                                                                                                                                                                          Print Date:9/2/2009

                                                                                                                                                 OEM Plant Location: North America
                                                                                                                                                                                                         Supplier Plant Location: North America
 OEM/T1 Classification: T1 Moderate Assembly Complexity
       Shipping Method: FOB Ship Point	
Packaging Specification:	
GENERAL COMPONENT INFORMATION
1
£

Tie
1A
1C
2A
Part Description

1 Supplier or OEM Processing
Manifold - Exhaust, Dual Wall (Mini)
Manifold - Exhaust, Dual Wall (Mini)
Manifold - Exhaust, Dual Wall (Mini)
Manifold - Exhaust, (Chrysler)
Manifold - Exhaust, Dual Wall (Chrysler)
Manifold - Exhaust, Dual Wall (Chrysler)
Part Number

& Assembly (Full Cos
201-N01 01 -01-02
201-N01 01 -01-01
201-N0101-01
201-B010 -01-02
201-B010 -01-01
201-B010 -01
Casting & Machining Assumptions:
Casting: Assumption processing time
increase due to part complexity and material
grade is offset by reduction in material
volume.
Machining: 50% premium paid on
machining NiResist material over base
nodular cast iron.


Purchase Part - Commodity ( Value taken from Purchas












D
?
CT

tma
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
GENERAL MANUFACTURING INFORMATION
Primary Process
Description

pping)
Heat Treat, Pre Machine
Machining
Heat Treat, Pre Machine
Machining
; Part Database)
0
0
0
0
0
0
0
0
0
0
0
0
0
0











OEM/Supplier
Classification


T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.







Material
Specification


iResist Iron, D5S, Cast
ot Applicable
ot Applicable
odularlron, Cast
ot Applicable
ot Applicable


Labor
Classification


Mold/Cast/Sinter Operator
MoloyCast/Sinter Operator
MoloyCast/Sinter Operator
MoloyCast/Sinter Operator


Burden
Classification


Sand Cast, HMC
Heat Treat, MLS, MHC
CMC Machining, MHC
Sand Cast, HMC
Heat Treat, MLS, MHC
CMC Machining, MHC


MANUFACTURING RATES
Finished Pieces Per Hour


141
129
120
-145
-125
-120


•Syndicates Componen is Supplied directly to T1 or OEM for Final or Sub-
Assembly.
'SAC'=(Supplier Accounted Costs) Indicates Component is Supplied directly to
T1 or OEM for Final or Sub-Assembly. In addition component material cost is
accounted for in T1 quote sheet. Thus component cost will only be included for
Mark-up Calculations.
'Alpha-Numeric Charac er1 = Indicates purchase parts are brought in by T2/T3
Supplier for Subassembly.
























Number of Operators


6
1
3
6
1
3
0
0
0
0
0
0
0
0
0
0
0







Number of Lines


1.5
1.5
2.5







Parallel Processing
Multiplier


2
1
1.5
1
1
1







S
1
|
CT


7.760
0.000
0.000
-12.920
0.000
0.000







Material
Cost
$/lb
(DB)


$3.50
$0.00
$0.00
$0.35
$0.00
$0.00
SN/A
SN/A
SN/A
SN/A
SN/A





T1 or


Labor
Rate
$/Hour
(DB)


$43.52
$46.52
$43.52
$43.52
$46.52
$43.52
N/A
N/A
N/A
N/A
N/A





Burden
Rate
$/Hour
(DB)


$150.07
$250.00
$45.00
$150.07
$250.00
$45.00
HI
HI
HI
HI
HI





Applied
Burden
Rate
$/Hour


$450.21
$750.00
$202.50
$225.11
$625.00
$135.00
SN/A
SN/A
SN/A
SN/A
SN/A





OEM Total Manufacturing Cost:
T1 or OEM Mark-Up Rates:
&T1 or OEM Mark-Up Values:
Base Cost mpact to Vehicle:



MANUFACTURING COSTS
Material
Cost


$27.16
$0.00
$0.00
-$4.52
$0.00
$0.00
SN/A
SN/A
SN/A
SN/A
SN/A




Material

2.64
Labor/ Part


$1.85
$0.36
$1.09
-$1.81
-$0.37
-$1.09
HI
HI
HI
HI
HI




Labor
$0.03

Burden/
Part


$3.19
$5.83
$1.69
-$1.56
-$5.00
-$1.13
N/A
N/A
N/A
N/A
N/A




Burden


IF
$
SL
H
CD


$32.20
$6.20
$2.78
-$7.89
-$5.37
-$2.21
SN/A
SN/A
SN/A
SN/A
SN/A




TMC


MARK-UP COSTS
End
Item
Scrap
Rate
(DB)


10.00%
0.00%
0.00%
5.00%
0.00%
0.00%
N/A
N/A
N/A
N/A
N/A




Scrap
0.50%
$0.14

SG&A
Rate
(DB)


0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
SN/A
SN/A
SN/A
SN/A
SN/A




SG&A
$1.85

Profit
Rate
(DB)


0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
N/A
N/A
N/A
N/A
N/A




Profit
$1.71

ED&T/
R&D
Rate
(DB)


0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
SN/A
SN/A
SN/A
SN/A
SN/A




ED&T
$0.71

Total
Mark-
up
Rate


10.00%
0.00%
0.00%
5.00%
0.00%
0.00%
N/A
N/A
N/A
N/A
N/A

Supplier
Cost
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

Total
Mark-up
$4.42

Total
Mark-
up
Cost


$3.22
$0.00
$0.00
-$0.39
$0.00
$0.00
SN/A
SN/A
SN/A
SN/A
SN/A

Purchase
Price/ Uni
$000
$000
$000
$000
$000
$000
$000
$000
$000
$000
$000
$000
$000
$000



TOTAL COSTS
2.
SL
+ —1
3? ^
I '
-c


$35.42
$6.20
$2.78
-$8.28
-$5.37
-$2.21
HI
HI
HI
HI
HI

Purchase
Price Net,
PIA
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

Q
	 m
	 *
Packaging Cost:
Net Cost Impact to Vehicle:
SL
si
is-
s
*


$35.42
$6.20
$2.78
-$8.28
-$5.37
-$2.21
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
Purchase
Price Net,
End Item
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
I
I
$28.52


-$0.12

TOOLING &
Tooling Assumptions
"X1000 "








$0
NVESTMENT
Investment Assumptions
"X1000 "








$0

FfeExhaust Subsystem 12 033009.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                 Appendix G.1-12,2of6
                                                                                                                                                                       Form Author: G. Kolwich
                                                                                                                                                                       (248)373-6000 Ext. 2411

-------
Manifold Exhaust 1201
                                                                                               Manufacturing Assumption and Quote Summary
                 Technology Level:  Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                     Vehicle Class: Compact/Economy 2-1 Pa!
                      Study Case#: N0101(N = New, 01 = Technology Package, 01 = Vehicle Class)
               System Description: 2007 Mini Cooper s. 1.6L n, 16V DOHC GDI Turbo
           Component Description: Manifold - Exhaust, Dual Wall
          Component Quote Level:   l~ Full Quote
                                                                                                              Part Number:  201-N0101-01
r Modilicatio
                         17 Ditterential Quote (Quote Summary includes
                                                                                      OEM Operating Pattern (Weeks/Year):
                                                                                              Annual Engine Volume (CPV):
                                                                                                   Components per Engine:
                                                                                                Annual Component Volume:
                                                                                               Weekly Component Volume:
                                                                                                    Estimated Product Life:
                                                                                                                                                                   APPENDIX G.1-12(1of4)
                                                                                                                                                                              Print Date:9/2/2009

                                                                                                                                                    OEM Plant Location: North America
                                                                                                                                                                                                             Supplier Plant Location: North America
 OEM/T1 Classification: T1 Moderate Assembly Complexity
       Shipping Method: FOB Ship Point	
Packaging Specification:	
GENERAL COMPONENT INFORMATION
1
S

Part Description

Part Number

D
?
CT

GENERAL MANUFACTURING INFORMATION
Primary Process
Description

OEM/Supplier
Classification

Material
Specification

Labor
Classification

Burden
Classification

MANUFACTURING RATES
Finished Pieces Per F
1
Number of Operato

NVESTMENT
Investment Assumpti
"X1000 "
z
                                                                     PACKAGING CALCULATIONS:  GEMA
                                                               Packaging Type: Option »2
                                                               Part Size: 380x280x130
                                                               Parts/Layer: 3x4
                                                               Numberof Layers: 6
                                                               Cost = $0.076/Part
PACKAGING CALCULATIONS: MINI
Packaging Type: Option #2
Part Size:320x1 20X115
Parts/Layer: 3x10
Number of Layers: 7
Cost $0.03/Part

Rack/Pallet Investment Amortization:
Expendable Packaging in Piece Cost:
Packaging Cost Total:
Cost per
Piece

csr
$0.00




Total

s:
$0.00
Lump Sum
Payment
(%]
0.00%

P.lk*R.ck
0
Total * of
Pieces


Price Per
$0.00
Number of
Months
60


0
Interest
Rate


,*„„
$0.00


Oh
„„„»,*
0
Cost per Pallet /Rack
$380
I Total Numberof Pallets/
Racks Required
798
I Number of Parts per Pallet/
Rack
72

$0.00 | 0 | $0.00

II!
IJ|
6
0
ill
I5i
?
57447

$0.152
File:Exhaust Subsystem 12 033009.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                   Appendix G.1-12,3of6
                                                                                                                                                                          Form Author: G. Kolwich
                                                                                                                                                                          (248)373-6000 Ext. 2411

-------
Exh. Brk)'s-HealShieHs1275
                                                                                               Manufacturing Assumption and  Quote Summary
                 Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/Compact Vehicle Clas
                     Vehicle Class: Compact/Economy 2-4 Passenger
OEM Operating Pattern (Weeks/Year):_
                                                                             APPENDIX G.1-12,(2of4)
                                                                                        Print Date:9/2/2009

                                                              OEM Plant Location: North America
                      Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class)
               System Description: 2007 Mini Cooper s. 1.6L n, 16V DOHC GDI Turbo
        Annual Engine Volume (CPV):    «o,ooo
             Components per Engine:^     1
                                                                                                                                                                                                            Supplier Plant Location: North America
           Component Description: Bracket Subassembly- Heat Shield, Top, Turbo
                                                                                                              Part Number: 1275-N0101-02
          Component Quote Level:   l~ Full Quote
                                                            F Modification
                                                                                     H? Differential Quote (Quote Summary includes
          Annual Component Volume:    «o,ooo
          Weekly Component Volume:     9,57<
               Estimated Product Life:      10
OEM/T1  Classification: T1 Low Assembly Complexity
     Shipping Method: FOB Ship Point
                                                                                                                                                                                                           Packaging Specification: (Included in piece c
GENERAL COMPONENT INFORMATION
1
3

Tie




Part Description

1 Supplier or OEM Processing
Bracket Subassembly- Heal Shield, Top, Turbo



Part Number

& Assembly (Full Cos
1275-N0101-02



D
?
S.

tma
1
*





GENERAL MANUFACTURING INFORMATION
Primary Process
Description

oping)
sssrrr™





OEM/Supplier
Classification


© Bottom.





Material
Specification


Fibertrax440





Labor
Classification


G,n,,,IA«mbl»





Burden
Classification


Mech Assembly, MC, Base





MANUFACTURING RATES
Finished Pieces Per Hour


450
ma





Number of Operators


1





Number of Lines


1
1





TJ
S!
fl
If

-------
Exhaust Sealing 1285
                                                                                              Manufacturing Assumption and  Quote Summary
                                                                                                                                                                 APPENDIX G.1-12,(3of4)
                                                                                                                                                                            Print Date:9/2/2009
                 Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                     Vehicle Class: Compact/Economy 2-1 Pa!
                      Study Case#: N0101(N = New, 01 = Technology Package, 01 = Vehicle Class)
               System Description: 2007 Mini Cooper s. 1.6L n, 16V DOHC GDI Turbo
          Component Description: Bracket Subassembly- Exhaust Manifold w. Integrated Gasket
          Component Quote Level:   r Full Quote
                                                                                                             Part Number: 1275-N0101-01
r Modilicatio
                                                                                      Ditterential Quote (Quote Summary includes
                                                                                    OEM Operating Pattern (Weeks/Year):
                                                                                            Annual Engine Volume (CPV):
                                                                                                 Components per Engine: _
                                                                                              Annual Component Volume:_
                                                                                              Weekly Component Volume:
                                                                                                   Estimated Product Life:
                                                                                                                                                                                                             OEM Plant Location: North America
                                                                                                                                                                                                          Supplier Plant Location: North America	
                                                                                                                                                                                                           OEM/T1 Classification: T1 Low Assembly Complexity
                                                                                                                                                                                                                Shipping Method: FOB Ship Point
                                                                                                                                                                                                         Packaging Specification:
GENERAL COMPONENT INFORMATION
1
£

Part Description

Part Number

D
?
CT

GENERAL MANUFACTURING INFORMATION
Primary Process
Description

Purchase Part - Commodity ( Value taken from Purchase Part Database)
1A



Bracket Subassembly - Exhaust Manifold w.
Integrated Gasket



1275-N0101-01



1
0
0
0
0
0
0





Jpgrade from 2 to 3 layer
sxhaust gasket. Only





OEM/Supplier
Classification


s





Material
Specification



Labor
Classification



Burden
Classification



MANUFACTURING RATES
Finished Pieces Per Hour



'Syndicates Componen is Supplied directly to T1 or OEM for Final or Sub-
Assembly.
'SAC'=(Supplier Accounted Costs) Indicates Component is Supplied directly to
T1 or OEM for Final or Sub-Assembly. In addition component material cost is
accounted for in T1 quote sheet. Thus component cost will only be included for
Mark-up Calculations.
'Alpha-Numeric Charac er1 = Indicates purchase parts are brought in by T2/T3
Supplier for Subassembly.
























Number of Operators








Number of Lines








Parallel Processing
Multiplier








s
1
I
CT








Material
Cost
$/lb
(DB)





T1 or


Labor
Rate
$/Hour
(DB)





Burden
Rate
$/Hour
(DB)





Applied
Burden
Rate
$/Hour





OEM Total Manufacturing Cost:
T1 or OEM Mark-Up Rates:
&T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:



MANUFACTURING COSTS
Material
Cost




Material
0.00
1.95
Labor/ Part




Labor
$0.00

Burden/
Part




Burden


IF
$
SL
H
CD








MARK-UP COSTS
End
Item
Scrap
Rate
(DB)









SG&A
Rate
(DB)






$0.00
0.00%


Profit
Rate
(DB)









ED&T/
R&D
Rate
(DB)






$0.00
0.00%


Total
Mark-
up
Rate

Supplier
Account
Cost
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

Total
Mark-up
$0.00

Total
Mark-
up
Cost

Price/ Uni
$0.95
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00



TOTAL COSTS
°.
°L
+ —i
3? ^
I"
•c

Purchase
Price Net,
PIA
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

Q
	 ^u
	 *•
Packaging Cost:
Net Cost Impact to Vehicle:
SL
si
is-
s
*

Purchase
Price Net,
End Item
$0.95
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
1
$0.95
$0.95



TOOLING &
Tooling Assumptions
"X1000 "






$0
NVESTMENT
Investment Assumptions
"X1000 "








PACKAGING CALCULATIONS:
Packaging Type:
Part Size:
Parts/Layer
Number of Layers:
Rack/Pallet Investment Amortization
Expendable Packaging in Piece Cost
Packaging CostTota
Piece

csr





£L
$0
;;-x
$0.00
Lump Sum
Payment
(%]

Si
0
Total * of
Pieces

Divider Pads,
$0.00
Number of
Months
60
D;:;ss
0
Interest
Rate

S
$0.00


„;,«,*
0
CostperPallet/Rack
$0
Ss
$0.00
I Total Number of Pallets/
Racte Required
57447
„;,«,*
0
I Number of Parts per Pallet/
«
1
P,±t'
$0.00
I Supplier,Customerand In-
transit Inventory
Requirements (Wee Is]
6
„;,«,*
0
I Supplier,Customerand In-
transit Inventory
Requirements [Parts]



$0.000
FfeExhaust Subsystem 12 033009.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                  Appendix G.1-12,5of6
                                                                                                                                                                        Form Author: G. Kolwich
                                                                                                                                                                        (248)373-6000 Ext. 2411

-------
Engine Assembly 1200
                                                                                              Manufacturing Assumption and Quote Summary
                  APPENDIX G.1-12 (4 0(4)
                             Print Dale:9/2/2009
                Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                     Vehicle Class: Compact/Economy 2-1 Pa!
                      Study Case#: N0101(N = New, 01 = Technology Package, 01 = Vehicle Class)
               System Description: 2007 Mini Cooper s. 1.6L 14, •
Component Description: Vehicle Operations or Engine Ai
Component Quote Level:   r Full Quote
                                                                 if Exhaust Components
                                                                                                            Part Number: 1200
                                                           r Modification
                                                                                   17 Differential Quote (Quote Summary includes
OEM Operating Pattern (Weeks/Year):
        Annual Engine Volume (CPV):
             Components per Engine: _
          Annual Component Volume:_
          Weekly Component Volume:
              Estimated Product Lite:
                                                                                                                                                                                                            OEM Plant Location: North America
                                                                                                                                                                                                         Supplier Plant Location: North America
 OEM/T1 Classification: OEM Engine Assembly
       Shipping Method: FOB Ship Point
Packaging Specification:_NA	
GENERAL COMPONENT INFORMATION
1
S

Tie

Part Description

Part Number

1 Supplier or OEM Processing & Assembly (Full Co:
1
No differential labor/burden costs incurred to assembly
exhaust system components.


D

tma
0
0
0
GENERAL MANUFACTURING INFORMATION
Primary Process
Description

pping)

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




Manifold Exhaust
Exhaust Brackets/Heat Shields
Exhaust Sealing
Nut - Exhaust Manifold to Turbo
201-N0101-01
275J85J-N0101-01
280-N0101-01
280-N0101-06
280-N0101-07
Cover cost of Nut-Exhaust Manifold to Turbo in Air
Induction Engine Assembly Cost Sheet.








1
1
1
10
3
4
0
0
0
0
0





(0.193-0.05)





OEM/Supplier
Classification




SAC
SAC
SAC
S





Material
Specification





Labor
Classification





Burden
Classification





MANUFACTURING RATES
Finished Pieces Per Hour


am
am
SSSSS


'Syndicates Component is Supplied directly to T1 or OEM for Final or Sub-
Assembly.
•SAC'=(Supplier Accounted Costs) Indicates Component is Supplied directly to
T1 or OEM for Final or Sub-Assembly. In addition component material cost is
accounted for in T1 quote sheet. Thus component cost will only be included for
Mark-up Calculations.
'Alpha-Numeric Character1 = Indicates purchase parts are brought in by T2/T3
Supplier for Subassembly.
























Number of Operators


0
0
0







Number of Lines


1
1
1







Parallel Processing
Multiplier


1
1
1







1
I


0.000
0.000
0.000







Material
Cost
$/lb
(DB)


SN/A
SN/A




T1 or


Labor
Rate
$/Hour
(DB)


SN/A
SN/A




Burden
Rate
$/Hour
(DB)


SN/A
SN/A




Applied
Burden
Rate
$/Hour


SN/A
SN/A




OEM Total Manufacturing Cost:
T1 or OEM Mark-Up Rates:
&T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:



MANUFACTURING COSTS
Material
Cost


SN/A
SN/A



Material

1. 89
Labor/ Part


SN/A
SN/A



Labor
$0.00

Burden/
Part


SN/A
SN/A



Burden


IF
e!
CD


SN/A
SN/A



TMC


MARK-UP COSTS
End
Item
Scrap
Rate
(DB)


SN/A
SN/A



Scrap
0.00%

SG&A
Rate
(DB)


SN/A
SN/A



SG&A


Profit
Rate
(DB)


SN/A
SN/A



Profit
0.00%

ED&T/
R&D
Rate
(DB)


SN/A
SN/A



ED&T


Total
Mark-
up
Rate


SN/A
SN/A
Supplier
Account
Cost
$32.82
$2.11
$0.95
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

Total
Mark-up
0.00%

Total
Mark-
up
Cost


SN/A
SN/A
Price/ Uni
$32.82
$2.11
$0.95
$0.18
$0.02
$000
$000
$000
$000
$000
$000



TOTAL COSTS
2.
SL
+ —i
3? ^
I"


SN/A
SN/A
Price Net,
PIA
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

Q

	 *
Packaging Cost:
Net Cost Impact to Vehicle:
SL
si
i?
1


$0.00
$0.00
$0.00
Price Net,
End Item
$32.82
$2.11
$0.95
$1.83
$0.06
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
I
I
$37.77
$37.77



TOOLING &
Tooling Assumptions
"X1000 "









NVESTMENT
Investment Assumptions
"X1000 "








$0

PACKAGING CALCULATIONS:
Packaaina Tvoe: No chanae to oackaaina
Part Size:
Parts/Layer
Number of Layers:
Rack/Pallet Investment Amortization


Expendable Packaging in Piece Cost
Packaging Cost Tota


Cost per
Piece

Cost pet













Total
$0
Tier Pad

$0.00



Lump Sum
Payment
0.00%
Tier Pads

0



Total * of
Pieces

Divider Pads,

$0.00



Number of
Months
60
Divider Pads

0



Interest
Rate
5.00",
0,he,,1
Price Per
$0.00





Other*
Pallet/Rack
0


8
per Pallet /Rack
$0
Othe,^
Price Per
$0.00


*i
i!
i
57447
Others
Pallet/Rack
0

=
1
of Parts per Pallet/
Rack
1
0,.,,,,
Pries Per
$0.00


=,,,
ill
s. |
6
OtherB
Pallet/Rack
0

£
jf -]|

57447




FfeExhaust Subsystem 12 033009.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                 Appendix G.1-12,6of6
                          Form Author: G. Kolwich
                          (248)373-6000 Ext. 2411

-------
                    Appendix G.1 - Subsystem 13
                       Lubrication Subsystem
                          Case Study #0101
                         MAQS Worksheets
File:13 Lubrication Subsystem 032309.xls
EPAContract:EP-C-07-069WA1-3                          Appendix G.1-13,1 of 11

-------
                                                                                             Manufacturing Assumption and  Quote Summary
                                                                                                                                                                APPENDIX G.1-13(1of6)
                                                                                                                                                                          Print Date:9/2/2009
                Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                     Vehicle Class: Compact/Economy 2-1 Pa!
                      Study Case#: N0101(N = New, 01 = Technology Package, 01 = Vehicle Class)
               System Description: 2007 Mini Cooper s. 1.6L n, 16V DOHC GDI Turbo
          Component Description: Oil Pump Assembly
          Component Quote Level:  r Full Quote
                                                                                                            Part Number: 1302-N0101-01
r Modilicatio
                         17 Ditterential Quote (Quote Summary includes
                                                                                   OEM Operating Pattern (Weeks/Year):
                                                                                           Annual Engine Volume (CPV):
                                                                                                Components per Engine:
                                                                                             Annual Component Volume:
                                                                                             Weekly Component Volume:
                                                                                                  Estimated Product Life:
                                                                                                                                                                                                           OEM Plant Location: North America
                                                                                                                                                                                                        Supplier Plant Location: North America	
                                                                                                                                                                                                         OEM/T1 Classification: "I High Assembly Complexity
       Shipping Method: FOB Ship Point
Packaging Specification:	
GENERAL COMPONENT INFORMATION
1
S


Part Description


Part Number


D
?
CT


GENERAL MANUFACTURING INFORMATION
Primary Process
Description


Purchase Part - Commodity ( Value taken from Purchase Part Database)
1A











Oil Pump Assembly











1302-N0101-01











1
0
0
0
0
0
0
0



0







20%(13%PCJ£5%Turbo)













OEM/Supplier
Classification



s













Material
Specification




Labor
Classification




Burden
Classification




MANUFACTURING RATES
Finished Pieces Per h
1



'Syndicates Componen is Supplied directly to T1 or OEM for Final or Sub-
Assembly.
'SAC'=(Supplier Accounted Costs) Indicates Component is Supplied directly to
T1 or OEM for Final or Sub-Assembly. In addition component material cost is
accounted for in T1 quote sheet. Thus component cost will only be included for
Mark-up Calculations.
'Alpha-Numeric Charac er1 = Indicates purchase parts are brought in by T2/T3
Supplier for Subassembly.




































Number of Operato
\1


	 *
Packaging Cost:
Net Cost Impact to Vehicle:
SL
si
Iff
£•
£-

Purchase
Price Net,
End Item
$3.08
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
1
$3.08
$3.08





TOOLING &
Tooling Assumptio
"X1000 "
0)














$0
NVESTMENT
Investment Assumpti
"X1000 "
w














$0

PACKAGING CALCULATIONS:
No Packaging Updates Required
Packaging Type:
Part Size:
Parts/Layer
Number of Layers:
Rack/Pallet Investment Amortization


Expendable Packaging in Piece Cost
Packaging Cost Tota

Cost per
Piece

Cost per











Total
$o
Tier Pad

$0.00


Lump Sum
Payment
(%]

Tier Pads




Total * of
Pieces

Divider Pads,

$0.00


Number of
Months
60
Divider Pads




Interest
Rate

Other #1

$0.00




Others




I
1
1
$0
Other*!

$0.00

_
ital Number of Pallets/
Racks Required
57447
Other*!




nberof Parts per Pallet/
Rack
1
Other #3

$0.00


plier,Customerand In-
transit Inventory
lequirements (Weeks)

Other *3
Pallet/Rad



equirements [Parts]





File:13 Lubrication Subsystem 032309.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                Appendix G.1-13,2ol11
                                                                                                                                                                       Form Author: G. Kolwich
                                                                                                                                                                       (248)373-6000 Ext. 2411

-------
Filler Cooler Assembly 1306
                                                                                        Manufacturing Assumption and Quote Summary
                  Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                       Vehicle Class: Compact/Economy 2-4 Passenger	
                                                                                                                       _OEM Operating Pattern (Weeks/Year):	«_
                                                                                                                                                                                            APPENDIX G.1-13(2of6)
                                                                                                                                                                                                        Print Date:9/2/2009
                                                                                                                                                                               OEM Plant Location:     NorthAmerica
                        Study Case#: N0101(N = New, 01 = Technology Package, 01 = Vehicle Class)
                System Description: 2007 Mini Cooper s. 1.6LI4, 16VDOHC GDI Turbo
Component Description: Filler Cooler Assembly - Oil (Includes Seals)
Component Quote Level:
                                                                                                 Part Number: 1306-N0101-01
Full Quote]   |
                                                                                       Modification Quote)
                                                                                             Annual Engine Volume (CPV):    "50,000      Supplier Plant Location:     NorthAmerica
                                                                                                   Components per Engine:      1              Shipping Method: 	F.O.B
                                                                                               Annual Component Volume:    «o,ooo     Packaging Specification:   R"umas"'"ra*™dabl9
                                                                                               Weekly Component Volume:     9,574                               	
                                                                                                    Estimated Product Life:      10
GENERAL COMPONENT INFORMATION
!

Tie
1A
2A
3A
Pu
1A
1B
2A
3A
4A
5A
6A
Part Description

1 Supplier or OEM Processin
Oil Cooler Adapter/Base Plate Subassembly
Oil Cooler
Filter Cooler Assembly - Oil (Includes Seals &
aux
chase Part - High Impact Item
Housing Oil Filter Preassembled
Housing Oil Filter Preassembled
Oil Cooler Adapter Plate
Oil Cooler Base Plate
OrlCoolerCoolrnoPla...^.™,
Oil Cooler Cooling Plate stack
Oil Cooler Top Plate
Part Number

3 & Assembly (Full Co
1306-N0101-01-02-1A
1306-N0101-01-02
1306-N0101-01
Full Cost Mapping)
1306-N0101-01-08
1306-N0101-01-08
1306-N0101-01-02-1
306-N0101-01-02-2
1306-N0101-01-02-3
1306-N0101-01-02-31
1306-N0101-01-02-4
QTY Per Assembly

st m
1
1
1

1
1
1
1
5
7
1
GENERAL MANUFACTURING INFORMATION
Primary Process
Description

pping)
ToggleLock Adaptor and
Fixture and Braze Weld
Final Assembly of filter/cooler
assembly (Only Consider
Furbo/DI Driven Costs)

Casting (50% Mass Attributed
loTurbo/DI oil cooler features)
Machine Casting Features
(Hole Attributed to Turbo/DI
Only)
S,amp,ng
Stamping
—
Slamping
Slamping
Purchase Part - Commodity ( Value taken from Purchase Part Database)
1A
2A
3A
4A
5A
6A
7A
8A






Gasket hou ng to block Oil
Gasket hou ng to block -coolant
Gasket Oil ooler Odd Shape
Gasket Oil ooler Sguare
Gasket Oil ooler Oval
Gasket Oil ooler Round
Bolt Oil Cooler to hou sing
Tube Assembly- Oil, Cooler/Filter Ass'y Outlet
toTurbocharger






1306-N0101-01-09
1306-N0101-01-10
1306-N0101-01-07
1306-N0101-01-06
1306-N0101-01-05
1306-N0101-01-04
1306-N0101-01-03
1370-N0101-01






1
1
1
1
1
1
5
1
0
0
0
0
0
0
0
0
0








OEM or Supplier


s
s
s

s
s
s
s
s
s
s

s
s
s
s
s
s
s
SAC

Material
Specification


Not Applicable
Not Applicable
Not Applicable

Aluminum-A380, Cast
Not Applicable
Aluminum-3003/4047B,
Aluminum-3003/4047B,
Aluminum-3003/4047A,
Aluminum-3003/4047A,
Aluminum-3003/4047A,


Labor Classification


General Assembly
General Assembly
0,n,»,Ass,mHy

Mold/Cast/Sinter Operator
Mold/Cast/Sinter Operator
Cut/Punch/Forming Operator
Cut/Punch/Forming Operator
Cut/Punch/Forming Operator
Cut/Punch/Forming Operator
Cut/Punch/Forming Operator


Burden
Classification


Mech.Assembly.MC
Mech.Assembly.MC
Mech.Assembly.MC

Diecast.LMC
Perm. Cast, MHC
Stamp/Form, SMS, LMC
Stamp/Form, SMS, LMC
Stamp/Form, SMS, LMC
Stamp/Form, SMS, LMC
Stamp/Form, SMS, LMC


MANUFACTURING RATES
Finished Pieces Per Hour


300
180
240

160
150
480
480
581
1161
581


"Syndicates Component is Supplied directly to T1 or OEM for
Final or Sub- Assembly.
"SAC"=(Supplier Accounted Costs) Indicates Component is
Supplied directly to T1 or OEM for Final or Sub-Assembly. In
addition component material cost is accounted for in T1 quote
sheet. Thus component cost will only be included for Mark-up
Calculations.
"Alpha-Numeric Character" = Indicates purchase parts are
brought in by T2AT3 Supplier for Subassembly.
I

I I

I I

.






Number of Operators


1
1
5

1
1
0.5
0.5
1
0.5
0.5









SL
c
f


0.000
0.000
0.000

0.900
0.000
0.253
0.253
0.018
0.018
°«









Material
Cost
$/lb


$0.00
$0.00
$0.00

$1.10
$0.00
$2.10
$2.10
$1.65
$1.65
$1.65









Labor
Rate
$/Hour


$35.51
$35.51
$35.51

$43.52
$43.52
$42.18
$42.18
$42.18
$42.18
$42.18









Burden
Rate
$/Hour


$125.19
$125.19
$125.19

$100.05
$150.06
$100.10
$100.10
$100.10
$100.10
$100.10









MANUFACTURING COSTS
Material
Cost


$0.00
$0.00
$0.00

$0.99
$0.00
$0.53
$0.53
$0.03
$0.03
$0.10









Labor/ Part


$0.12
$0.20
$0.74

$0.27
$0.29
$0.04
$0.04
$0.07
$0.02
$0.04









Burden/
Part


$0.42
$0.70
$0.52

$0.63
$1.00
$0.21
$0.21
$0.17
$0.09
$0.17









Total 1 =
Material + Labor + Burden


$0.54
$0.89
$1.26

$1.89
$1.29
$0.78
$0.78
$0.27
$0.13
$0.31









MARK-UP COSTS
End
Item
Scrap
Rate


0.00%
0.00%
0.00%

0.30%
0.30%
0.30%
0.30%
0.30%
0.30%
0.30%









SG&A
Rate


0.00%
0.00%
0.00%

6.00%
6.00%
6.00%
6.00%
6.00%
6.00%
6.00%









Profit
Rate


0.00%
0.00%
0.00%

4.00%
4.00%
4.00%
4.00%
4.00%
4.00%
4.00%









ED&T/
R&D
Rate


0.00%
0.00%
0.00%

0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%









Total
Mark-
up
Rate


0.00%
0.00%
0.00%

10.30%
10.30%
10.30%
10.30%
10.30%
10.30%
10.30%
Supplier
Account
Cost
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$4.09
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
Total
Mark-
up
Cost


$0.00
$0.00
$0.00

$0.19
$0.13
$0.08
$0.08
$0.03
$0.01
$0.03
Purchase
Price/ Unit
$0.07
$0.06
$0.06
$0.06
$0.06
$0.05
$0.01
$4.09
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
TOTAL COSTS
Total 2 =
Totall + Total Mark-up


$0.54
$0.89
$1.26

$2.08
$1.42
$0.86
$0.86
$0.30
$0.15
$0.34
Purchase
Price Net,
PIA
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
"^ —1
g §•
1 "
w_


$0.54
$0.89
$1.26

$2.08
$1.42
$0.86
$0.86
$1.52
$1.04
$0.34
Purchase
Price Net,
End Item
$0.07
$0.06
$0.06
$0.06
$0.06
$0.05
$0.06
$4.09
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
TOOLING &
Tooling Assumptions
"X1000 "






















NVESTMENT
Investment Assumptions
"X1000 "






















File:13 Lubrication Subsystem 032309.xls
EPAContract: EP-C-07-069WA1-3
                                                                                                        Appendix 6.1 -13, 3 of 1 1
                                                                                                                                                                                                    Form Author: G.Kolwich
                                                                                                                                                                                                    (248)373-6000 Ext. 2411

-------
Filler Cooler Assembly 1306
                                                                                           Manufacturing Assumption and  Quote Summary
                                                                                                                                                              APPENDIX G.1-13(2of6)
                   Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                       Vehicle Class: Compact/Economy 2-4 Passenger	
                        Study Case*: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class)
                 System Description: 2007 Mini Cooper S. 1.6L14,16V DOHC GDI Turbo
            Component Description: Filler Cooler Assembly - Oil (Includes Seals)
            Component Quote Level:
                                                                                                    Part Number: 1306-N0101-01
Full Quote]    |
                                         Modification Quote
                                                                                       _OEM Operating Pattern (Weeks/Year):      "?
                                                                                                Annual Engine Volume (CPV):    "50,ooo
                                                                                                      Components per Engine:      1
                                                                                                  Annual Component Volume:    450,000
                                                                                                  Weekly Component Volume:     9,574
                                                                                                       Estimated Product Life:      10
    OEM Plant Location:
 Supplier Plant Location:
       Shipping Method:
Packaging Specification:
                                                                                                                                                                                                                          Print Date:9/2/2009
                                                                                                                                                                                                                          North America
                                                                                                                                                                                                                        Returnable w. Expendable
GENERAL COMPONENT INFORMATION
!




Part Description




Part Number




QTY Per Assembly






GENERAL MANUFACTURING INFORMATION
Primary Process
Description






OEM or Supplier






Material
Specification






Labor Classification






Burden
Classification






MANUFACTURING RATES
Finished Pieces Per Hour






Number of Operators






si
c
f



T1o


Material
Cost
$/lb



Labor
Rate
$/Hour



Burden
Rate
$/Hour



OEM Total Manufacturing Cost:
T1 or OEM Mark-Up Rates:
C)ST1 or OEM Mark-Up Values:
Base Cost Impact


o Vehicle:

MANUFACTURING COSTS
Material
Cost


Material
$7.02

Labor/ Part


Labor
$2.23
$2.23
Burden/
Part


Burden
$5.31

Total 1 =
Material + Labor + Burden


TMC


MARK-UP COSTS
End
Item
Scrap
Rate


Scrap
$0.02
0.50%
$0.08

SG&A
Rate


SG&A
$0.44
6.50%
$1.00

Profit
Rate


Prolit
6.00%
$0.92

ED&T/
R&D
Rate


EDST
2.50%
$0.38

Total
Mark-
up
Rate


Total
Mark-up
$0.76
1 5.50%
$2.38

Total
Mark-
up
Cost




TOTAL COSTS
Total 2 =
Total 1 + Total Mark-up


LI

	 *•
Packaging Cost:
Net Cost Impac to Vehicle:
Total2'QtyperAss'y


$1
1


5.33
$15.33
$1
3.61
$0.16
$1
3.78

TOOLING &
Tooling Assumptions
"X1000 "




$0
NVESTMENT
Investment Assumptions
"X1000 "




$0



Packaging Calculations


Rack/Pallet Investment Amortization:
Expendable Packaging in Piece Cost:
Packaging Cost Total:


Cost per
Piece


$0.068
Cost per
Pece
$0.10
$0.164











Total
Amount


$136,778
Tier Pad
Price Per
$1.00



LumpSum
Payment {%]


0.00%
Tier Pads
Pallet/Rack
8



Total) of Pieces


2,250,000
Divider Pads,
Price Per
$0.00



Number of
Months


60
Divider Pads
Pallet/Rack
0



Rate



Otherffl
Packaging
Price Per
$0.00







Otherffl
Pads
Pallet/Rack
0



Cost per
Pallet /Rack


$200
Otherf)2
Packaging
Price Per
$0.00


Total
Nuirtoerof
Pallets/
Racks
Required

684
Otherf)2
Pads
Pallet/Rack
0



Nuirtoerof
Parts per
Pallet/ Rack


84
Otherf)3
Packaging,
Price Per
$0.00

Supplier,
Customer
and In-
Inventory
Ftequiremei
ts {Weeks]
6
Otherf)3
Pads
Pallet/Rack
0

Supplier,
Customer
andln-
Inventory
Requiremei
fc {Parts]
57447



                                                                                                                                                                                                           Option #2 Packaging with expendable
                                                                                                                                                                                                           tier dividers and pads.

                                                                                                                                                                                                           Two parts nested together.

                                                                                                                                                                                                           Part Packaging Volume: 300x360x120

                                                                                                                                                                                                           Parts/Layer = 3x4=12
                                                                                                                                                                                                           Number of Layers = 7
File:13 Lubrication Subsystem 032309.xls
EPAContract: EP-C-07-069WA1-3
                                                                                                             )endixG.1-13,4of11
                                                                                                                                                                      Form Author: G.Kolwich
                                                                                                                                                                      (248)373-6000 Ext. 2411

-------
Tube Ass'y Turbo to Block 1370
                                                                                        Manufacturing Assumption and Quote Summary
                                                                                                                 APPENDIX G.1-13, (3of6)
                  Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                       Vehicle Class: Compact/Economy 2-4 Passenger	
                        Study Case*: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class)
                System Description: 2007 Mini Cooper S. 1.6L14,16V DOHC GDI Turbo
            Component Description: Tube Assembly - Oil, Turbo to Engine Block
            Component Quote Level:
                                                                                                  Part Number: 1370
Modification Quote
                                            _OEM Operating Pattern (Weeks/Year):      "?
                                                     Annual Engine Volume (CPV):    "50,ooo
                                                           Components per Engine:      1
                                                       Annual Component Volume:    450,000
                                                       Weekly Component Volume:     9,574
                                                            Estimated Product Life:      10
    OEM Plant Location:
 Supplier Plant Location:
       Shipping Method:
Packaging Specification:
                                                                                                                                                                                                                    Print Date:9/2/2009
                                                                                                                                                                                                                    North America
   Return able w.
Expendable Separators
GENERAL COMPONENT INFORMATION
!




Tie



Pu
1A
1B
1C
2A
2B

Part Description




1 Supplier or OEM Processin

Tube Assembly - Oil, Turbo to Engine Block

chase Part - High Impact Item
ube Stock - Oil, Turbo to Engine Block
ube Stock - Oil, Turbo to Engine Block
ube Stock - Oil, Turbo to Engine Block
itting Tube End
itting Tube End
itting Tube End
Part Number




3 & Assembly (Full Co

1370-N0101-02

Full Cost Mapping)
1370-N0101-02-2
1370-N0101-02-1
1370-N0101-02-3
1370-N0101-02-4
1370-N0101-02-4
1370-N0101-02-4
QTY Per Ass
I
s.


st m

1


1
1
1
2
2
2
GENERAL MANUFACTURING INFORMATION
Primary Process
Description




pping)
Assemble End Fittings and fl-
ings onto Tube and Crimp in
ace. ressure est

Tube Bending
Flare Tube Ends
Plate
Forge Blank
Machine
Plate
Purchase Part - Commodity ( Value taken from Purchase Part Database)

1A



















0-ring- Tube Fitting



















1370-N0101-02-3

































































O
5
~o





S


S
s
s
s
s
s


s






















Material
Specification






Not Applicable


LC-Steel-1215, Tubing
Not Applicable
General Underhood Pla
MC-Steel-1018, Bar
Not Applicable
General Underhood Pla



Labor Classification






General Assembly


Cut/Punch/Forming Operator
Cut/Punch/Forming Operator
Plating/Coating Operator
Forging Operator
CNC Operator
Plating/Coating Operator



Burden
Classification






Mech.Assembly.LC


Hydro/CNC Form, SMS
Hydro/CNC Form, SMS
Plate/Finish, SMS, MHC
Cold Forge, LMC
CNC Milling, SMS, LC
Plate/Finish, SMS, MHC



MANUFACTURING RATES
Finished Pieces


1



240


360
240
720
900
360
1800



"Syndicates Component is Supplied directly to T1 or OEM for
Final or Sub-Assembly.

"SAC"=( Supplier Accounted Costs) Indicates Component is
Supplied directly to T1 or OEM for Final or Sub- Assembly. In
addition component material cost is accounted for in T1 quote
sheet. Trius component cost will only be included for Mark-up



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






































Number of Op


1



2


0.5
1
1
0.5
0.5
1

























Si.
c
To

w



0.000


0.210
0.210
0.001
0.165
0.000
0.001



















Material
Cost
$/lb






$0.00


$0.62
$0.00
$15.00
$0.55
$0.00
$15.00



















Labor
Rate
$/Hour






$35.51


$42.18
$42.18
$55.17
$38.52
$35.70
$55.17



















Burden
Rate
$/Hour






$100.19


00.12
00.12
25.17
00.09
00.15
25.17



















T1 or OEM Total Manufactur ng Cost:





T1 or OEM Mark-Up Rates:
C)&T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:






MANUFACTURING COSTS
Material
Cost






$0.00


$0.13
$0.00
$0.02
$0.09
$0.00
$0.02


















Material
$0.42

0.00

Labor/ Part






$0.30


$0.06
$0.18
$0.08
$0.02
$0.05
$0.03


















Labor
$0.81


$0.81
Burden/
Part






$0.42


$0.28
$0.42
$0.17
$0.11
$0.28
$0.07


















Burden
$2.20



h
+ "
c1
i



$0.71


$0.47
$0.59
$0.27
$0.22
$0.33
$0.12


















TMC




MARK-UP COSTS
End
Item
Scrap
Rate





0.00%


0.00%
0.00%
0.30%
0.00%
0.00%
0.30%


















Scrap
$0.00
0.30%
$0.01

SG&A
Rate






0.00%


0.00%
0.00%
6.00%
0.00%
0.00%
6.00%


















SG&A
$0.03
6.00%
$0.21

Profit
Rate






0.00%


0.00%
0.00%
4.00%
0.00%
0.00%
4.00%


















Profit
$0.02
4.00%
$0.14

ED&T/
R&D






0.00%


0.00%
0.00%
0.00%
0.00%
0.00%
0.00%


















ED&T
$0.00
0.00%
$0.00

Total
Mark-
up
Rate





0.00%


0.00%
0.00%
10.30%
0.00%
0.00%
10.30%
Supplier
Account

$0.00
$0.00




$0.00

$0.00


$0.00
$0.00
$0.00


Total
Mark-up
$0.05
1 0.30%
$0.36

Total
Mark-
up
Cost





$0.00


$0.00
$0.00
$0.03
$0.00
$0.00
$0.01
Purchase

$0.06
$0.00




$0.00

$0.00


$0.00
$0.00
$0.00






TOTAL COSTS
Total 2
Total 1 + Total
i
3-
^



$0.71


$0.47
$0.59
$0.29
$0.22
$0.33
$0.13
Purchase
Price Net,

$0.00
$0.00




$0.00

$0.00


$0.00
$0.00
$0.00


rj
	 >\1


	 *•
Packaging Cost:
Net Cost Impact to Vehicle:
—1
ro
S
*
£

1
"




$0.71

$0.47
$0.59
$0.29
$0.45
$0.66
$0.25
Purchase
Price Net,


$0.06
$0.00





$0.00

$


.00


$0.00
$0.00
$


$
.00


.48
$3.48




$3.84
$0.06
$3.90

TOOLING &
Tooling Assun
"X1000
.5
o
3


































so
NVESTMENT
Investment Ass
"X1000
t

1


































$0


File:13 Lubrication Subsystem 032309.xls
EPAContract: EP-C-07-069WA1-3
                                                                                                          jendix 6.1-13,5 of 11
                                                                                                                         Form Author: G.Kolwich
                                                                                                                         (248)373-6000 Ext. 2411

-------
Tube Ass'y Turbo to Block 1370
                                                                                        Manufacturing Assumption and Quote Summary
                                                            APPENDIX G.1-13, (3of6)
       Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
           Vehicle Class: Compact/Economy 2-4 Passenger	
            Study Case*: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class)	
     System Description: 2007 Mini Cooper S. 1.6L14,16V DOHC GDI Turbo	
Component Description: Tube Assembly - Oil, Turbo to Engine Block	
Component Quote Level:
                                                                                                                                   _OEM Operating Pattern (Weeks/Year):	«_
                                                                                                  Part Number: 1370
                                               Full Quote
                                                                                       Modification Quote
Annual Engine Volume (CPV):    "50,ooo
     Components per Engine:      1
  Annual Component Volume:    450,000
  Weekly Component Volume:    9,574
       Estimated Product Life:      10
    OEM Plant Location:
 Supplier Plant Location:
       Shipping Method:
Packaging Specification:
                                                                                                                                                                                                                    Print Date:9/2/2009
                                                                                                                                                                                                                    North America
                                                                                                                                                                                                                    Return able w.
                                                                                                                                                                                                                 Expendable Separators
GENERAL COMPONENT INFORMATION
!
•*

Part Description


Part Number


QTYPerAss
1
"*
GENERAL MANUFACTURING INFORMATION
Primary Process
Description


o
5
W'

Material
Specification


Labor Classification














Burden
Classification



Finished Pieces
Z
g





MANUFACTURING RATES
Number of Op
5
1
SL
c
^






Packaging Calculations








Rack/Pallet Investment Amortization:

Expendable Packaging

n Piece Cost:
Material
Cost
$/lb
(DB)






Cost per




$0.055
Cost per
Pece
$0.00
Labor
Rate
gmour















Burden
Rate
gmour







Total





Tier Pad
Price Per
$0.00
MANUFACTURING COSTS
Material
Cost







LumpSum




0.00%
Tier Pads
Pallet/Rack
0
Labor/ Part







Total) of Pieces




2,250,000
Divider Pads,
Price Per
$0.00
Burden/
Part







Number of




60
Divider Pads
Pallet/Rack
0
h
i "
i











Otherffl
Packaging
Price Per
$0.00
MARK-UP COSTS
End
Item
Scrap
Rate












Otherffl
Pads
Pallet/Rack
0
SG&A
Rate







Cost per




$4,420
Otherf)2
Packaging
Price Per
$0.00
Profit
Rate






Total
Nuirtoerof
Pallets/

Required


25
Otherf)2
Pads
Pallet/Rack
0
ED&T/
R&D







Nuirtoerof




2304
Otherf)3
Packaging,
Price Per
$0.00
Total
Mark-
up
Rate





Customer
and In-
transit

Requiremen
ts {Weeks]


6
Otherf)3
Pads
Pallet/Rack
0
Total
Mark-
up
Cost





Customer
and In-
transit

Requiremei
fc {Parts]





Packaging Cost Total: $0.055
TOTAL COSTS
Total 2
Total 1 + Total
1
±










!i
j
4-
TOOLING &
Tooling Assun
"X1000

3
NVESTMENT
Investment Ass
"X1000
|
i

Opt on #3: Returnable Totes and
Dividers


Part Nest Size: 300x30x90

Parts per layer 16
Number of Layers = 3
- 48 Parts per Tote



File:13 Lubrication Subsystem 032309.xls
EPAContract: EP-C-07-069WA1-3
                                                                                                        Appendix 6.1-13,6 of 11
                                                                    Form Author: G.Kolwich
                                                                    (248)373-6000 Ext. 2411

-------
Tube Ass'y Oil Cool-Turbo1370
                                                                                         Manufacturing Assumption and  Quote Summary
                   Technology Level:  Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                       Vehicle Class:  Compact/Economy 2-4 Passenger
                        Study Case*: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class)
                 System Description:  2007 Mini Cooper S. 1.6L14,16V DOHC GDI Turbo
            Component Description: Tube Assembly- Oil, Cooler/Filler Ass'y Outlet to Turbocharger
            Component Quote Level:          Full Quote|~X~|
                                                                                                   Part Number: 1370-N0101-01
Modification Quotef
_OEM Operating Pattern (Weeks/Year):     "?
         Annual Engine Volume (CPV):   "50,ooo
               Components per Engine:      1
           Annual Component Volume:   450,000
           Weekly Component Volume:    9,574
                Estimated Product Life:     10
                                                                                                                  APPENDIX G.1-13, (4of6)
                                                                                                                              Print Dale:9/2/2009
                                                                                                          OEM Plant Location:     North America
                                                                                                       Supplier Plant Location:
                                                                                                             Shipping Method:
                                                                                                      Packaging Specification:
   North America
      F.O.B
   Return able w.
Expendable Separators
GENERAL COMPONENT INFORMATION

!


Tie
1A
1B
Pu

1A

2A
3A

Part Description


1 Supplier or OEM Processin
Fitting Hose Oil Cooler to Turbo
Tube Assembly- Oil, Cooler/Filler Ass'y Outlet
to Turbocharger
chase Part - High Impact Item

Hose Oil Cooler to Turbo

Tube Fitting end
Bracket Tube Fitting end attach

Part Number


3 & Assembly (Full Co
1306-N0101-01-11-2
1306-N0101-01-11
(1370-N0101-01)
Full Cost Mapping)

1306-N0101-01-11-1

1306-N01 01 -01-11-2-1
1306-N0101-01-11-2-1-1
3
Y Per Assembl


st m
1
1


1

1
1
GENERAL MANUFACTURING INFORMATION

Primary Process
Description


pping)
Braze weld Tube Fitting to
Bracket Mount
Crimp End Fitting to Hose and
Add Protective Heat Shield,
Oring and Clamp


ExtrudeS Shape Hose

Machining
Fine blank, LMC
Purchase Part - Commodity ( Value taken from Purchase Part Database)

2f.
3A


















Heat Shield, Hose
Hose Clamp



















1306-N0101-01-11-3































































O
EM or Supplier



s
s


s

s
s


s
s





















Material
Specification



Not Applicable
Not Applicable

SBR-RberRein.
W. Outer Wrap,
Extruded
LC-Steel-1215, Tubing
LC-Steel-1000S,Coil



Labor Classification



GeneralAssembly
General Assembly


Extruding/Drawing Operator

CNC Operator
Cut/Punch/Forming Operator



Burden
Classification



Mech.Assembly.LC
Mech.Assembly.LC


Comp./Ext. Mold, LMC

CNCTurning.LMC
Fine blank, LMC


MANUFACTURING RATES
1
ed Pieces Per
1


257
240


545

200
1000


"Syndicates Component is Supplied directly to T1 or OEM for
Final or Sub-Assembly.

"SAC"=( Supplier Accounted Costs) Indicates Component is
Supplied directly to T1 or OEM for Final or Sub- Assembly. In
addition component material cost is accounted for in T1 quote
sheet. Trius component cost will only be included for Mark-up



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


































W
ber of Operato
55


1
3


1.5

0.25
0.5
























|
i!
c
if



0.000
0.000


0.007

0.150
0.207



















T1o





Material
Cost
$/lb



$0.00
$0.00


$2.05

$0.62
$0.45




















Labor
Rate
$/Hour



$35.51
$35.51


$54.35

$35.70
$42.18




















Burden
Rate
$/Hour



$100.19
$100.19


$100.04

$100.00
$100.13



















OEM Total Manufacturing Cost:
T1 or OEM Mark-Up Rates:
C)&T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:






MANUFACTURING COSTS

Material
Cost



$0.00
$0.00


$0.01

$0.09
$0.09


















Material
$1.27
0.00


Labor/ Part



$0.14
$0.44


$0.15

$0.04
$0.02


















Labor
$0.80

$0.80

Burden/
Part



$0.39
$0.42


$0.18

$0.50
$0.10


















Burden
$1.59


1
||
i


$0.53
$0.86


$0.35

$0.64
$0.21


















TMC



MARK-UP COSTS

End
Item
Scrap
Rate



0.00%
0.00%


0.00%

0.00%
0.30%


















Scrap
$0.00
0.30%
$0.01


SG&A
Rate



0.00%
0.00%


0.00%

0.00%
6.00%


















SG&A
$0.01
6.00%
$0.22


Profit
Rate



0.00%
0.00%


0.00%

0.00%
4.00%


















Profit
$0.01
4.00%
$0.15


ED&T/
R&D
Rate



0.00%
0.00%


0.00%

0.00%
0.00%


















ED&T
$0.00
0.00%
$0.00


Total
Mark-up
Rate



0.00%
0.00%


0.00%

0.00%
10.30%
Supplier
Account
Cost

$0.00
$0.00




$0.00

$0.00


$0.00
$0.00
$0.00


Total Mark-
$0.02
10.30%
$0.38
$0.40

Total
Mark-up
Cost



$0.00
$0.00


$0.00

$0.00
$0.02
Purchase
Price/ Unit

$0.75
$0.22




$0.00

$0.00


$0.00
$0.00
$0.00





TOTAL COSTS
1
Total 2 =
1 + Total Mark
5


$0.53
$0.86


$0.35

$0.64
$0.24
Purchase
Price Net, PIA

$0.00
$0.00




$0.00

$0.00


$0.00
$0.00
$0.00


m
»LI

	 *•
Packaging Cost:
Net Cost Impact to Vehicle:
ET
It
1 "
£


$0.53
$0.86


$0.35

$0.64
$0.24
Purchase Price
Net, End Item

$0.75
$0.22




$0.00

$0.00


$0.00
$0.00
$0.00
1
I
$3.68
$3.68

$4.06
$0.03
$4.09

TOOLING & INVESTMENT
I
ng Assumptio
"X1000 "
"































»
1
x= S
If
i































w


File:13 Lubrication Subsystem 032309.xls
EPAContract: EP-C-07-069WA1-3
                                                                                                           jendix 6.1-13,7 of 11
                                                                                                                           Form Author: G.Kolwich
                                                                                                                          (248)373-6000 Ext. 2411

-------
Tube Ass'y Oil Cool-Turbo1370
                                                                                         Manufacturing Assumption and  Quote Summary
                   Technology Level:  Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                       Vehicle Class:  Compact/Economy 2-4 Passenger	
                        Study Case*: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class)
                 System Description:  2007 Mini Cooper S. 1.6L14,16V DOHC GDI Turbo
            Component Description: Tube Assembly- Oil, Cooler/Filler Ass'y Outlet to Turbocharger
            Component Quote Level:          Full Quote|~X~|
                                                                                                   Part Number: 1370-N0101-01
Modification Quote
                                             _OEM Operating Pattern (Weeks/Year):      "?
                                                      Annual Engine Volume (CPV):    "50,ooo
                                                           Components per Engine:       1
                                                        Annual Component Volume:    450,000
                                                        Weekly Component Volume:     9,574
                                                             Estimated Product Life:      10
            APPENDIX G.1-13, (4of6)
                        Print Dale:9/2/2009
    OEM Plant Location:      North America
 Supplier Plant Location:
       Shipping Method:
Packaging Specification:
   North America
      F.O.B
   Return able w.
Expendable Separators
GENERAL COMPONENT INFORMATION

!


Part Description


Part Number

3
YPerAssemb
-<
GENERAL MANUFACTURING INFORMATION

Primary Process
Description

0
EM or Supplie


Material
Specification


Labor Classification












Burden
Classification


1
ed Pieces Per
g




MANUFACTURING RATES
?
a
o
3
IS
|
i!
c





Packaging Calculations






Rack/Pallet Investment Amortization:

Expendable Packaging

a Piece Cost:

Material
Cost
$/lb





Cost per
Piece



$0.026
Cost per
Pece
$0.00

Labor
Rate
$/Hour













Burden
Rate
$/Hour





Total
Amount




Tier Pad
Price Per
$0.00
MANUFACTURING COSTS

Material
Cost





LumpSum



0.00%
Tier Pads
Pallet/Rack
0

Labor/ Part





Total) of Pieces



2,250,000
Divider Pads,
Price Per
$0.00

Burden/
Part





Number of
Months



60
Divider Pads
Pallet/Rack
0
1
||
i




Rate




OtherU
Packaging
Price Per
$0.00
MARK-UP COSTS

End
Item
Scrap
Rate










Otherffl
Pads
Pallet/Rack
0

SG&A
Rate





Cost per
Pallet /Rack



$5,860
Otherf)2
Packaging
Price Per
$0.00

Profit
Rate




Total
Nuirtoerof
Pallets/
Racks
Required


9
Otherf)2
Pads
Pallet/Rack
0

ED&T/
R&D
Rate





Nuirtoerof
Pallet/ Rack



6480
Otherf)3
Packaging,
Price Per
$0.00

Total
Mark-up
Rate





In-transit
Inventory



6
Otherf)3 Pads
Pallet/Rack
0

Total
Mark-up
Cost




Supplier,
Customer and h
transit Inventor)
Requirements
{Parts]


57447


Packaging Cost Total: $0.026
TOTAL COSTS
S. ?
P ^
•§ •<








TOOLING & INVESTMENT
I
ng Assumptk
"X1000 "
3

Packaging Option #3: Returnabl
Dividers

Part Nesting Size: 220x30x30

Parts per Layer: 15
Layers per Tote: 9


1
X= %
If
1

Totes &









File:13 Lubrication Subsystem 032309.xls
EPAContract: EP-C-07-069WA1-3
                                                                                                         Appendix 6.1-13,8 of 11
                                                                                                                           Form Author: G.Kolwich
                                                                                                                          (248)373-6000 Ext. 2411

-------
Oil - Synthetic 1399
                                                                                         Manufacturing Assumption and Quote Summary
                                                                                                                  APPENDIX G.1-13, (5of6)
                   Technology Level:  Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                       Vehicle Class:  Compact/Economy 2-4 Passenger	
                                             _OEM Operating Pattern (Weeks/Year):	«_
                        Study Case*: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class)
                 System Description:  2007 Mini Cooper S. 1.6L14,16V DOHC GDI Turbo
            Component Description: Oil - Synthetic
            Component Quote Level:
                                                                                                   Part Number: 1399-N0101-08
Modification Quote
                                                      Annual Engine Volume (CPV):    "50,ooo
                                                           Components per Engine:      1
                                                        Annual Component Volume:    450,000
                                                        Weekly Component Volume:     9,574
                                                             Estimated Product Life:      10
    OEM Plant Location:
 Supplier Plant Location:
       Shipping Method:
Packaging Specification:
                                                                                                                                                                                                                      Print Date:9/2/2009
                                                                                                                                                                                                                      North America
   Return able w.
Expendable Separators
GENERAL COMPONENT INFORMATION

£
1





Part Description





Part Number



O

%
£
o-
~°
GENERAL MANUFACTURING INFORMATION


Primary Process
Description




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

1A









OIL - ENGINE OW-40 ILSAC GF3MS-10725









NA









1
























o
s
5
•o





S













Material
Specification







Labor Classification







Burden
Classification





MANUFACTURING RATES
i!
Q.
1


i


"Syndicates Component is Supplied directly to T1 or OEM for
Final or Sub-Assembly.
"SAC"=( Supplier Accounted Costs) Indica es Component is
Supplied directly oT1 or OEM for Final or Sub-Assembly. In
addition component material cost is accounted for in T1 quote
sheet. Trius 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.









?
Sf
a
o

S1
















|
|.
c
To












Material
Cost
$/lb













Labor
Rate
$/Hour













Burden
Rate
$/Hour












T1 or OEM Tola Manufacturing Cost:





1 '
C) &T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:






MANUFACTURING COSTS


Material
Cost










Material







Labor/ Part










Labor

$0.00


$0.00


Burden/
Part










Burden





1


+ "
ro
i







TMC





MARK-UP COSTS

End
Item
Scrap
Rate









Scrap



$0.00



SG&A
Rate










SG&A



$0.00



Profit
Rate










Profit







R&D










ED&T






Total
Mark-
up
Rate



Account
Cost

$0.00



Total



$0.00


Total
Mark-
up
Cost



Price/ Unit

$4.00








TOTAL COSTS
1
^ _,
1 w
i "
3-

Purchase
Price Net,
PIA

$0.00



E

	 fTJ


	 >•
Packaging Cost:
Net Cost Impact to Vehicle:
—i
10
Q
*
>
w_
Pun


1
"



Price Net,
End Item

$



$


.00



.00

$4.00




$4.00
$0.00
$4.00

TOOLING &
I
.3
3. >
§ i
.5














$0
NVESTMENT
1

2. A
§ >
1

•g.
i












$0




Packaging Calculations


Rack/Pallet Investment Amortization:
Expendable Packaging in Piece Cost:
Packaging Cost Total:


Cost per
Piece


$0.000
Cost per
Pece

$0.000











Total
Amount


$0
Tier Pad
Price Per
$0.00



LumpSum


0.00%
Tier Pads
Pallet/Rack
0



Total) of Pieces


4,500,000
Divider Pads,
Price Per
$0.00



Nuirtoerof
Months


60
Divider Pads
Pallet/Rack
0



Interest
Rate



Otherffl
Packaging
Price Per
$0.00







Otherffl
Pads
Pallet/Rack
0



Cost per
Pallet /Rack


$0
Otherf)2
Packaging
Price Per
$0.00


Total
Numberof
Pallets/
Racks
Required

57447
Otherf)2
Pads
Pallet/Rack
0



Numberof
Pallet/ Rack


1
Otherf)3
Packaging,
Price Per
$0.00

Supplier,
Customer
and In-
transit
Inventory
Ftequiremei
ts {Weeks]
6
Otherf)3
Pads
Pallet/Rack
0

Supplier,
Customer
andln-
transit
Inventory
Requiremei
fc {Parts]
57447



                                                                                                                                                                                                       Standard Pallet L4'xW4'xD3'
                                                                                                                                                                                                       Area= 122cmx 114cm= 1440sq.cm
                                                                                                                                                                                                       Depth = 86cm

                                                                                                                                                                                                       Part Size:
                                                                                                                                                                                                       Parts Per Layer:
                                                                                                                                                                                                       Parts Per Pallet:
File:13 Lubrication Subsystem 032309.xls
EPAContract: EP-C-07-069WA1-3
                                                                                                           jendix 6.1-13,9 of 11
                                                                                                                           Form Author: G.Kolwich
                                                                                                                          (248)373-6000 Ext. 2411

-------
Engine Assembly 1300
                                                                                         Manufacturing Assumption and  Quote Summary
Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
    Vehicle Class: Compact/Economy 2-4 Passenger	
                                                                                                                                     _OEM Operating Pattern (Weeks/Year):
     Study Case*: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class)
                 System Description:  2007 Mini Cooper S. 1.6L14,16V DOHC GDI Turbo
                                                                                                                                              Annual Engine Volume (CPV):    "50,ooo
                                                                                                                                                   Components per Engine:       1
Component Description : OEM Assembly of Additional or Revised Lubrication Components to Engine
Component Quote Level:          Full Quote|~X~|
                                                                                                   Part Number: 1300-N0101-00
                                                                                        Modification Quote)
                                                                                                                              Annual Component Volume:    450,000
                                                                                                                             Weekly Component Volume:    9,574
                                                                                                                                   Estimated Product Life:      10
                                                                                                                                                                                               APPENDIX G.1-13, (6of6)
                                                                                                                                                                                                           Print Dale:9/2/2009
                                                                                                                                                                                       OEM Plant Location:     North America
                                                                                                                                                                                    Supplier Plant Location:     North America
                                                                                                                                                                                          Shipping Method:         F.o.B
                                                                                                                                                                                    Packaging Specification:      Returnablew.
                                                                                                                                                                                                              Expendable Separators
GENERAL COMPONENT INFORMATION
!

Tie
1A
2A
3A
Part Description

1 Supplier or OEM Processin
Tube Assembly - Oil, Turbo to Engine Block
Tube Assembly- Oil, Cooler/Filler Ass'y Outlet
toTurbocharger
Filter Cooler Assembly - Oil (Includes Seals)
Part Number

3 & Assembly (Full Co
1370-N0101-02
1306-N0101-01-11
(1370-N0101-01)
1306-N0101-01
QTY Per Assembly

st m
1
1
1
GENERAL MANUFACTURING INFORMATION
Primary Process
Description

pping)
InstallTube Assembly to
Engine
Install Hose to Turbo
Assembly, Run Down Bolt
Install Filter Cooler Assembly
and Run Down 4 Bolts
Purchase Part - Commodity ( Value taken from Purchase Part Database)
1A
2A
3A
4A
5A
6A
7A



Bolt - Tube Assembly , Oil, Turbo Outlet S Block
Washer - Bolt - Tube Assembly , Oil, Turbo
Outlet
Tube Assembly - Oil, Turbo to Engine Block
Bolt hose oil cooler to turbo
Bolt -Filter Cooler Assembly
Filter Cooler Assembly - Oil (Includes Seals)
Tube Assembly- Oil, Cooler/Filter Ass'y Outlet
toTurbocharger



1380-N0101-06
1380-N0101-09
1370-N0101-02
1306-N0101-01-12
1380-N0101-08
1306-N0101-01
1370-N0101-01



2
4
1
1
4
1
1





Banjo Bolts
Banjo Washers





OEM or Supplier


OEM
OEM
OEM

S
S
SAC
S
SAC
SAC





Material
Specification


Not Applicable
Not Applicable
Not Applicable


Labor Classification


General Assembly-OEM
General Assembly-OEM


Burden
Classification


EngineAssembly.OEM
EngineAssembly.OEM
EngineAssembly.OEM


MANUFACTURING RATES
Finished Pieces Per Hour


129
240
180


"Syndicates Component is Supplied directly to T1 or OEM for
Final or Sub-Assembly.
"SAC"=( Supplier Accounted Costs) Indicates Component is
Supplied directly to T1 or OEM for Final or Sub- Assembly. In
addition component material cost is accounted for in T1 quote
sheet. Thus component cost will only be included for Mark-up
Calculations.
"Alpha-Numeric Character" = Indicates purchase parts are
brought in by T2/T3 Supplier for Subassembly.
^ 	 1



















Number of Operators


1
1
1







SL
c
if


0.000
0.000
0.000




T1o



Packaging Calculations
Rack/Pallet Investment Amortization:
Expendable Packaging in Piece Cost:
Material
Cost
$/lb


$0.00
$0.00
$0.00




Labor
Rate
$/Hour


$83.31
$83.31
$83.31




Burden
Rate
$/Hour


$150.21
$150.21
$150.21




OEM Tola Manufacturing Cost:
T1 or OEM Mark-Up Rates:
m &T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:


Cost per
Piece
$0.000
Cost per
Pfece
$0.00








Total
Amount
$0
Tier Pad
Price Per
$0.00
MANUFACTURING COSTS
Material
Cost


$0.00
$0.00
$0.00



Material
$22.64

Labor/ Part


$0.65
$0.35
$0.46



Labor
$1.46
$1.46
Burden/
Part


$1.17
$0.63
$0.83



Burden
$2.63

Total 1 =
Material + Labor + Burden


$1.82
$0.97
$1.30



TMC


MARK-UP COSTS
End
Item
Scrap
Rate


0.00%
0.00%
0.00%



Scrap
0.00%
$0.00

SG&A
Rate


0.00%
0.00%
0.00%



SG&A
0.00%
$0.00

Profit
Rate


0.00%
0.00%
0.00%



Profit
0.00%
$0.00

ED&T/
R&D
Rate


0.00%
0.00%
0.00%



ED&T
0.00%
$0.00

Total
Mark-up
Rate


0.00%
0.00%
0.00%
Supplier
Account Cost
$0.00
$0.00
$3.84
$0.00
$0.00
$13.78
$4.09

Total Mark-
up
$0.00
0.00%
$0.00
$0.00
Total Mark
up Cost


$0.00
$0.00
$0.00
Price/ Unit
$0.24
$0.03
$3.84
$0.05
$0.07
$13.78
$4.09



TOTAL COSTS
Total 2 =
Totall + Total Mark-up


$1.82
$0.97
$1.30
Price Net, PIA
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

LT]

	 >
Packaging
Cost:
Net Cost Impact to Vehicle:


Total 3 =
Total 2 * Qty per Ass'y


$1.82
$0.97
$1.30
Net, End Item
$0.48
$0.12
$3.84
$0.05
$0.28
$13.78
$4.09
I

1
$26.72
$26.72
$5.02
$0.00
$5.02

TOOLING &
Tooling Assumptions
"X1000 "








$0
NVESTMENT
Investment Assumptions
"X1000 "








$0


Lump Sum
Payment {%]
0.00%
Tier Pads
Pallet/Rack
0
Total) of Pieces
4,500,000
Divider Pads,
Price Per
$0.00
Nuirtoerof
Months
60
Divider Pads
Pallet/Rack
0
Interest
Rate

Otherffl
Packaging
Price Per
$0.00


Otherffl
Pads
Pallet/Rack
0
Cost per
Pallet /Rack
$0
Otherf)2
Packaging
Price Per
$0.00
Total
Nuirtoerof
Pallets/
Racks
Required
57447
Otherf)2
Pads
Pallet/Rack
0
Nuirtoerof
Parts per
Pallet/ Rack
1
Otherf)3
Packaging,
Price Per
$0.00
Supplier,
Customer and
In-transit
Inventory
Requirements
{Weeks]
6
Other #3 Pads
Pallet/Rack
0
Supplier,
transit Inventory
Requirements
{Parts]
57447


Packaging Cost Total: $0.000


Packaging Cost for Fasteners included in
fastener piece price.
No other packaging costs required.

File:13 Lubrication Subsystem 032309.xls
EPAContract: EP-C-07-069WA1-3
                                                                                                         Appendix 6.1-13,10of11
                                                                                                                                                                                                       Form Author: G.Kolwich
                                                                                                                                                                                                       (248)373-6000 Ext. 2411

-------
Engine Assembly 1300
                                                                                         Manufacturing Assumption and Quote Summary
                                                                     APPENDIX G.1-13, (6of6)
                  Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                       Vehicle Class: Compact/Economy 2-4 Passenger	
                        Study Case*: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class)
                 System Description: 2007 Mini Cooper S. 1.6L14,16V DOHC GDI Turbo
Component Description:  OEM Assembly of Additional or Revised Lubrication Components to Engine
Component Quote Level:          Full Quote|~X~|
                                                                                                  Part Number: ISOO-NOIOI-OO
                                                                                        Modification Quote
_OEM Operating Pattern (Weeks/Year):      47
         Annual Engine Volume (CPV):    450,ooo
              Components per Engine:      1
           Annual Component Volume:    450,000
           Weekly Component Volume:     9,574
                Estimated  Product Life:      10
                                                                                                                                                                                      OEM Plant Location:
                                                                                                                                                                                   Supplier Plant Location:
                                                                                                                                                                                         Shipping Method:
                                                                                                                                                                                   Packaging Specification:
                                                                                                                                                                                                                         )ale:9/2/2009
                                                                                                                                                                                                                           North America
   Returnable w.
Expendable Separators
GENERAL COMPONENT INFORMATION


!



Part Description



Part Number


%
YPerAssembl

GENERAL MANUFACTURING INFORMATION


Primary Process
Description


0
EM or Supplier



Material
Specification



Labor Classification



Burden
Classification

MANUFACTURING RATES
-n
^
ed Pieces Per
°

?
ber of Operato
ii

i
i!
c
sf



Material
Cost
$/lb



Labor
Rate
$/Hour



Burden
Rate
$/Hour

MANUFACTURING COSTS


Material
Cost



Labor/ Part



Burden/
Part

s
1
||
i
MARK-UP COSTS


End
Item
Scrap
Rate



SG&A
Rate



Profit
Rate



ED&T;
R&D
Rate



Total
Mark-up
Rate



Total Mark
up Cost

TOTAL COSTS

1
Total 2 =
1+ Total Mark
•5

§
J|
•<"
TOOLING &

I
ngAssumptio
"X1000 "
«
NVESTMENT
—
1
x= S
If
i
File:13 Lubrication Subsystem 032309.xls
EPAContract: EP-C-07-069WA1-3
                                                                                                        Appendix 6.1-13,11 of 11
                                                                              Form Author: G.Kolwich
                                                                             (248)373-6000 Ext. 2411

-------
                   Appendix G.1 - Subsystem 14
                        Cooling Subsystem
                         Case Study #0101
                        MAQS Worksheets
File:14 Cooling System 033109.xls
EPA Contract:EP-C-07-069 WA1-3                           Appendix G.1-14,1 of 9

-------
Pump-Aux. Coolant 1401 R5
                                                                                              Manufacturing Assumption and Quote Summary
                                                                                                                                                                APPENDIX G.1-14(1of5)
                                                                                                                                                                           Print Dale:9/2/2009
                Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                     Vehicle Class: Compact/Economy 2-1 Passenger
                      Study Case#: N0101(N = New, 01 = Technology Package, 01 = Vehicle Class)
               System Description: 2007 Mini Cooper s. 1.6L n, 16V DOHC GDI Turbo
          Component Description: Pump-Auxiliary Coolant, Electric
          Component Quote Level:   I* Full Quote
                                                                                                            Part Number: H01-N0101-02
r Modification
                         F Differential Quote (Quote Summary includes
OEM Operating Pattern (Weeks/Year):      n
        Annual Engine Volume (CPV):	
             Components per Engine:      1
          Annual Component Volume:    <50,ooo
          Weekly Component Volume:     9,57<
              Estimated Product Life:      10
                                                                                                                                                                                                            OEM Plant Location: North America
                                                                                                                                                                                                         Supplier Plant Location: North Americ
                                                                                                                                                                                                          OEM/T1 Classification:
                                                                                                                                                                                                                                         	
                                                                                                                                                    Shipping Method: FOB Ship Point
                                                                                                                                              Packaging Specification:	
GENERAL COMPONENT INFORMATION
1
£

Tie
A
2A
3A
Pu
A
2A
3A
4A
1A
1B
1C
Part Description

1 Supplier or OEM Processing
Charge Impeller Assembly
INTENTIONAL BLANK SPACE
Pump-Auxiliary Coolant, Electric Subassembly
chase Part - High Impact Item
Motor Housing Assembly
End Cap Motor close out
Housing Impellor Cavity
ImpellorWater Pump
INTENTIONAL BLANK SPACE
Bracket Suba sembly - Auxiliary Pump to Oil
Bracket Suba sembly - Auxiliary Pump to Oil
Bracket Suba sembly - Auxiliary Pump to Oil
Part Number

& Assembly (Full Cos
401-N01 01 -02-3-1
401-N0101-00(NewP/N)
Full Cost Mapping)
401-N01 01 -02-1-1
401-N01 01 -02-1-2
401-N01 01 -02-2-1
401-N01 01 -02-3-1-1
475-N0101-01-03
147 5-N01 01 -01-02
147 5-N01 01 -01-01
Purchase Part - Commodity ( Value taken from Purchas
2
3
4
5
10A
1 A
12A



0-ring - Motor Housing to Impeller Housing
Motor Winding Assembly
E-Clip
Bolt pumpto bracket
Wire Harness Retention Clips
Hose Assembly - Oil Filer/Cooler Assy to
Auxiliary Pump



1 40 1-N010 1-02-72
1401-N01 01 -02-1-1-3
401-N0101-02-5
401-N01 01 -02-2-2
NA
470-N0101-04
470-N01 01-03



D
?
CT

tma
1
1
0
1
0

1
1
1
1
0
GENERAL MANUFACTURING INFORMATION
Primary Process
Description

pping)
Magnetize Impeller Assembly
Final Assembly

Apply Coating
; Part Database)
1
1
4
1
1
4
3
2
1
1





Terminals Tin Plate
(Uncharged, Approx 10x20x2.5)
Reguired for 02 Sensor, Thus
No Cost Impact.





OEM/Supplier
Classification


T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.

T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.
F2/T3 Plate/Finish Mech., SSLC

S
S
S
S
S
SAC
SAC





Material
Specification


Not Applicable
Not Applicable
Not Applicable

PPS-GF40, Inject.
PPS-GF35-MF30, Inject.
PPS-GF35-MF30, Inject.
PPS-GF40, Inject.
Not Applicable


Labor
Classification


General Assembly

MoloyCast/Sinter Operator
MoloyCast/Sinter Operator
MoloyCast/Sinter Operator
MoloyCast/Sinter Operator
Cut/Punch/Forming Operator
Plating/Coating Operator


Burden
Classification


Mech Assembly, MC, Base
Mech Assembly, LC, Base

Inject. Mold, MLS
Inject. Mold, MLS
Inject. Mold, MLS
Inject. Mold, MLS
Plate/Finish, SMS, LMC


MANUFACTURING RATES
Finished Pieces Per Hour


240
240
SSSSS
200
am

360
769
626
333
am
600
240
720


'Syndicates Componen is Supplied directly to T1 or OEM for Final or Sub-
Assembly.
'SAC'=(Supplier Accounted Costs) Indicates Component is Supplied directly to
T1 or OEM for Final or Sub-Assembly. In addition component material cost is
accounted for in T1 quote sheet. Thus component cost will only be included for
Mark-up Calculations.
'Alpha-Numeric Charac er1 = Indicates purchase parts are brought in by T2/T3
Supplier for Subassembly.
























Number of Operators


1
2
0
4
0

0.5
0.5
0.5
0.5
0
0.5







Number of Lines


1
1
1
1
1

1
1
1
1
1
1
1
1







Parallel Processing
Multiplier


1
9
1
4
1

2
1
1
1.5
1
1
1
1







S
1
I
CT


0.000
0.000
0.000
0.000
0.000

0.110
0.025
0.094
0.100
0.000
0.808
0.000
0.010







Material
Cost
$/lb
(DB)


$0.00
$0.00
SN/A
$0.00


$6.02
$3.86
$3.86
$6.02
$0.45
$0.00
$20.00




T1 or


Labor
Rate
$/Hour
(DB)


$35.51
$35.51
SN/A
$35.51


$43.52
$43.52
$43.52
$43.52
$42.18
$42.18
$55.17




Burden
Rate
$/Hour
(DB)


$30.00
$30.00
SN/A
$15.00


$150.01
$150.01
$150.01
$150.01
$100.10
$100.10
$100.17




Applied
Burden
Rate
$/Hour


$30.00
$270.00
SN/A
$60.00


$300.02
$150.01
$150.01
$225.02
$100.10
$100.10
$100.17




OEM Total Manufacturing Cost:
T1 or OEM Mark-Up Rates:
&T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:



MANUFACTURING COSTS
Material
Cost


$0.00
$0.00
SN/A
$0.00


$0.66
$0.10
$0.36
$0.60
$0.36
$0.00
$0.20



Material

3.90
Labor/ Part


$0.15
$0.30
SN/A
$0.71


$0.06
$0.03
$0.03
$0.07
$0.04
$0.18
$0.08



Labor
$1.63

Burden/
Part


$0.13
$1.13
SN/A
$0.30


$0.83
$0.20
$0.24
$0.68
$0.17
$0.42
$0.14



Burden


IF
$
SL
H
CD


$0.27
$1.42
SN/A
$1.01


$1.56
$0.32
$0.64
$1.34
$0.57
$0.59
$0.42



TMC


MARK-UP COSTS
End
Item
Scrap
Rate
(DB)


0.00%
0.00%
SN/A
0.00%


0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.30%



Scrap
$0.18

SG&A
Rate
(DB)


0.00%
0.00%
SN/A
0.00%


0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
6.00%



SG&A
$1.80

Profit
Rate
(DB)


0.00%
0.00%
SN/A
0.00%


0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
4.00%



Profit
$2.05

ED&T/
R&D
Rate
(DB)


0.00%
0.00%
SN/A
0.00%


0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%



ED&T
$1.03

Total
Mark-
up
Rate


0.00%
0.00%
SN/A
0.00%


0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
10.30%
Supplier
Cost
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$2.07
$3.81

Total
Mark-up
19.70%
$5.06

Total
Mark-
up
Cost


$0.00
$0.00
SN/A
$0.00


$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.04
Purchase
Price/ Uni
$0.09
$0.04
$0.45
$4.50
$5.00
$0.02
$0.05
$0.02
$0.01
$0.00
$2.07
$3.81



TOTAL COSTS
2.
SL
+ —i
S" ^
I"
-c


$0.27
$1.42
SN/A
$1.01


$1.56
$0.32
$0.64
$1.34
$0.57
$0.59
$0.46
Purchase
Price Net,
PIA
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

Q
	 m
	 *
Packaging Cost:
Net Cost Impact to Vehicle:
SL
si
is-
s
£


$0.27
$1.42
$0.00
$1.01
$0.00

$1.56
$0.32
$0.64
$1.34
$0.00
$0.57
$0.59
$0.46
Purchase
Price Net,
End Item
$0.09
$0.04
$1.80
$4.50
$5.00
$0.02
$0.05
$0.08
$0.03
$0.00
$2.07
$3.81
I
I
$25.67
$25.67



TOOLING &
Tooling Assumptions
"X1000 "










$0
NVESTMENT
Investment Assumptions
"X1000 "










$0

File:14 Cooling System 033109.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                 Appendix G.1-14,2of9
                                                                                                                                                                       Form Author: G. Kolwich
                                                                                                                                                                       (248)373-6000 Ext. 2411

-------
Pump-Aux. Coolant 1401 R5
                                                                                             Manufacturing Assumption and  Quote Summary
                   APPENDIX G.1-14(1of5)
                             Print Date:9/2/2009
                Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                     Vehicle Class: Compact/Economy 2-1 Pa!
                      Study Case#: N0101(N = New, 01 = Technology Package, 01 = Vehicle Class)
               System Description: 2007 Mini Cooper s. 1.6L n, 16V DOHC GDI Turbo
Component Description: Pump-Auxiliary Coolant, Electric
Component Quote Level:   I* Full Quote
                                                                                                            Part Number: H01-N0101-02
                                                          r Modilicatio
                                                                                   F Differential Quote (Quote Summary includes
OEM Operating Pattern (Weeks/Year):
        Annual Engine Volume (CPV):
             Components per Engine: _
          Annual Component Volume:_
          Weekly Component Volume:
              Estimated Product Life:
                                                                                                                                                                                                           OEM Plant Location: North America
                                                                                                                                                                                                        Supplier Plant Location: North Americ
                                                                                                                                                                                                         OEM/T1 Classification:
                                                                                                                                                                                                                                        	
       Shipping Method: FOB Ship Point
Packaging Specification:	
GENERAL COMPONENT INFORMATION
1
S

Part Description

Part Number

D
?
CT

GENERAL MANUFACTURING INFORMATION
Primary Process
Description

OEM/Supplier
Classification

Material
Specification

Labor
Classification

Burden
Classification

MANUFACTURING RATES
Finished Pieces Per F
1
Number of Operato

NVESTMENT
Investment Assumpti
"X1000 "
3,
PACKAGING CALCULATIONS:
Packaging Type: Option 1 w. Expendable Dividers
Part Size: 340X130X90
Parts/Layer3X9
Number of Layers: 9
Rack/Pallet Investment Amortization


Expendable Packaging in Piece Cost
Packaging CostTota


Cost per
Piece





$0.00












Total
Amount





$0.00


Lump Sum
OT








Total * of
Pieces





$0.00


Number of
Months

60






Interest
Rate


Other *1
Packaging

$0.00






Other*!

Pallet/Rack


£
1
1
1
$500
Other*!
Packaging

$0.00
_
g,|
% 3
=.9.

236
Other*!

Pallet/Rack

=
1

Z 9

243
Other #3

Price Per
$0.00
f

| £•
-------
Hose,0il Cool. -Aux Pump 1470D
                                                                                                    Manufacturing Assumption and Quote Summary
                                                                                                                                                                                                                      APPENDIX G.1-14(2of5)
                                                                                                                                                                                                                                 Print Dale:9/2/2009
                 Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                     Vehicle Class: CompacKEconorny24 Passenger	
                      Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class;
               System Description: 2007 Mini Cooper s. 1.6L 14,16V DOHC GDI Turbo
 Component Description: Hose Assembly - Oil Filer/Cooler Assy to Auxiliary Pump
Component Quote Level:         Full Ouotel X  I
                                                                                                Part Number: 1470-N0101-04
                                                                                             n Quote|    |
_OEM Operating Pattern (Weeks/Year):     n
_       Annual Engine Volume (CPV):_
_             Components per Engine:_
_          Annual Component Volume:_
_         Weekly Component Volume:    9,57<
                Estimated Product Lite:     10
                                                                                                                                                                                         OEM Plant Location:     North America
                                                                                                                                                                 <50,ooo     Supplier Plant Location:     North America
                                                                                                                                                                    1              Shipping Method:        F.O.B
                                                                                                                                                                 <50,ooo     Packaging Specification:      Retumablew.
                                                                                                                                                                                                                Expendable Separators
GENERAL COMPONENT INFORMATION
1
S

Tie
1A
2A
Part Description

1 Supplier or OEM Processing
Hose -Oil Filter/Cooler Ass'y to Auxiliary Pump
Hose -Oil Filter/Cooler Ass'y to Auxiliary Pump
Part Number

& Assembly (Full Cos
1470-N0101-04-1
1470-N0101-04-1
O
?
CT

tma
1
1
0
GENERAL MANUFACTURING INFORMATION
Primary Process
Description

pping)
Extrude & Shape Hose
Purchase Part - Commodity ( Value taken from Purchase Part Database)
1A
2A



Hose Clamp



1470-N0101-04-2
1470-N0101-03-1



2
0
0
0
0
0
0
0
0
0
0
0
0





Nylon
Steel- Zinc Phosphate





OEM or Supplier


s
s

B2B
B2B





Material
Specification


SBR-Fiber Rein.,
Extruded
Purchased Parts


Labor Classification


Extruding/Drawing Operator
General Assembly


Burden
Classification


CompVExl. Mold, LMC
Mech Assembly, LC,
Base


MANUFACTURING RATES
Finished Pieces Per Hour


273
240
sssss


'Syndicates Component is Supplied directly to T1 or OEM for
Final or Sub- Assembly.
'SAC'=(Supplier Accounted Costs) Indicates Component is
Supplied directly to T1 or OEM for Final or Sub-Assembly. In
addition component material cost is accounted for in T1 quote
sheet. Thus component cost will only be ncluded for Mark-up
Calculations.
'Alpha-Numeric Character' = Indicates purchase parts are
brought in by T2/T3 Supplier for Subassembly.

























Number of Operators


1.5
2
0







s
1
I
CT


0.127
$0.62
0.000




T1 o



Packaging Calculations
Rack/Pallet Investment Amort zation:
Expendable Packaging in Piece Cost:
Materia
Cost
$/lb
(DB)


$1.85
$1.00
SN/A




Labor
Rate
$/Hour
(DB)


$54.35
$35.51
SN/A




Burden
Rate
$/Hour
(DB)


$100.04
$15.00
SN/A




OEM Total Manufacturing Cost:
T1 or OEM Mark-Up Rates:
&T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:


c;r

c;r









AT::I,
$0
Price Per
$0.00
MANUFACTURING COSTS
Materia
Cost


$0.23
$0.62
SN/A



Material


Labor/ Part


$0.30
$0.30
SN/A



Labor
$0.59

Burden/
Part


$0.37
$0.06
SN/A



Burden


IF
$
SL
H
CD


$0.90
SN/A



TMC


MARK-UP COSTS
End
Item
Scrap
Rate


0.00%
0.00%
0.00%



Scrap
0.30%
$0.01

SG&A
Rate


0.00%
0.00%
0.00%



SG&A
$0.11

Profit
Rate


0.00%
0.00%
0.00%



Profit
4.00%
$0.03

ED&T/
R&D
Rate


0.00%
0.00%
0.00%



ED&T
$0.00

Tola
Mark-
up
Rate


0.00%
0.00%
0.00%
Supplier
Account
Cost
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

Total
Mark-up
10.30%
$0.19

Total
Mark-
up
Cos


$0.00
$0.00
SN/A
Price/ Uni
$0.28
$0.17
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00



TOTAL COSTS
2.
SL
+ —i
s? ^
I '
•c


$0.90
$0.98
SN/A
Purchase
Price Net,
PIA
$0.28
$0.34
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

Q
	 >\1
	 *
Packaging Cost:
Net Cost Impact to Vehicle:

»i

™-




"S*
$0.00


60
Divider Pads

0



o,he,,t

$0.00



Other*

0


$0
Other,

$0.00
Total


Othe,^

0
™
1
0,he,«

$0.00
ts (Weeks

0,he,«

0
Repiremer
ts (Paris



Packaging Cost Total: $0.000

SL
si
is-
S
*


$0.90
$0.98
$0.00
Purchase
Price Net,
End Item
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
1
$1.88
$1.88



TOOLING &
Tooling Assumptions
"X1000 "








$0
NVESTMENT
Investment Assumptions
"X1000 "








$0


Packaging Options: Shipped w. Aux.
Pump, No Packaging Costs Required

File:14 Cooling System 033109.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                    Appendix G.1-14,4of9
                                                                                                                                                                                                                              Form Author: G. Kolwich
                                                                                                                                                                                                                              (248)373-6000 Ext. 2411

-------
HoseAss'y-Turbo-Aux Pump 1470C
                                                                                        Manufacturing Assumption and  Quote Summary
                                                                                                                 APPENDIX G.1-14(3of5)
                  Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                       Vehicle Class: Compact/Economy 2-4 Passenger	
                                            _OEM Operating Pattern (Weeks/Year):	«_
                        Study Case*: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class)
                System Description: 2007 Mini Cooper S. 1.6L14,16V DOHC GDI Turbo
                                                     Annual Engine Volume (CPV):    "50,ooo
                                                          Components per Engine:_     1
            Component Description: Hose Assembly - Auxiliary Pump to Turbo
            Component Quote Level:
                                                                                                 Part Number: 1470-N0101-03
Modification Quote
                                                       Annual Component Volume:    450,000
                                                       Weekly Component Volume:    9,574
                                                            Estimated Product Life:     10
    OEM Plant Location:
 Supplier Plant Location:
       Shipping Method:
Packaging Specification:
                                                                                                                                                                                                                   Print Date:9/2/2009
                                                                                                                                                                                                                   North America
   Return able w.
Expendable Separators
GENERAL COMPONENT INFORMATION


I




Tie
1A
2A
3A
4A
5A
6A
7A



Part Description




1 Supplier or OEM Processin
Fitting Hose End
Fitting Tube End
Tube
Tube Assembly - Banjo Joint for Turbo
Hose Assembly -Auxiliary Pump to Turbo
Hose Assembly -Auxiliary Pump to Turbo
Hose Assembly -Auxiliary Pump to Turbo



Part Number




3 & Assembly (Full Co
1306-N0101-01-11-5
1370-N0101-02-4
1306-N0101-01-11-5-2
1470-N01 01 -03-03
1470-N01 01 -03-02
1470-N01 01 -03-01
1470-N0101-03


3
?
>
S
2


st m
1
1
1
1
1
1
1
0
GENERAL MANUFACTURING INFORMATION


Primary Process
Description




pping)
Cold Headed Tubing
CNC Machine
Cut to size and form
Assemble, Braze and Plate
ExtrudeS Shape Hose
Overmold BanjoTubeto Hose
GScifmr9*"98"'

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

1A
2A















Hose Clamp
Sheath Hose protection (Turbo)















1470-N0101-03-1
1470-N0101-03-2



































Steel- Zinc Phosphate




















O
S
5
~o




S
S
s
s
s
s
s



B3C
B3C




















Material
Specification





LC-Steel-1215, Tubing
LC-Steel-1215, Bar
LC-Steel-1215, Tubing
Not Applicable
SBR-FiberRein.,
Ex ruded
^JylonGe, Inject.
Purchased Parts






Labor Classification





-orging Operator
CNC Operator
Cut/Punch/Forming Operator
G™,IASS-I»
E»,u*g,D,,ingOp»,,.,
Mold/Cast/Sinter Operator
General Assembly






Burden
Classification





Cold Forge, LMC
CNC Turning, MHC
Hydro/CNC Form,
SMS, LMC
Mech.Assembly.LC
Comp./Ext. Mold, LMC
Inject. Mold, SMS
Mech Assembly, LC,




MANUFACTURING RATES
-n
3.
3!
1


1


720
240
360
257
581
360
200
###«



"Syndicates Component is Supplied directly to T1 or OEM for
Final or Sub-Assembly.

"SAC"=( Supplier Accounted Costs) Indicates Component is
Supplied directly to T1 or OEM for Final or Sub- Assembly. In
addition component material cost is accounted for in T1 quote
sheet. Trius component cost will only be included for Mark-up
Calculations.

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


































w
s.
o

?T
55


0.5
0.5
0.5
2
1.5
1
1
0























i
i!
c
(5
Sf



0.092
0.270
0.030
0.000
0.091
0.007
$0.30
0.000

















T1o






Material
Cost
$/lb





$0.62
$0.62
$0.62
$0.00
$1.85
$1.74
$1.00
#N/A



















Labor
Rate
$/Hour





$38.52
$35.70
$42.18
$35.51
$54.35
$43.52
$35.51
#N/A



















Burden
Rate
$/Hour





$100.09
$125.00
$100.12
$100.19
$100.04
$100.01
$15.00
#N/A

















OEM Total Manufacturing Cost:
T1 or OEM Mark-Up Rates:
&T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:






MANUFACTURING COSTS


Material
Cost





$0.06
$0.17
$0.02
$0.00
$0.17
$0.01
$0.30
#N/A
















Material
$0.72




Labor/ Part





$0.03
$0.07
$0.06
$0.28
$0.14
$0.12
$0.18
#N/A
















Labor
$0.87

$0.87


Burden/
Part





$0.14
$0.52
$0.28
$0.39
$0.17
$0.28
$0.08
#N/A
















Burden
$1.85


S
1
||
+ "
^
i


$0.22
$0.76
$0.36
$0.67
$0.48
$0.41
$0.55
#N/A
















TMC



MARK-UP COSTS


End
Item
Scrap
Rate




0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
















Scrap
$0.00
0.30%
$0.01



SG&A
Rate





0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
















SG&A
6.00%
$0.21



Profit
Rate





0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
















Profit
4.00%
$0.14



ED&T/
R&D





0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
















ED&T
0.00%
$0.00



Total
Mark-
up
Rate




0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
Supplier
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

Total
Mark-up
1 0.30%
$0.36



Total
Mark-
up
Cost




$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
#N/A
Purchase

$0.17
$0.13
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00




TOTAL COSTS

1
if
S n
i "
S-
±


$0.22
$0.76
$0.36
$0.67
$0.48
$0.41
$0.55
#N/A
Purchase
Price Net,

$0.17
$0.13
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

E
*-u

	 >
Packaging Cost:
Net Cost Impac to Vehicle:

§
10
s
Y

£



1
"




$0.22
$0.76
$0.36
$0.67
$0.48
$0.41
$0.55
$0.00
Purchase
Price Net,


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

r
.00
.00

.45
$3.45


$3.81
$0.00
$3.81

TOOLING &

I
j2
3. >
§ 1
.5
o'
3





























$0
NVESTMENT
—
1
= S>
Li «.
§ >
1

•g.
1





























$0


File:14Cooling System 033109*
EPA Contract: EP-C-07-069WA1-3
                                                                                                        Appendix 6.1-14,5 of 9
                                                                                                                         Form Author: G.Kolwich
                                                                                                                        (248)373-6000 Ext. 2411

-------
HoseAss'y-Turbo-Aux Pump 1470C
                                                                                        Manufacturing Assumption and  Quote Summary
                                                                                                                 APPENDIX G.1-14(3of5)
                  Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                       Vehicle Class: Compact/Economy 2-4 Passenger	
                                            _OEM Operating Pattern (Weeks/Year):      "7
                        Study Case*: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class)
                System Description: 2007 Mini Cooper S. 1.6L14,16V DOHC GDI Turbo
            Component Description: Hose Assembly - Auxiliary Pump to Turbo
            Component Quote Level:
                                                                                                 Part Number: 1470-N0101-03
Modification Quote
                                                     Annual Engine Volume (CPV):    "50,ooo
                                                          Components per Engine:      1
                                                       Annual Component Volume:    450,000
                                                       Weekly Component Volume:    9,574
                                                            Estimated Product Life:      10
    OEM Plant Location:
 Supplier Plant Location:
       Shipping Method:
Packaging Specification:
                                                                                                                                                                                                                   Print Date:9/2/2009
                                                                                                                                                                                                                   North America
   Return able w.
Expendable Separators
GENERAL COMPONENT INFORMATION
!
*

Part Description


Part Number


QTYPerAss
1
~°
GENERAL MANUFACTURING INFORMATION
Primary Process
Description


o
9
51

Material
Specification


Labor Classification











Burden
Classification



Finished Pieces
1
i




MANUFACTURING RATES
Number of Op
3
§
si
c






Packaging Calculations






Rack/Pallet Investment Amortization:

Expendable Packaging

n Piece Cost:
Material
Cost
$/lb
(DB)









$0.000
Cost per
Pece
$0.00
Labor
Rate
$/Hour













Burden
Rate
$/Hour










$0
Tier Pad
Price Per
$0.00
MANUFACTURING COSTS
Material
Cost










0.00%
Tier Pads
Pallet/Rack
0
Labor/ Part






Total) of Pieces



4,500,000
Divider Pads,
Price Per
$0.00
Burden/
Part










60
Divider Pads
Pallet/Rack
0
h
i "
i









Otherffl
Packaging
Price Per
$0.00
MARK-UP COSTS
End
Item
Scrap
Rate










Otherffl
Pads
Pallet/Rack
0
SG&A
Rate










$0
Otherf)2
Packaging
Price Per
$0.00
Profit
Rate





Total
Pallets/

Required

57447
Otherf)2
Pads
Pallet/Rack
0
ED&T/
R&D










1
Otherf)3
Packaging,
Price Per
$0.00
Total
Mark-
up
Rate



Supplier,
Customer
transit

Ftequiremei
ts {Weeks]
6
Otherf)3
Pads
Pallet/Rack
0
Total
Mark-
up
Cost



Supplier,
Customer
transit

Requiremei
fc {Parts]



Packaging Cost Total: $0.000
TOTAL COSTS
Total 2
Total 1 + Total
3-
±









!i
;
•<
TOOLING &
Tooling Assun
"X1000

3
NVESTMENT
Investment Ass
"X1000
1
i

Packaging Options: Shipped w. Aux.
Pump, No Packag ng Costs Required







File:14 Cooling System 033109.xls
EPAContract: EP-C-07-069WA1-3
                                                                                                        Appendix 6.1-14,6 of 9
                                                                                                                         Form Author: G.Kolwich
                                                                                                                        (248)373-6000 Ext. 2411

-------
HoseAss'yTurbo-Thermo, 1470
                                                                                        Manufacturing Assumption and Quote Summary
                                                                                                                 APPENDIX G.1-14, (4of5)
                                                                                                                             Print Date:9/2/2009
                  Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                       Vehicle Class: Compact/Economy 2-4 Passenger	
                        Study Case*: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class)
                System Description: 2007 Mini Cooper S. 1.6L14,16V DOHC GDI Turbo
            Component Description: Hose Assembly - Turbo Assembly to Thermostat/Coolant Valve
            Component Quote Level:          Full Quote|~X~|
           Part Number: 1470-N0101-02
Modification QuotelI
_OEM Operating Pattern (Weeks/Year):      "?
         Annual Engine Volume (CPV):    "50,ooo
              Components per Engine:      1
           Annual Component Volume:    450,000
           Weekly Component Volume:     9,574
                Estimated Product Life:      10
    OEM Plant Location:
 Supplier Plant Location:
       Shipping Method:
Packaging Specification:
                                                                                                                                   Return able w.
                                                                                                                                Expendable Separators
GENERAL COMPONENT INFORMATION

!


Tie
1A
2A
3A
4A


Part Description


1 Supplier or OEM Processin
Tube Assembly Prefabricated
Tube Assembly Prefabricated
Tube Assembly Prefabricated
Hose Assembly - Turbo Assembly to
Thermostat/Coolant Valve

Purchase Part - High Impact Item
1A
2A
3A
4A
5A
Fitting Tube End
Bracket Tube Attachment
Preformed Tube 1 0mm OD
Preformed Tube 1 4mm OD
Hose - Oil Filter/Cooler Ass'y to Auxiliary Pump

Part Number


3 & Assembly (Full Co
1470-N01 01 -02-04-01
470-N01 01 -02-04-02
1470-N01 01 -02-04-02
1470-N0101-02

Full Cost Mapping)
1370-N0101-02-4
1470-N0101-02-4-4
1470-N01 01 -02-4-1
1470-N0101-02-4-2
1470-N0101-04-1
3
Y Per Assembl


st m
1
1
1
1
0

1
1
1
1
1
GENERAL MANUFACTURING INFORMATION

Primary Process
Description


pping)
Assemble, Braze
Projection Weld Brkt
Plating
Assemble SBR Tube with two
lose clamps


CNC Machine
Stamping
Cu,,.siz,,ndtam
Cu,,.siz,,ndtam
ExtrudeS Shape Hose
Purchase Part - Commodity ( Value taken from Purchase Part Database)
1A
2A
















Hose Clamp small ID
Hose Clamp large ID
















1470-N0101-02-2
1470-N0101-02-3
























































O
EM or Supplier



s
s
s
s


s
s
s
s
s

s
s




















Material
Specification



Not Applicable
Not Applicable
General Underhood
Plating
Not Applicable


LC-Steel-1215, Bar
LC-Steel-1000S,Coil
LC-Steel-1215, Tubing
LC-Steel-1215, Tubing
SBR-FiberRein.,
Extruded



Labor Classification



General Assembly
General Assembly
Plating/Coating Operator
General Assembly


CNC Operator
Cut/Punch/Forming Operator
Cut/Punch/Forming Operator
Cut/Punch/Forming Operator
Extruding/Drawing Operator



Burden
Classification



Mech Assembly,
HC, Base
Mech Assembly, LC,
Base
Plate/Finish, MLS, LMC
Mech Assembly, LC,
Base


CNCTurning.MHC
Stamp/Form, SMS,
LMC
Hydro/CNC Form,
SMS, LMC
Hydro/CNC Form,
SMS, LMC
Comp./Ext. Mold, LMC


MANUFACTURING RATES
1
ed Pieces Per
1


240
240
720
240
###«

;40
600
360
240
933


"Syndicates Component is Supplied directly to T1 or OEM for
Final or Sub-Assembly.

"SAC"=( Supplier Accounted Costs) Indica es Component is
Supplied directly oT1 or OEM for Final or Sub-Assembly. In
addition component material cost is accounted for in T1 quote
sheet. Trius component cost will only be included for Mark-up
Calculations.

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


































W
ber of Operato
55


1
1
1
2
0

0.5
0.5
0.5
1
1.5





















|
i!
c
if



0.000
0.000
0.001
0.000
0.000

0.270
0.233
0.150
0.060
0.055
















T1o





Material
Cost
$/lb



$0.00
$0.00
$15.00
$0.00
#N/A

$0.62
$0.45
$0.62
$0.62
$1.85

















Labor
Rate
$/Hour



$35.51
$35.51
$55.17
$35.51
#N/A

$35.70
$42.18
$42.18
$42.18
$54.35

















Burden
Rate
$/Hour



$45.00
$15.00
$150.17
$15.00
#N/A

$125.00
$100.10
$100.12
$100.12
$100.04
















OEM Tola Manufacturing Cost:
T1 or OEM Mark-Up Rates:
C) &T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:






MANUFACTURING COSTS

Material
Cost



$0.00
$0.00
$0.02
$0.00
#N/A

$0.17
$0.10
$0.09
$0.04
$0.10















Material
$1.02
0.00
$1.02

Labor/ Part



$0.15
$0.15
$0.08
$0.30
#N/A

$0.07
$0.04
$0.06
$0.18
$0.09















Labor
$1.10

$1.10

Burden/
Part



$0.19
$0.06
$0.21
$0.06
#N/A

$0.52
$0.17
$0.28
$0.42
$0.11















Burden



1
||
i


$0.34
$0.21
$0.30
$0.36
#N/A

$0.76
$0.31
$0.43
$0.63
$0.30















TMC
$4.13


MARK-UP COSTS

End
Item
Scrap
Rate



0.00%
0.00%
0.00%
0.00%
0.00%

0.00%
0.00%
0.00%
0.00%
0.00%















Scrap
0.03%
$0.00


SG&A
Rate



0.00%
0.00%
0.00%
0.00%
0.00%

0.00%
0.00%
0.00%
0.00%
0.00%















SG&A
6.00%
$0.25


Profit
Rate



0.00%
0.00%
0.00%
0.00%
0.00%

0.00%
0.00%
0.00%
0.00%
0.00%















Profit
4.00%
$0.17


ED&T/
R&D
Rate



0.00%
0.00%
0.00%
0.00%
0.00%

0.00%
0.00%
0.00%
0.00%
0.00%















ED&T
0.00%
$0.00


Total
Mark-up
Rate



0.00%
0.00%
0.00%
0.00%
0.00%

0.00%
0.00%
0.00%
0.00%
0.00%
Supplier
Account
Cost
$0.00
$0.00
$0.00







$0.00
$0.00
$0.00
$0.00


Total Mark-
up
$0.00
10.03%
$0.41
$0.41

Total Mark
up Cost



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

$0.00
$0.00
$0.00
$0.00
$0.00
Purchase Price
Unit
$0.24
$0.00




$000

$0.00
$0.00
$0.00
$0.00
$0.00





TOTAL COSTS
1
Total 2 =
1 + Total Mark
5


$0.34
$0.21
$0.30
$0.36
#N/A

$0.76
$0.31
$0.43
$0.63
$0.30
Purchase Price
Net, PIA
$0.00
$0.00
$0.00







$0.00
$0.00
$0.00
$0.00


rj
*L

	 >•
Packaging Cost:
Net Cost Impact to Vehicle:
ET
It
1 "
£


$0.34
$0.21
$0.30
$0.36
$0.00

$0.76
$0.31
$0.43
$0.63
$0.30
Purchase
Price Net, End
Item
$0.24
$0.26
$0.00







$0.00
$0.00
$0.00
$0.00
I

$4.13
$4.13

$4.55
$0.04
$4.59

TOOLING &
I
ng Assumptio
"X1000 "
"































su
NVESTMENT
1
x= %
S **
, 1
i































»


File:14Cooling System 033109xls
EPA Contract: EP-C-07-069WA1-3
                                                                                                        Appendix 6.1-14,7 of 9
                                                                                                                          Form Author: G.Kolwich
                                                                                                                         (248)373-6000 Ext. 2411

-------
HoseAss'yTurbo-Thermo, 1470
                                                                                        Manufacturing Assumption and  Quote Summary
                                                                                                                  APPENDIX G.1-14, (4of5)
                                                                                                                             Print Date:9/2/2009
                  Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                       Vehicle Class: Compact/Economy 2-4 Passenger	
                        Study Case*: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class)
                System Description: 2007 Mini Cooper S. 1.6L14,16V DOHC GDI Turbo
            Component Description: Hose Assembly - Turbo Assembly to Thermostat/Coolant Valve
            Component Quote Level:          Full Quote|~X~|
           Part Number: 1470-N0101-02
Modification QuotelI
_OEM Operating Pattern (Weeks/Year):      "?
         Annual Engine Volume (CPV):    "50,ooo
              Components per Engine:      1
           Annual Component Volume:    450,000
           Weekly Component Volume:     9,574
                Estimated Product Life:      10
                                                                                                          OEM Plant Location:
                                                                                                       Supplier Plant Location:
                                                                                                             Shipping Method:
                                                                                                      Packaging Specification:
   Return able w.
Expendable Separators
GENERAL COMPONENT INFORMATION

!


Part Description


Part Number

%
YPerAssemb

GENERAL MANUFACTURING INFORMATION

Primary Process
Description

0
EM or Supplier


Material
Specification


Labor Classification












Burden
Classification

MANUFACTURING RATES
1
ed Pieces Per
i
W
a.
o
S
is
i
i!
c




Packaging Calculations


Rack/Pallet Investment Amortization:


Expendable Packaging in Piece Cost:

Material
Cost
$/lb




Cost per
Piece


$0.015


Pece
$0.03

Labor
Rate
$/Hour













Burden
Rate
$/Hour




Total
Amount





Price Per
$1.00
MANUFACTURING COSTS

Material
Cost




LumpSum
Payirent{%]


0.00%


Pallet/Rack
10

Labor/ Part




Total) of Pieces


2,250,000


Price Per
$3.00

Burden/
Part




Number of
Months


60


Pallet/Rack
0
1
||
i



Rate





Price Per
$0.00
MARK-UP COSTS

End
Item
Scrap
Rate










Pallet/Rack
0

SG&A
Rate




Cost per
Pallet /Rack


$200


Price Per
$0.00

Profit
Rate




Nuirtoerof
Pallets/
Required

152


Pallet/Rack
0

ED&T/
R&D
Rate




Nuirtoerof


378


Price Per
$0.00

Total
Mark-up
Rate



Supplier,
Customerand
In-transit
Inventory
{Weeks]

6


Pallet/Rack
0

Total Mark
up Cost





{Parts]

57447




Packaging Cost Total: $0.042
TOTAL COSTS
1
Total 2 =
1+ Total Mark
i






§
It
1 "
1-

TOOLING &
I
ngAssumptio
"X1000 "
3
NVESTMENT
1
x= S
§ >
, 1
1

Pallet Option »1 w. Expendable Tier Pads

Part Size 400x80x90
Parts/Layer = 3x14
Number of Layers = 9






File:14 Cooling System 033109.xls
EPAContract: EP-C-07-069WA1-3
                                                                                                           jendix G.1-14,8 of 9
                                                                                                                          Form Author: G.Kolwich
                                                                                                                         (248)373-6000 Ext. 2411

-------
Engine Assembly 1400
                                                                                        Manufacturing Assumption and Quote Summary
                                                                                                                 APPENDIX G.1-14, (5of5)
                  Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                       Vehicle Class: Compact/Economy 2-4 Passenger	
                                            _OEM Operating Pattern (Weeks/Year):	«_
                        Study Case*: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class)
                System Description: 2007 Mini Cooper S. 1.6L14,16V DOHC GDI Turbo
                                                     Annual Engine Volume (CPV):    «o,ooo
                                                           Components per Engine:_    1
            Component Description: OEM Assembly of Additional or Revised Assembly Components to Engine
            Component Quote Level:          Full Quote|~X~|
                                                                                                  Part Number: HOO-NOIOI-OO
Modification Quote
Annual Component Volume:    450,000
Weekly Component Volume:     9,574
     Estimated Product Life:      10
    OEM Plant Location:
 Supplier Plant Location:
       Shipping Method:
Packaging Specification:
                                                                                                                                                                                                                    Print Dale:9/2/2009
                                                                                                                                                                                                                    North America
                                                                                                                             Return able w.
                                                                                                                          Expendable Separators
GENERAL COMPONENT INFORMATION
!
Tie
1A
2A
3A
4A
Part Description
1 Supplier or OEM Processin
Assembly Pump-Aux. Coolant Subassembly
Hose Assembly, Turbo -Aux Pump and Hose
Ass'y- Turbo - Thermostat Valve
Hose, Oil Cooler to Aux Pump and Hose Ass'y
Turbo Thermostat Valve to Thermostat Valve
Hose Assembly - Turbo Assembly to
Thermostat/Coolant Valve
Part Number
3& Assembly (Full Co
1401-N0101-02+Subs
1470-N0101-02/03
1470-N0101-02/04
1470-N0101-02
QTY Per Assembly
st m
1
1
1
0
GENERAL MANUFACTURING INFORMATION
Primary Process
Description
pping)
Mount Auxiliary Pump to Oil
Cooler/Filter (2 Screws), Make
Install and run Banjo bolt (x2)
© turbo.
Press on Tubes and release
Hose Clamps
Run fastener to secure Hose
Assembly Bracket to Engine
Purchase Part - Commodity ( Value taken from Purchase Part Database)
1A
2A
3A
4A
5A
6A



Bolt-Hose, coolant Inlet and Outlet © Turbo
Washer banjo Bolt-Hose, coolant Inlet and Outle
Bolt-Hose Bracket, coolant Inlet and Outlet ©
Turbo
Bolt Aux pump bracket to oil cooler
Pump- Auxiliary Coolant, Electric
Hose Assembly - Turbo Assembly to
Thermostat/Coolant Valve



1480-N0101-06
1480-N0101-13
1480-N0101-14
1480-N0101-07
1401-N0101-02
1470-N0101-02



2
4
1
3
1
1





Banjo Bolts
Banjo Washers





OEM or Supplier

OEM
OEM
OEM
OEM

S
S
1
3,0





Material
Specification

Not Applicable
Not Applicable
Not Applicable
Not Applicable


Labor Classification

General Assembly-OEM
General Assembly-OEM
General Assembly-OEM


Burden
Classification

EngineAssembly.OEM
EngineAssembly.OEM
EngineAssembly.OEM
EngineAssembly.OEM


MANUFACTURING RATES
Finished Pieces Per Hour

129
129
129
300


Number of Operators

1
1
1
1


|"S"= Indicates Component is Supplied directly to T1 or OEM for
Final or Sub-Assembly.
"SAC"=( Supplier Accounted Costs) Indicates Component is
Supplied directly to T1 or OEM for Final or Sub-Assembly. In
addition component material cost is accounted for in T1 quote
sheet. Thus component cost will only be included for Mark-up
Calculations.
"Alpha-Numeric Character" = Indicates purchase parts are
brought in by T2/T3 Supplier for Subassembly.




















SL
c
f

0.000
0.000
0.000
0.000




T1o



Packaging Calculations
Rack/Pallet Investment Amortization:


Expendable Packaging in Piece Cost:
Material
Cost
$/lb

$0.00
$0.00
$0.00
$0.00




Labor
Rate
$/Hour

$83.31
$83.31
$83.31
$83.31




Burden
Rate
$/Hour

$150.21
$150.21
$150.21
$150.21




OEM Total Manufacturing Cost:
T1 or OEM Mark-Up Rates:
&T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:


Cost per
Piece
$0.000
Cost per
Pfece
$0.00








Total
Amount
$0
Tier Pad
Price Per
$0.00
MANUFACTURING COSTS
Material
Cost

$0.00
$0.00
$0.00
$0.00



Material
$30.23

Labor/ Part

$0.65
$0.65
$0.65
$0.28



Labor
$1.94
$1.94
Burden/
Part

$1.17
$1.17
$1.17
$0.50



Burden
$3.50

Total 1 =
Material + Labor + Burden

$1.82
$1.82
$1.82
$0.78



TMC


MARK-UP COSTS
End
Item
Scrap
Rate

0.00%
0.00%
0.00%
0.00%



Scrap
0.00%
$0.00

SG&A
Rate

0.00%
0.00%
0.00%
0.00%



SG&A
0.00%
$0.00

Profit
Rate

0.00%
0.00%
0.00%
0.00%



Profit
0.00%
$0.00

ED&T/
R&D
Rate

0.00%
0.00%
0.00%
0.00%



ED&T
0.00%
$0.00

Total
Mark-
up
Rate

0.00%
0.00%
0.00%
0.00%
Supplier
Account
Cost
$0.00
$0.00
$0.00
$0.00
$24.91
$4.59

Total
Mark-up
0.00%
$0.00

Total
Mark-
up
Cost

$0.00
$0.00
$0.00
$0.00
Purchase
Price/ Unit
$0.24
$0.02
$0.12
$0.02
$24.91
$4.59



TOTAL COSTS
Total 2 =
Totall + Total Mark-up

$1.82
$1.82
$1.82
$0.78
Purchase
Price Net,
PIA
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

LT
	 ^u
	 >
Packaging Cost:
Net Cost Impac to Vehicle:
Total 3 =
Total 2 * Qty per Ass'y

$1.82
$1.82
$1.82
$0.00
Purchase
Price Net,
End Item
$0.48
$0.08
$0.12
$0.06
$24.91
$4.59
I
$35.68
$35.68
$6.19
$0.00
$6.19

TOOLING &
Tooling Assumptions
"X1000 "







$0
NVESTMENT
Investment Assumptions
"X1000 "







$0


Lump Sum
Payment {%]
0.00%
Tier Pads
Pallet/Rack
0
Total) of Pieces
4,500,000
Divider Pads,
Price Per
$0.00
Nuirtoerof
Months
60
Divider Pads
Pallet/Rack
0
Interest
Rate

Otherffl
Packaging
Price Per
$0.00


Otherffl
Pads
Pallet/Rack
0
Cost per
Pallet /Rack
$0
Otherf)2
Packaging
Price Per
$0.00
Total
Numberof
Pallets/
Racks
Required
57447
Otherf)2
Pads
Pallet/Rack
0
Numberof
Parts per
Pallet/ Rack
1
Otherf)3
Packaging,
Price Per
$0.00
Supplier,
Customer
and In-
Inventory
Requiremen
ts {Weeks]
6
Otherf)3
Pads
Pallet/Rack
0
Supplier,
Customer
andln-
Inventory
Requiremei
fc {Parts]
57447


Packaging Cost Total: $0.000
Packaging Cost for Fasteners ncluded in
fastener piece price.
No other packaging costs required.

File:14Cooling System 033109*
EPA Contract: EP-C-07-069WA1-3
                                                                                                        Appendix 6.1-14,9
                                                                                                                         Form Author: G.Kolwich
                                                                                                                         (248)373-6000 Ext. 2411

-------
                    Appendix G.1 - Subsystem 15
                 Air Induction Charging Subsystem
                          Case Study #0101
                         MAQS Worksheets
File:15 Air Induction Charging System 040109A.xls
EPA Contract:EP-C-07-069 WA1-3                          Appendix G.1-15,1 of 16

-------
Turbo Assembly 1501 Rev 5
                                                                                              Manufacturing Assumption and Quote Summary
                                                                                                                                         APPENDIX G.1-15(1of11)
                                                                                                                                                    Print Date:9/1/2009
              Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                  Vehicle Class: Compact/Economy 2-1 Pa!
                   Study Case#: N0101(N = New, 01 = Technology Package, 01 = Vehicle Class)
            System Description: 2007 Mini Cooper s. 1.6L n, 16V DOHC GDI Turbo
        Component Description: Turbo Charging Assembly
       Component Quote Level:   17 Full Quote
                                                                                                          Part Number: 1501-N0101-01
                                                        r Modification Quote
l~~ Differential Quote (Quote Summary includes
                                                           OEM Operating Pattern (Weeks/Year):
                                                                   Annual Engine Volume (CPV):
                                                                        Components per Engine: _
                                                                     Annual Component Volume:_
                                                                    Weekly Component Volume:
                                                                         Estimated  Product Life:
                                                                                                                                                                                                         OEM Plant Location: North America
                                                                                                                                                                                                      Supplier Plant Location: North America
                                                                                                                                                                                                       OEM/T1 Classification: T1 High Assembly Complexity
                                                                                                                                                                                                            Shipping Method: FOB Ship Point	
                                                                                                                                                                                                      Packaging Specification: Returnable
GENERAL COMPONENT INFORMATION
1
£


Part Description


Tier 1 Supplier or OEM Processing

1A
2A
3A

4A

5A

Block Turbo shaft support - cooling & lub
Housing Turbo Exhaust
Final Assembly Line

Turbine Shaft Assembly -Welded

Turbo Assembly Center Housing Rotating
Assembly (CHRA) Balancing
Purchase Part - High Impact Item

I
2A
2B
3A
3B
3C
4A
4B
4C
«

8A
9A
10A
10B
10C
11A
11B
11C
12A
12B
13A
14A
14B
14C
14D

15A
15B

15D
16A

Housing Turbo Intake Casting
Block Center Bearing Support
Block Center Bearing Support
Housing Turbo Exhaust
Housing Turbo Intake Casting
Housing Turbo Exhaust
Support Plate intake side
Support Plate intake side
Support Plate intake side
rir^tir"'

Bushing -Turbine Shaft
Seal Carrier support plate mount
Valve Exhaust Dump
ValY.Exh.ua Dump
Valve Exhaust Dump
Am - Valve to Shaft
Am -Valve to Shaft
Am -Valve to Shaft
Block control rod attachment
Block control rod attachment
AmDumpValveCortrol
impellerlntake
Impeller Intake
Impellerlntake

Turbine Wheel
Turbine Wheel
.
Turbine Wheel
Turnbine Shaft
Part Number


D
?
CT


& Assembly (Full Cost ma

1201-N01 01 -01-10
,2,,-N,,,,-,,-,S
1501-N0101-01

1201-N01 01 -01-01 -24-01

1201-N0101-01-01-24
Full Cost Mapping)

1201-N01 01 -01-07 -01-1
1201-N01 01 -01-30-02
1201-N01 01 -01-30-01
™-II-!!Io,-02
1201-N01 01 -01-09-01-01
1201-N01 01 -01-09-01
1201-N01 01 -01-26-02
1201-N01 01 -01-26-01
1201-N01 01 -01-26
1201-N01 01 -01-34

1201-N01 01 -01-32
1201-N01 01 -01-27-01
1201-N01 01 -01-09-01-05-02
1201-N0101-01-09-01-05-01
1201-N01 01 -01-09-01-05
1201-N01 01 -01-09-01-06-02
1201-N0101-01-09-01-06-01
1201-N01 01 -01-09-01-06
1201-N01 01 -01-09-01-10
1201-N0101-01-09-01-10
1201-N01 01 -01-09-01-08
1201-N01 01 -01-16-03
1201-N01 01 -01-16-02
1201-N01 01 -01-16-01
1201-N01 01 -01-16

1201-N01 01 -01-01 -24-05
1201-N01 01 -01-01 -24-04

,20,-NO,0,-0,-0,-24-02
1201-N01 01 -01-01 -24-03-01

1
1
1

1

1


1
1
1
1
1
1
1
1
1
1

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

1
1

1
1
GENERAL MANUFACTURING INFORMATION
Primary Process
Description


pping)

Block
SubassemblyExhaus, Housing
:inal Product Assembly & Test
Electron Beam Weld Turbine
Impeller to Shaft andGrind
Profile
High Speed Dynamic Balancing


F5 Heat Treat
Sand Casting
T5 Heat Treat
Sand Casting
T5 Heat Treat
Machine Casting
Recasting
F5 Heat Treat
Machine Casting
Stamp
;amp
3 crew Machine
Screw Machine
Investment Cast
Heat Treat
Machine
nvestmentCast
Heat Treat
Machine
3ermanent Cast
Machine
permanent Cast
Rubber/Piaster Mold
F6 Heat Treat
2 Plane Dynamic Balance

nvestment Cast
Heat Treat

2 Plane Dynamic Balance
Machines Grind Shaft
OEM/Supplier
Classification




© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.
T1 Assembly, Mark-up Applied
© Bottom.

T1 Assembly, Mark-up Applied
'
T1 Assembly, Mark-up Applied
© Bottom.


T2/T3 Heat Treat, MSMC
T2/T3 Sand Cast, MSMC
T2/T3 Heat Treat, MSMC
T2/T3 Sand Cast, MSMC
T2/T3 Heat Treat, MSMC
T2/T3 CMC Milling, MSMC
T2/T3 Diecast, SSLC
T2/T3 Heat Treat, MSMC
T2/T3 CMC Turning, SSLC
T2/T3 Stamp/Form, SSLC

T2/T3 CMC Turning, MSMC
T2/T3 CMC Turning, MSMC
T2/T3 Invest. Cast, LSHC
T2/T3 Heat Treat, MSMC
T2/T3 CMC Milling, MSMC
T2/T3 Invest. Cast, LSHC
T2/T3 Heat Treat, MSMC
T2/T3 CMC Milling, MSMC
T2/T3 Perm. Cast, SSLC
T2/T3 CMC Milling, MSMC
T2/T3 Perm. Cast, SSLC
T2/T3 Invest. Cast, LSHC
T2/T3 Heat Treat, MSMC
T2/T3 CMC Turning, MSMC
T2/T3 CMC Turning, MSMC

T2/T3 Invest. Cast, LSHC
T2/T3 Heat Treat MSMC

T2/T3 CMC Turning, MSMC
T2/T3 CMC Turning, MSMC
Material
Specification




Not Applicable
Not Applicable
Not Applicable

Not Applicable

Not Applicable


Not Applicable
SiMo Ductile Iron, Cast
Not Applicable
NiResist Iron, D5S, Cast
Not Applicable
Not Applicable
Aluminum -A380, Cast
Not Applicable
Not Applicable
SPR-Steel, Coil

Bronze-89320, Bar
A-Steel-4140, Bar
Nickel Alloy Gen, Cast
Not Applicable
Not Applicable
Nickel Alloy Gen, Cast
Not Applicable
Not Applicable
S-Steel-310, Cast
Not Applicable
S-S,«I-3,0,C«,
Aluminum-356-T6,C,s,
Not Applicable
Not Applicable
Not Applicable

lnconel-713, Cast
Not Applicable

Not Applicable
A-Steel-4140,Bar
Labor
Classification




General Assembly
G,n,»l Assembly
G,n,»l Assembly

General Assembly

General Assembly


H,,,T,,,,Op,,,,,
Mold/Cast/Sinter Operator
H,,,T,,,,Op,™,«
Mold/Cast/Sinter Operator
Heat Treat Operator
CNC Operator
MoloyCast/Sinter Operator
Heat Treat Operator
CNC Operator
Cut/Punch/Forming Operator

CNC Operator
CNC Operator
Mold/Cast/Sinter Operator
Heat Treat Operator
CNC Operator
Mold/Cast/Sinter Operator
Heat Treat Operator
CNC Operator
MoloyCast/Sinter Operator
CNC Operator
MoloyCast/Sinter Operator
MoloyCast/Sinter Operator
CNC Operator
Precision Assembly

MoloyCast/Sinter Operator
Heat Treat Operator

Precision Assembly
CNC Operator
Burden
Classification




Mech Assembly, MC, Base
Mech Assembly, LC, Base
Mech Assembly, LC, Base

Mech Assembly, MC, Base

Mech Assembly, HC, Base


Heat Treat, MLS, LMC
Sand Cast, HMC
Heat Treat, MLS, LMC
Sand Cast, HMC
Heat Treat, MLS, LMC
CNC Machining, MHC, PREM.
Diecast, LMC
Heat Treat, MLS, LMC
CNC Turning, MC
Stamp/Form, SMS, LMC

S-CNC Turning, HC
S-CNC Turning, LC
Invest. Cast, HMC
Heat Treat, MLS, LMC
CNC Machining, LMC, PREM.
Invest. Cast, HMC
Heat Treat, MLS, LMC
CNC Machining, LMC, PREM.
Perm. Cast, LMC
CNC Machining, LMC, PREM.
Perm. Cast, LMC
,™,S,.C,S,,HMC
Heat Treat, MLS, LMC
CNC Turning, MC
Balancing, SMS, MHC

Invest. Cast, HMC
Heat Treat MLS LMC
.
Balancing, SMS, MHC
S-CNC Turning, MC
MANUFACTURING RATES
| Finished Pieces Per h
1



177
180
130

130

180


125
160
167
120
114
114
275
267
129
720

117
160
120
118
180
120
118
120
960
200
960
180
174
164
180

180
178

180
176
Number of Operatoi
ta



4
2
11

1

4.5


1
9
1
6
1
3
1
1
1
0.5

1
1
7
1
0.5
7
1
0.5
3
0.5
3
5
1
4.5

9
1

4.5
1
Number of Lines




1
1
1

1

s


1
1
1
1
1
6
1
1
2
1

2.5
2
1
1
1
1
1
1
1
1
1
1.25
1.5
2.5
3

1.5
1.5

3
2.5
I Parallel Processini
I Multiplier




8
3
13

2

1


1
1
1
1
1
1
1
1
1
1

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

1
1

1
1
S
1
I
CT
=



0.000
0.000
0.000

0.000

0.000


0.000
3.500
0.000
6.890
0.000
0.000
0.421
0.000
0.000
0.005
'
0.070
0.040
0.150
0.000
0.000
0.153
0.000
0.000
0.042
0.000
0.050
0.064
0.000
0.000
0.000

0.075
0.000

0.000
0.255
Material
Cost
$/lb
(DB)




$0.00
$0.00
$0.00

$0.00

$0.00


$0.00
$0.60
$0.00
$3.50
$0.00
$0.00
$1.10
$0.00
$0.00
$0.65
'
$2.56
$0.78
$5.00
$0.00
$0.00
$5.00
$0.00
$0.00
$2.40
$0.00
$2.40
$1.20
$0.00
$0.00
$0.00

$6.00
$0.00

$0.00
$0.78
Labor
Rate
$/Hour
(DB)




$35.51
$35.51
$35.51

$35.51

$35.51


$46.52
$43.52
$46.52
$43.52
$46.52
$35.70
$43.52
$46.52
$35.70
$42.18
'
$35.70
$35.70
$43.52
$46.52
$35.70
$43.52
$46.52
$35.70
$43.52
$35.70
$43.52
$43.52
$46.52
$35.70
$25.74

$43.52
$46.52

$25.74
$35.70
Burden
Rate
$/Hour
(DB)




$30.00
$15.00
$15.00

$30.00

$45.00


$100.00
$150.07
$100.00
$150.07
$100.00
$55.00
$100.05
$100.00
$45.00
$100.10
'
$85.00
$35.00
$150.08
$100.00
$35.00
$150.08
$100.00
$35.00
$100.06
$35.00
$100.06
$150.08
$100.00
$45.00
$45.00

$150.08
$100.00

$45.00
$55.00
Applied
Burden
Rate
$/Hour




$240.00
$45.00
$195.00

$60.00

$135.00


$100.00
$150.07
$100.00
$150.07
$100.00
$330.00
$100.05
$100.00
$90.00
$100.10
'
$212.50
$70.00
$150.08
$100.00
$35.00
$150.08
$100.00
$35.00
$100.06
$35.00
$100.06
$187.60
$150.00
$112.50
$135.00

$225.12
$150.00

$135.00
$137.50
MANUFACTURING COSTS
Material
Cost




$0.00
$0.00
$0.00

$0.00

$0.00


$0.00
$2.10
$0.00
$24.12
$0.00
$0.00
$0.46
$0.00
$0.00
$0.00
1
$0.18
$0.03
$0.75
$0.00
$0.00
$0.77
$0.00
$0.00
$0.10
$0.00
$0.12
$0.08
$0.00
$0.00
$0.00

$0.45
$0.00

$0.00
$0.20
Labor/ Part




$0.80
$0.39
$2.17

$0.20

$0.89


$0.37
$2.45
$0.28
$2.18
$0.41
$0.94
$0.16
$0.17
$0.28
$0.03
'
$0.31
$0.22
$2.54
$0.39
$0.10
$2.54
$0.39
$0.15
$0.14
$0.09
$0.14
$1.21
$0.27
$0.22
$0.64

$2.18
$0.26

$0.64
$0.20
Burden/
Part




$1.35
$0.25
$1.08

$0.33

$0.75


$0.80
$0.94
$0.60
$1.25
$0.88
$2.90
$0.36
$0.38
$0.70
$0.14
'
$1.82
$0.44
$1.25
$0.84
$0.19
$1.25
$0.84
$0.29
$0.10
$0.18
$0.10
$1.04
$0.86
$0.69
$0.75

$1.25
$0.84

$0.75
$0.78
IF
$
SL
H
CO
1



$2.15
$0.64
$3.25

$0.53

$1.64


$1.17
$5.49
$0.88
$27.54
$1.28
$3.34
$0.99
$0.55
$0.98
$0.17
'
$2.30
$0.69
$4.54
$1.24
$0.29
$4.55
$1.24
$0.44
$0.34
$0.26
$0.36
$2.33
$1.13
$0.91
$1.39

$3.88
$1.11

$1.39
$1.18
MARK-UP COSTS
End
Item
Scrap
Rate
(DB)




0.00%
0.00%
0.00%

0.00%

10.00%


0.50%
5.00%
0.50%
5.00%
0.50%
0.50%
5.00%
0.50%
0.30%
0.30%
'
0.50%
0.50%
5.00%
0.50%
0.50%
5.00%
0.50%
0.50%
5.00%
0.50%
5.00%
25.00%
20.00%
20.00%
20.00%

25.00%
20.00%
(
20.00%
10.00%
SG&A
Rate
(DB)




0.00%
0.00%
0.00%

0.00%

0.00%


6.50%
650%
6.50%
6.50%
6.50%
6.50%
6.00%
6.50%
6.00%
6.00%
(°
6.50%
6.50%
700%
6.50%
6.50%
700%
6.50%
6.50%
600%
6.50%
600%
700%
6.50%
6.50%
6.50%

700%
6.50%
(
6.50%
650%
Profit
Rate
(DB)




0.00%
0.00%
0.00%

0.00%

0.00%


6.00%
6.00%
6.00%
6.00%
6.00%
6.00%
4.00%
6.00%
4.00%
4.00%
'
6.00%
600%
8.00%
6.00%
6.00%
8.00%
6.00%
6.00%
4.00%
6.00%
4.00%
8.00%
6.00%
6.00%
6.00%

8.00%
6.00%
(
6.00%
6.00%
ED&T/
R&D
Rate
(DB)




0.00%
0.00%
0.00%

0.00%

0.00%


1 .00%
1 .00%
1.00%
1.00%
1 .00%
1.00%
0.00%
1.00%
0.00%
0.00%
1
1.00%
1 .00%
2.00%
1.00%
1 .00%
2.00%
1.00%
1 .00%
0.00%
1.00%
0.00%
2.00%
1 .00%
1.00%
1 .00%

2.00%
1.00%
(
1.00%
1 .00%
Total
Mark-
up
Rate




0.00%
0.00%
0.00%

0.00%

10.00%


14.00%
18.50%
14.00%
18.50%
14.00%
14.00%
15.00%
14.00%
10.30%
10.30%
'
14.00%
14.00%
22.00%
14.00%
14.00%
22.00%
14.00%
14.00%
15.00%
14.00%
15.00%
42.00%
33.50%
33.50%
33.50%

42.00%
33.50%
(
33.50%
23.50%
Total
Mark-
up
Cost




$0.00
$0.00
$0.00

$0.00

$0.16


$0.16
$1.01
$0.12
$5.10
$0.18
$0.54
$0.15
$0.08
$0.10
$0.02
'
$0.32
$0.10
$1.00
$0.17
$0.04
$1.00
$0.17
$0.06
$0.05
$0.04
$0.05
$0.98
$0.38
$0.30
$0.47

$1.63
$0.37

$0.47
$0.28
TOTAL COSTS
Total 2 =
Total! + Total Mark-
•c



$2.15
$0.64
$3.25

$0.53

$1.80


$1.34
$6.50
$1.00
$32.64
$1.46
$4.38
$1.13
$0.63
$1.08
$0.19
'
$2.63
$0.79
$5.54
$1.41
$0.33
$5.56
$1.41
$0.50
$0.39
$0.30
$0.41
$3.31
$1.51
$1.21
$1.86

$5.51
$1.48

$1.86
$1.46
SL
sl
Iff
£•
£



$2.15
$0.64
$3.25

$0.53

$1.80


$1.34
$6.50
$1.00
$32.64
$1.46
$4.38
$1.13
$0.63
$1.08
$0.19

$2.63
$0.79
$5.54
$1.41
$0.33
$5.56
$1.41
$0.50
$0.39
$0.30
$0.41
$3.31
$1.51
$1.21
$1.86

$5.51
$1.48

$1.86
$1.46
TOOLINGS NVESTMENT
Tooling Assumptior
"X1000 "
0)



































Investment Assumpti
"X1000 "
w



































Impeller Wheels, 5%
Casting fallout, 10%
Wheel Balance
Fallout and 10% Final
Assembly Balance
Fallout






File:15 Air Induction Charging System 040109A.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                APPENDIX G.1-15,2of 16
                                                                                                                                                 Form Author: G. Kolwich
                                                                                                                                                 (248)373-6000 Ext. 2411

-------
Turbo Assembly 1501  Rev 5
Manufacturing Assumption and  Quote Summary
                    APPENDIX G.1-15(1of11)
                               Print Dale:9/1/2009
              Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                  Vehicle Class: Compact/Economy 2-1 Passenger
                                              OEM Operating Pattern (Weeks/Year):
                                                                                                                                                                                                          OEM Plant Location: North America
                   Study Case#: N0101(N = New, 01 = Technology Package, 01 = Vehicle Class)
            System Description: 2007 Mini Cooper s. 1.6L n, 16V DOHC GDI Turbo
        Component Description: Turbo Charging Assembly
                                                                                                          Part Number: 1501-N0101-01
       Component Quote Level:  17 Full Quote
                                                        r Modification Quote
                                                                                 l~~ Differential Quote (Quote Summary includes
                                                      Annual Engine Volume (CPV): _
                                                           Components per Engine:      1
                                                        Annual Component Volume:   <50,ooo
                                                        Weekly Component Volume:    9,57<
                                                             Estimated Product Life:     10
                                                                                                                                                                                                       Supplier Plant Location: North America
OEM/T1 Classification: T1 High Assembly Complexity
     Shipping Method: FOB Ship Point	
                                                                                                                                                                                                      Packaging Specification: Returnable
GENERAL COMPONENT INFORMATION
1
16B
Part Description
Turnbine Shaft
Part Number
1201-N01 01 -01-01 -24-03
Purchase Part - Commodity ( Value taken from Purchas
2
3
4
5
10A
1 A
12A
13A
14A
15A
16A
17A
18A
19A
20A
2 A
22A
23A
24A
25A
26A
27A
28A
29A



Plug Threaded
Sleeve Shaft Bushing
C-Clip -Bushing Retainer
0-Ring Inner ID of support plate to block
Seal - Shaft Support Plate to seal carrier
Nut turbine Shaft
0-Ring Intake Housing to block seal
Pin Housing to Center Block Locating
Nut Saddle Clamp
Solenoid Intake Bypass
Gasket Intake Housing Solenoid
Diaphram Exhaust dumpvalve
Nut Exhaust Diaphram Shaft
Nut Diaphram to Intake Housing
Nut -Turbo to exhaust Manifold
Tag ID
Rivet ID Tag



1201-N01 01 -01-25
1201-N01 01 -01-30-03
1201-N01 01 -01-31
201-N01 01 -01-33
201-N01 01-01-21
201-N01 01 -01-20
201-N0101-01-28
201-N01 01 -01-15
201-N01 01 -01-14
201-N01 01 -01-09-01-13
201-N01 01 -01-09-01-09
201-N01 01 -01-09-01-07
201-N01 01 -01-09-01-11
280-N0101-07
201-N01 01 -01-13
201-N01 01 -01-05
201-N01 01 -01-12
201-N01 01 -01-06
201-N01 01 -01-01
201-N01 01 -01-02
201-N01 01 -01-03
285-N0101-01
280-N0101-10
201-N0101-01-07-02
201-N0101-01-07-03



D
1
GENERAL MANUFACTURING INFORMATION
Primary Process
Description
Heat Treat
; Part Database)
1
2
1
1
1
1
1
1
4
1
1
4
3
1
1
3
1
2
2
4
1
0





;M2 Tool Steel Slnconel)
(Specialized Alloy or Nitrided)
Steel
Stainless (A286)
Stainless





OEM/Supplier
Classification
T2/T3 Heat Treat, MSMC

S
S
S
S
S
S
S
S
S
S
S
S
S





Material
Specification
Not Applicable


Labor
Classification
Heat Treat Operator


Burden
Classification
Heat Treat, MLS, LMC


MANUFACTURING RATES
Finished Pieces Per Hour



•Syndicates Componen is Supplied directly to T1 or OEM for Final or Sub-
Assembly.
'SAC'=(Supplier Accounted Costs) Indicates Component is Supplied directly to
T1 or OEM for Final or Sub-Assembly. In addition component material cost is I
accounted for in T1 quote sheet. Thus component cost will only be included for
Mark-up Calculations.
'Alpha-Numeric Charac er1 = Indicates purchase parts are brought in by T2/T3
Supplier for Subassembly.

























Number of Operators
1







Number of Lines
1







Parallel Processing
Multiplier
1







1
I
0.000








PACKAGING CALCULATIONS:
Packaging Type: Option #2
Part Size: 300x200X1 90
Parts/Layer 4x5
Number of Layers: 4
Rack/Pallet Investment Amortization:
Expendable Packaging in Piece Cost:
Packaging CostTota :
Materia
Cost
S/lb
(DB)
$0.00




T1 or



Piece

csr

Labor
Rate
$/Hour
(DB)





Burden
Rate
$/Hour
(DB)





Applied
Burden
Rate
$/Hour





OEM Total Manufacturing Cost:
T1 or OEM Mark-Up Rates:
&T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:








£L

s:
$0.00


Lump Sum
Payment

Si
0
MANUFACTURING COSTS
Materia
Cost




Material
0.00
9.30
Labor/ Part




Labor
$26.79

Burden/
Part
$0.40



Burden


IF
e!
CD
$0.59



TMC
$109.84

MARK-UP COSTS
End
Item
Scrap
Rate
(DB)




Scrap
$0.89

SG&A
Rate
(DB)




SG&A
$5.38
7.00%
$8.87

Profit
Rate
(DB)




Profit
$10.14

ED&T/
R&D
Rate
(DB)




ED&T
$0.94
4.00%
$5.07

Tola
Mark-
up
Rate

Supplier
Cost
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

Total
Mark-up
$24.97

Total
Mark-
up
Cost

Purchase
Price/ Uni
$1.00
$0.04
$0.03
$0.02
$0.01
$0.18
$0.06
$0.02
$0.08
$0.08
$0.07
$0.01
$0.86
$0.17
$0.03
$0.27
$0.37
$1.24
$0.03
$6.00
$0.08
$0.06
$5.00
$0.01
$0.01
$1.60
$0.09
$0.10
$0.01
$0.00



TOTAL COSTS
2.
SL
+ —i
S" ^
I"
$0.72
Purchase
Price Net,
PIA
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

Q

	 *•
Packaging Cost:
Net Cost Impact to Vehicle:

Total * of
Pieces

Divider Pads,
$0.00
Number of
Months
60
D;:;ss
0
Interest
Rate

S
$0.00


P..^cK
0
Cost per Pallet /Rack
$300
Ss
$0.00
J-
mber of Pallets/
s Required
718
„;,«,*
0
\
u
1
80
pp±r
$0.00

ill

,„»,*
0
f|f
PI



$0.108
SL
si
Iff
%
$0.72
Purchase
Price Net,
End Item
$1.00
$0.08
$0.03
$0.02
$0.01
$0.18
$0.06
$0.02
$0.08
$0.08
$0.30
$0.01
$0.86
$0.17
$0.03
$1.07
$1.10
$1.24
$0.03
$6.00
$0.08
$0.18
$5.00
$0.01
$0.02
$1.60
$0.35
$0.10
$0.01
$0.00
1
$126.77
$126.77

$0.11

TOOLING &
Tooling Assumptions
"X1000 "






$0
NVESTMENT
Investment Assumptions
"X1000 "









File:15 Air Induction Charging System 040109A.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                APPENDIX G.1-15,3of 16
                                                                                                                                     Form Author: G. Kolwich
                                                                                                                                     (248)373-6000 Ext. 2411

-------
Cooler Assembly 1505
                                                                                                    Manufacturing Assumption and Quote Summary
                                                                                                                                     APPENDIX G.1-15(2of11)
                                                                                                                                                 Print Dale:9/1/2009
              Technology Level: Downsized, Tuibochaiged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                   Vehicle Class: Compacl/Economy24 Passenger	
                                    _OEM Operating Pattern (Weeks/Year):      n
                                                                                                                                                                                            OEM Plant Location:     North America
                    Study Case#: N0101 (N = New,  01 = Technology Package, 01 = Vehicle Class;
            System Description: 2007 Mini Cooper s. 1.6L 14,16V DOHC GDI Turbo
                                             Annual Engine Volume (CPV):   <50,ooo
                                                   Components per Engine:^      1
        Component Description: Cooler Assembly - Charged Air
       Component Quote Level:          Full Quolel X I
                                                                                              Part Number: 1505-N0101-01
n Quote|    |
                                                Annual Component Volume:   «o,ooo
                                               Weekly Component Volume:    9,57<
                                                    Estimated Product Life:     10
 Supplier Plant Location:     North America
       Shipping Method:        F.O.B
Packaging Specification:     Retumablew.
                          Expendable Separators
GENERAL COMPONENT INFORMATION
1



Tie

1B


2C

Pu
1A
2A
3A
4A

4B

5A
5B
Part Description



1 Supplier or OEM Processing

Tube with cooling fins


Cooler A»mbl»-Cn,,gedAi, He,, E»n,nge,

chase Part - High Impact Item
Tube
-""= —
Top/Bottom Plates
Cooling Fins Outer

Header Plate

End Cap R Cooler Assembly - Charged Air Heat
End Cap L Cooler Assembly - Charged Air Heat
Exchange
Part Number



& Assembly (Full Cos

505-N01 01 -01-1-1


505-N0101-01-01-02

Full Cost Mapping)
505-N01 01 -01-1-2
«»,„-„-„-„
505-N01 01 -01-1-4
«»,„-„-«-„

505-N01 01 -01-1-6-01

,505-NO,0,-0,-2
1505-N0101-01-3
O
CT


tma

5


1


5
5
2
6

2

'
1
GENERAL MANUFACTURING INFORMATION
Primary Process
Description



pping)
Insert Cooling Fins, Laser
weld seem on Tube, Pressure
Test.
Assemble Tube Assemblies,
Outer Fins, Top/Bottom Plates
and Header Plates, Gaskets
End Caps

Pre-FormS Cut to Length
F_,ndCu,,,L,nc,n
Form and Cut to Length
Ura,F.m,M,.l.nJh

Pierce and Form

lni,c,i,nM,ld
Injection Mold
Purchase Part - Commodity ( Value taken from Purchase Part Database)

1A

















Gasket End Cap

















1505-N0101-01-4

















2
0







































OEM orSuppI
2




s


s


s
s
s
s

s

s
s






















Material
Specification





Not Applicable


Not Applicable


Aluminum-3003/4047A,
Aluminum-3003/4047A,
Cladding
Aluminum-3003/4047A,
Aluminum-3003/4047A,
Cladding
Aluminum-
3003/4047B,
Cladding
Nylon66-30GF, Inject.
Nyion66-50GF, Inject.

Labor Classification





General Assembly


General Assembly


Cut/Punch/Forming Operator
Cut/Punch/Forming Operator
Cut/Punch/Forming Operator
Cut/Punch/Forming Operator

Cut/Punch/Forming Operator

Mold/Cast/Sinter Operator
Mold/Cast/Sinter Operator

Burden
Classification





Mech. Assembly, MC


Mech. Assembly, MC


Stamp/Form, SMS, MH
— '»»
Stamp/Form, SMS, MH
a,mp,F,,m,SMS,MH

Stamp/Form, SMS, MH

Inject. Mold, SMS
Inject. Mold, SMS

MANUFACTURING RATES
Finished Pieces PC

1



566


116


514
720
720
720

529

655
643

•Syndicates Component is Supplied directly to T1 or OEM for
Final or Sub- Assembly.

'SAC'=(Supplier Accounted Costs) Indicates Component is
Supplied directly to T1 or OEM for Final or Sub-Assembly. In
addition component material cost is accounted for in T1 quote
sheet. Thus component cost will only be included for Mark-up
Calculations.

'Alpha-Numeric Character1 = Indicates purchase parts are
brought in by T2/T3 Supplier for Subassembly.





































Number of Oper
0




2


5


0.5
0.5
0.5
0.5

0.25

0.5
0.5






















1
o-
=



0.000


0.000


0.320
0.100
0.110
0.140

0.130

0.254
0.299
















Material
Cost
fflb
(DB)





$0.00


$0.00


$1.65
$1.65
$1.65
$1.65

$2.10

$1.54
$1.54
















Labor
Rate
ffHour
(DB)





$35.51


$35.51


$42.18
$42.18
$42.18
$42.18

$42.18

$43.52
$43.52
















Burden
Rate
$/Hour
(DB)





$125.19


$125.19


$125.10
$125.10
$125.10
$125.10

$125.10

$100.01
$100.01
















T1 or OEM Total Manufacturing Cost:





T1 or OEM Mark-Up Rates:
&T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:






MANUFACTURING COSTS
Material
Cost





$0.00


$0.00


$0.53
$0.17
$0.18
$0.23

$0.27

$0.39
$0.46















Material


0.00
i.91
Labor/ Part





$0.13


$1.53


$0.04
$0.03
$0.03
$0.03

$0.02

$0.03
$0.03















Labor
$2.85



Burden/
Part





$0.22


$1.08


$0.24
$0.17
$0.17
$0.17

$0.24

$0.15
$0.16















Burden




IF
e!
H
^
S



$0.35


$2.61


$0.81
$0.37
$0.38
$0.43

$0.53

$0.58
$0.65















TMC




MARK-UP COSTS
End
Item
Scrap
Rate





0.00%


0.00%


0.00%
0.00%
0.00%
0.00%

0.00%

0.00%
0.00%















Scrap

0.50%
$0.08

SG&A
Rate





0.00%


0.00%


0.00%
0.00%
0.00%
0.00%

0.00%

0.00%
0.00%















SG&A
$0.00
6.00%
$0.97

Profit
Rate





0.00%


0.00%


0.00%
0.00%
0.00%
0.00%

0.00%

0.00%
0.00%















Profit

6.00%
$0.97

ED&T/
R&D
Rate





0.00%


0.00%


o.w%
0.00%
0.00%
0.00%

0.00%

0.00%
0.00%















ED&T
$0.00
2.00%


Total
Mark-up
Rate





0.00%


0.00%


0.00%
0.00%
0.00%
0.00%

0.00%

0.00%
0.00%
Supplier
Cost

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


Total Mark
up
$0.00
14.50%

S2.
Total Mark
up Cost





$0.00


$0.00


$0.00
$0.00
$0.00
$0.00

$0.00

$0.00
$0.00
Purchase Price
Unit

$0.15
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00






TOTAL COSTS
2.
SL
+ —1
1 ""





$0.35


$2.61


$0.81
$0.37
$0.38
$0.43

$0.53

$0.58
$0.65
Purchase Price
Net, PIA

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


m
	 ivLL


	 *
Packaging Cost:
Net Cost Impact to Vehicle:
SL
s|
u>
5





!



.73


$2.61



$4.06
S
.84
$0.77
$2.60


$1.06


$0.58
$0.65
Purchase Prfc<
Net, End Item


$0.30
$1
.00
$0.00
$0.00
$0.00
$0.00
$0.00
$1
.00
$0.00
$0.00
$0.00


s


i.20
$16.20





$0.10
$18.65

TOOLING & INVESTMENT
Tooling Assump
"X1000 "
o

-------
Cooler Assembly 1505
                                                                                                   Manufacturing Assumption and Quote Summary
                                                                                                                                APPENDIX G.1-15(2of11)
                                                                                                                                           Print Date:9/1/2009
              Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                  Vehicle Class: CompaclfEconomy24 Passenger	
                   Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class;
            System Description: 2007 Mini Cooper s. 1.6L 14,16V DOHC GDI Turbo
        Component Description: Cooler Assembly - Charged Air
       Component Quote Level:         Full Quolel X  I
                                                                                             Part Number: 1505-N0101-01
                                                                                  Modification Quot
te|   |
                               _OEM Operating Pattern (Weeks/Year):_
                               _        Annual Engine Volume (CPV):_
                               _             Components per Engine:_
                               _          Annual Component Volume:_
                               _         Weekly Component Volume:_
                                               Estimated Product Lite:
    OEM Plant Location:
 Supplier Plant Location:
       Shipping Method:
Packaging Specification:
   Returnable w.
Expendable Separators
GENERAL COMPONENT INFORMATION
1


Part Description


Part Number


O
?
a-

GENERAL MANUFACTURING INFORMATION
Primary Process
Description


OEM orSuppi
5

Material
Specification


Labor Classification


Burden
Classification


MANUFACTURING RATES
Finished Pieces P<

1
Number of Oper
0

1
CT
=
Material
Cost
Sib
(DB)


Labor
Rate
SHour
(DB)


Burden
Rate
$/Hour
(DB|


MANUFACTURING COSTS
Material
Cost


Labor/ Part


Burden/
Part


H
™
|
MARK-UP COSTS
End
Item
Scrap
Rate


SGSA
Rate


Profit
Rate


EDST/
RSD
Rate


Total
Mark-up
Rate


Total Mark
up Cost


TOTAL COSTS
a
SL
+ -H
| ""


sl
is-
&
f
TOOLING & INVESTMENT
Tooling Assump
"X1000 "
o

-------
Tube Ass'y-Wasle Gale 1570A
                                                                                                    Manufacturing Assumption and  Quote Summary
                                                                                                  APPENDIX G.1-15(3of11)
                                                                                                             Print Dale:9/1/2009
              Technology Level: Downsized, Turbccharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                   Vehicle Class: Compacl/Economy24 Passenger	
_OEM Operating Pattern (Weeks/Year):_

                                                                                                                                                                                        OEM Plant Location:    North America
                    Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class;
            System Description: 2007 Mini Cooper s. 1.6L 14,16V DOHC GDI Turbo
 Component Description: Tube Assembly - Turbo Waste Gate Pneumatic Control
Component Quote Level:         Full Ouotel X I
                                                                                              Part Number: 1570-N0101-03
                                                                                           n Quote|    |
          Annual Engine Volume (CPV):   <50,ooo
               Components per Engine:      1
            Annual Component Volume:
           Weekly Component Volume:
                Estimated Product Life:
                                                                                 North America
                                                                                                                                                                             Supplier Plant Location:
                                                                                                                                                                  	        Shipping Method:        F.O.B
                                                                                                                                                                  <50,ooo     Packaging Specification:     Retumablew.
                                                                                                                                                                           9,57<
                                                                                                                                                                                                              Expendable Separators
                                                                                                                                                                            10
GENERAL COMPONENT INFORMATION
1
S
Tie
1A
2A
3A
Pu
1A
2A
3A
Part Description
1 Supplier or OEM Processing
Tube Reservoir to Solenoid
Tube Reservoir to Pump
Tube-SoltoWastegate
chase Part - High Impact Item
Tube Reservoir to Solenoid
Tube Preformed
Tube-SoltoWastegate
Part Number
& Assembly (Full Cos
770-N0101-03-1
770-N0101-03-4
Full Cost Mapping)
1770-N01 01 -03-1-1
1770-N01 01 -03-4-1
O
?
CT
tma
1
1

1
1
GENERAL MANUFACTURING INFORMATION
Primary Process
Description
pping)
Assemble sheathing and glue
Assemble sheathing and glue


Extrude and Form
Purchase Part - Commodity ( Value taken from Purchase Part Database)
1
2
3
5
e



Zip Tie - lube to lube
Zip Tie Edge Bitter- lube to lube



1770-N01 01 -03-1-2
1770-N01 01 -03-2-2
770-N0101-03-3
770-N0101-03-5



4
1
3
1





Rubber
Nylon
Nylon
Nylon





OEM or Supplier

s


s
s

s
s
s
s





Material
Specification

Not Applicable
Not Applicable


Nyion12, Inject.
Nyion12, Inject.
Thermoset-SBR

'Syndicates Con
Final or Sub-Asse
•SAC'=(Supplier/
Supplied directly!
addition com pone
sheet. Thus com
Calculations.
'Alpha -Numeric C
brought in by T2/T





Labor Classification

General Assembly
General Assembly


Extruding/Drawing Operator
Extruding/Drawing Operator
Extruding/Drawing Operator

Burden
Classification

Mech. Assembly, LC
Mech. Assembly, LC
Mech. Assembly, LC

CompVExl. Mold, LMC
CompVExl. Mold, LMC
CompVExl. Mold, LMC

ponent is Supplied direc ly to T1 or OEM fo
mbly.
Accounted Costs) Indicates Component is
o T1 or OEM for Final or Sub-Assembly. In
nt material cost is accounted for in T1 quote
onent cost will only be ncluded for Mark-up
laracter1 = Indicates purchase parts are
3 Supplier for Subassembly.









MANUFACTURING RATES
Finished Pieces Per Hour

180
157
300

400
257
514

r






Number of Operators

1
1
1

1.5
1.5
0.5







S
1
I
CT

0.000
0.000
0.000

0.009
0.020
0.095




T1 o



Packaging Calculations
Rack/Pallet Investment Amort zation:
Expendable Packaging in Piece Cost:
Material
Cost
Sib
(DB)

$0.00
$0.00
$0.00

$3.03
$3.03
$1.32




Labor
Rate
ffHour
(DB)

$35.51
$35.51
$35.51

$54.35
$54.35
$54.35




Burden
Rate
$/Hour
(DB)

$100.19
$100.19
$100.19

$100.04
$100.04
$100.04




OEM Total Manufacturing Cost:
T1 or OEM Mark-Up Rates:
&T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:


Cost per

Cost per









AT::I,

ri
$1.00
MANUFACTURING COSTS
Materia
Cost

$0.00

$0.03
$0.06
$0.13



Material


Labor/ Part

$0.20
$0.23
$0.12

$0.20
$0.32
$0.05



Labor
$1.12
$1.12
Burden/
Part

$0.56
$0.64
$0.33

$0.25
$0.39
$0.19



Burden


IF
$
SL
H
CD

$0.75
$0.87
$0.45

$0.48
$0.77
$0.37



TMC


MARK-UP COSTS
End
Item
Scrap
Rate

0.00%
0.00%
0.00%

0.00%
0.00%
0.00%



Scrap
0.30%
$0.02

SG&A
Rate

0.00%
0.00%
0.00%

0.00%
0.00%
0.00%



SG&A
$0.32

Profit
Rate

0.00%
0.00%
0.00%

0.00%
0.00%
0.00%



Profit
4.00%
$0.22

ED&T/
R&D
Rate

0.00%
0.00%
0.00%

0.00%
0.00%
0.00%



ED&T
$0.05

Tola
Mark-
up
Rate

0.00%
0.00%
0.00%

0.00%
0.00%
0.00%
Supplier
Account
Cost
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

Total
Mark-up
11.30%
$0.61

Total
Mark-
up
Cos

$0.00
$0.00
$0.00

$0.00
$0.00
$0.00
Price/ Uni
$0.04
$0.20
$0.50
$0.60
$0.02
$0.12
$0.08



TOTAL COSTS
2.
SL
+ —i
s? ^
I '
-c

$0.75
$0.87
$0.45

$0.48
$0.77
$0.37
Price Net,
PIA
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

Q
	 m
	 *
Packaging
Cost:
Net Cost Impact to Vehicle:

Payment {%}

Si
10
To,a,,o, Pieces
2,250,000
"S*
$3.00
":r
60
D;:;ss
9
':r

';*:;:;
$0.00


Pa«tk
0
,ri
$200
"'""
$0.00
Racks
133
™
0
™
432
Packaging,
™
$0.00
ts (Weeks}

0
Reguiremer
ts {Paris}


Packaging Cost Total: $0.099


il
si
is-
S
*

$0.75
$0.87
$0.45

$0.48
$0.77
$0.37
Price Net,
End Item
$0.16
$0.20
$0.50
$0.60
$0.06
$0.12
$0.08
I
I
$5.41
$5.41

$0.10

TOOLING &
Tooling Assumptions
"X1000 "









$0
NVESTMENT
Investment Assumptions
"X1000 "









$0


Packaging Option #1 with expendable
dividers.
12 Cells per Layer, 4 parts per Cell.
9 Layers.
Tola # of Parts/Pallet =432

File:15 Air Induction Charging System 040109A.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                    Appendix G.1-15,6ol16
                                                                                                          Form Author: G. Kolwich
                                                                                                          (248)373-6000 Ext. 2411

-------
Tube Assembly-Inlet 1570B
                                                                                                      Manufacturing Assumption and Quote Summary
                                                                                                   APPENDIXG.1-15(4of11)
                                                                                                               Print Dale:9/1/2009
               Technology Level: Downsized, Turbccharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                   Vehicle Class: Compacl/Economy24 Passenger	
                    Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class;
             System Description: 2007 Mini Cooper s. 1.6L 14,16V DOHC GDI Turbo
 Component Description: Tube Ass'y w. Vehicle Tie Down Canister, Air Cooler Inlet
Component Quote Level:          Full Quolel X I
                                                                                               Part Number: 1570-N0101-20/21/22
                                                                                            n Quote|   |
_OEM Operating Pattern (Weeks/Year):_
_        Annual Engine Volume (CPV):_
_             Components per Engine:_
_          Annual Component Volume:_
_         Weekly Component Volume:_
                 Estimated Product Lite:
                                                                                                                                                                                          OEM Plant Location:      North America
                                                                                                                                                                               Supplier Plant Location:     North America
                                                                                                                                                                                      Shipping Method:        F.O.B
                                                                                                                                                                               Packaging Specification:     Retumablew.
                                                                                                                                                                                                                 Expendable Separators
GENERAL COMPONENT INFORMATION
1



Tie
A

2A
Pu
1A
1B
2A
3A
3B
Part Description



1 Supplier or OEM Processing
Resonator Tube Sub-Assembly
Tube AssV w Vehicle Tie Down Canister Air
Cooler
chase Part - High Impact Item
Hose Long
Hose Long w. Oermold Clamp
Hose Short Preformed
Housing Outer Shell
Baffle Inner Tube & End Cap
Part Number



& Assembly (Full Cos
570-N0101-21

570-N0101-19
Full Cost Mapping)
570-N0101-19-2
570-N0101-19-2
1570-N0101-19-6
1570-N01 01 -19-4-1
1570-N01 01 -19-4-2
O
3:


tma
1

1

1
1
1
1
1
GENERAL MANUFACTURING INFORMATION
Primary Process
Description



pping)
Spin Weld Housing Inner to
Baffle Inner

Assembly Tubes to Resonator

Extrude and Form
Oerm old Clampto Hose
Exirude and Form
Injection Mold
Injection Mold
Purchase Part - Commodity ( Value taken from Purchase Part Database)

1
2
3
4
5







Hose Clamp
Sleeve Tube Anti-Crush
Hose clamp
Grommet Fastener Isolator
Sleeve Anti-Crush, Fastener







1570-N0101-19-3
1570-N01 01 -19-4-3
1570-N0101-19-8
1570-N01 01 -19-4-4
570-N01 01 -19-4-5







3
2
1
1
1










2"
Steel, Nickel/Zinc Plate
2"w. Retention Teeth











OEM orSuppI
%



s

s

s
s
s
s
s


s
s
s
s
s









Material
Specification




Not Applicable

Not Applicable

SBR-FiberRein.,
Not Applicable
SBR-FiberRein.,
Extruded
Nyion66-30GF, Inject.
Nyion66-50GF, Inject.

Labor Classification




General Assembly

General Assembly

Extruding/Drawing Operator
Extruding/Drawing Operator
Exlruding/Drawing Operator
Mold/Cast/Sinter Operator
Mold/Cast/Sinter Operator

Burden
Classification




Mech. Assembly, LC

Mech. Assembly, LC



CompVExl. Mold, LMC
CompVExl. Mold, LMC
Inject. Mold, SMS
Inject. Mold, SMS

MANUFACTURING RATES
Finished Pieces Pe
~*
i


300

200



240
450
554
610

'Syndicates Component is Supplied directly to T1 or OEM for
Final or Sub- Assembly.

'SAC'=(Supplier Accounted Costs) Indicates Component is
Supplied directly to T1 or OEM for Final or Sub-Assembly. In
addition component material cost is accounted for in T1 quote
sheet. Thus component cost will only be ncluded for Mark-up
Calculations.




























Number of Opere
0
0)


3





1
1.5
0.25
0.25
















1
1
o-
•


0.000

0.000



0.000
0.387
0.513
0.203











T1 o




Material
Cost
Sib
(DB)




$0.00

$0.00



$0.00
$1.85
$1.54
$1.54











Labor
Rate
ffHour
(DB)




$35.51

$35.51



$54.35
$54.35
$43.52
$43.52











Burden
Rate
$/Hour
(DB)




$100.19

$100.19



$100.04
$100.04
$100.01
$100.01











OEM Total Manufacturing Cost:
T1 or OEM Mark-Up Rates:
&T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:






MANUFACTURING COSTS
Material
Cost




$0.00

$0.00



$0.00
$0.71
$0.79
$0.31










Material


1.98
Labor/ Part




$0.36

$0.53

$0.28
$0.23
$0.18
$0.02
$0.02










Labor
$1.61

$1.61
Burden/
Part




$0.33

$0.50

$0.34
$0.42
$0.22
$0.18
$0.16










Burden



IF
e!
H
c1
S


$0.69

$1.03

$1.89
$0.64
$1.12
$0.99
$0.49










TMC



MARK-UP COSTS
End
Item
Scrap
Rate




0.00%

0.00%

0.00%
0.00%
0.00%
0.00%
0.00%










Scrap
0.30%
$0.03

SG&A
Rate




0.00%

0.00%

0.00%
0.00%
0.00%
0.00%
0.00%










SG&A

$0.53

Profit
Rate




0.00%

0.00%

0.00%
0.00%
0.00%
0.00%
0.00%










Profit
4.00%
$0.35

ED&T/
R&D
Rate




0.00%

0.00%

0.00%
0.00%
0.00%
0.00%
0.00%










ED&T

$0.09

Total
Mark-
up
Rate




0.00%

0.00%

0.00%
0.00%
0.00%
0.00%
0.00%
Supplier
Account
Cost

$0.00
$0.00
$0.00
$0.00
$0.00



Total
Mark-up
11.30%
$0.99

Total
Mark-
up
Cost




$0.00

$0.00

$0.00
$0.00
$0.00
$0.00
$0.00
Price/ Uni

$0.27
$0.30
$0.35
$0.08
$0.05






TOTAL COSTS
2.
SL
+ —i
i"
s-
•£


$0.69

$1.03

$1.89
$0.64
$1.12
$0.99
$0.49
Price Net,
PIA

$0.00
$0.00
$0.00
$0.00
$0.00



Q
»u

	 *
Packaging Cost:
Net Cost Impact to Vehicle:
SL
si
^?
£•
5


$0.69

$1.03

$1.89
$0.64
$1.12
$0.99
$0.49
Price Net,
End Item

$0.81
$0.60
$0.35
$0.08
$0.05
I


$8.75
$8.75



	
TOOLING &
Tooling Assump
"X1000 "
0
0)
























$0
NVESTMENT
Investment Assum
"X1000 "
H
w
























$0



Packaging Calculations
Rack/Pallet Investment Amortization:
Expendable Packaging in Piece Cost:

Piece

c;r
$0.05






Amount
$59,840
Price Per
$1.00

Payment <%}
0.00%
>'—
9

	
2,250,000
"S*
$0.00

Months
60
»™
0

Rate
5.00%
';*:;:;
$0.00



„;,«,*
0

Pallet /Rad
$200
';*:;:;
$0.00

it,
299
„;,«,*
0

™
192
Packaging,
$0.00
Supplier,
Reguiremen
ts lWeeks|

„;,«,*
0
Supplier,
Reguiremei
ts {Parts}
57447


Packaging Cost Total: $0.077
                                                                                                                                                                                                     Option »1 with Tier Pad Dividers

                                                                                                                                                                                                     Part Size =600x180x110
                                                                                                                                                                                                     Parts per Pallet = 2 Rows of 12,8
                                                                                                                                                                                                       irs= 192 parts
File:15 Air Induction Charging System 040109A.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                      Appendix G.1-15,7ol16
                                                                                                           Form Author: G. Kolwich
                                                                                                           (248)373-6000 Ext. 2411

-------
Tube Assembly-Outlet-1570C
                                                                                                     Manufacturing Assumption and  Quote Summary
                                                                                                                                              APPENDIX G.1-15(5of11)
                                                                                                                                                         Print Dale:9/1/2009
              Technology Level: Downsized, Turbccharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                   Vehicle Class: Compacl/Economy24 Passenger	
                    Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class;
            System Description: 2007 Mini Cooper s. 1.6L 14,16V DOHC GDI Turbo
        Component Description: Tube Ass'y w. Vehicle Tie Down Canister, Air Cooler Outlet
        Component Quote Level:          Full Quolel X I
           Part Number: 1570-N0101-30
Modification Quote|    |
_OEM Operating Pattern (Weeks/Year):_
_        Annual Engine Volume (CPV):_
_             Components per Engine:_
_          Annual Component Volume:_
_         Weekly Component Volume:_
                Estimated Product Life:
                                                                                                                                                                                        OEM Plant Location:     North America
                                                                                                 Supplier Plant Location:     North America
                                                                                                        Shipping Method:        F.O.B
                                                                                                 Packaging Specification:     Retumablew.
                                                                                                                                                                                                              Expendable Separators
GENERAL COMPONENT INFORMATION
1
S

Tie
A
Pu
1A
2A
3A
4A
5A
SB
Part Description

1 Supplier or OEM Processing
Tube
Tube - Charge Air Cooler Outlet
chase Part - High Impact Item
Tube
Tube
Tube Attachment 11
Tube Attachment 12
Tube Attachment 13
Hosew/Clamps
Part Number

& Assembly (Full Cos
570-N0101-30-5
Full Cost Mapping)
570-N01 01 -30-5-2
1570-N0101-30-5-32
1570-N0101-30-3
Purchase Part - Commodity ( Value taken from Purchas
2
3
4
5
9



Sleeve Tube Anti-Crush
Sleeve Anti-Crush, Fastener
Nut-Flagw/lsolator
Sleeve Anti Crush
Hose Clamp
Bolt -Sensor, Charge Air Temperature



1570-N01 01 -19-4-3
1570-N01 01 -19-4-5
570-N0101-30-8
599-N0101-03
580-N0101-10



O
?
CT

tma
1

1
1
1
GENERAL MANUFACTURING INFORMATION
Primary Process
Description

pping)
InstalllnsertsandGrommets

Friction Weld
&!rude£ Blow Form Tube
Injection Mold
; Part Database)
2
1
1
2
1
1











OEM or Supplier


s

s
s
s

s
s
s
s
s





Material
Specification


Not Applicable
Not Applicable

Not Applicable
Nylon6-15GF, Inject.
*/lon6-15GF, Inject.
Nyion6-15GF, Inject.
*/lon6-15GF, Inject.
SBR-FiberRein., Exlrui
Not Applicable


Labor Classification


General Assembly
General Assembly

Mold/Cast/Sinter Operator
Mold/Cast/Sinter Operator
Extruding/Drawing Operator
Extruding/Drawing Operator


Burden
Classification


Mech. Assembly, LC
Mech. Assembly, LC

Inject. Mold SMS
Inject. Mold SMS
Inject. Mold SMS
Inject. Mold SMS
Inject. Mold SMS
CompVExl. Mold, LMC
CompVExl. Mold, LMC


MANUFACTURING RATES
Finished Pieces Per Hour


240
180

180
145
720
720
720
367
240


'Syndicates Component is Supplied directly to T1 or OEM for
Final or Sub- Assembly.
'SAC'=(Supplier Accounted Costs) Indicates Component is
Supplied directly to T1 or OEM for Final or Sub-Assembly. In
addition component material cost is accounted for in T1 quote
sheet. Thus component cost will only be included for Mark-up
Calculations.




















Number of Operators


5
2

3
1
0.25
0.25
0.25
1.5
1







S
1
I
CT


0.000
0.000

0.000
1.612
0.015
0.015
0.015
0.676
0.000




T1 o


Material
Cost
Sib
(DB)


$0.00
$0.00

$0.00
$1.59
$1.59
$1.59
$1.59
$1.85
$0.00




Labor
Rate
ffHour
(DB)


$35.51
$35.51

$43.52
$43.52
$43.52
$43.52
$43.52
$54.35
$54.35




Burden
Rate
$/Hour
(DB)


$100.19
$100.19

$100.01
$100.01
$100.01
$100.01
$100.01
$100.04
$100.04




OEM Total Manufacturing Cost:
T1 or OEM Mark-Up Rates:
&T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:



MANUFACTURING COSTS
Material
Cost


$0.00
$0.00

$0.00
$2.56
$0.02
$0.02
$0.02
$1.25
$0.00



Material

$10.83
Labor/ Part


$0.74
$0.39

$0.73
$0.30
$0.02
$0.02
$0.02
$0.22
$0.23



Labor
$2.65
$2.65
Burden/
Part


$0.42
$0.56

$0.56
$0.69
$0.14
$0.14
$0.14
$0.27
$0.42



Burden


IF
$
SL
H
CD


$1.16
$0.95

$1.28
$3.55
$0.18
$0.18
$0.18
$1.74
$0.64



TMC


MARK-UP COSTS
End
Item
Scrap
Rate


0.00%
0.00%

0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%



Scrap


SG&A
Rate


0.00%
0.00%

0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%



SG&A
6.00%

Profit
Rate


0.00%
0.00%

0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%



Profit


ED&T/
R&D
Rate


0.00%
0.00%

0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%



ED&T
1.00%

Total
Mark-
up
Rate


0.00%
0.00%

0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
Supplier
Cost
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

Total
Mark-up
S1.90

Total
Mark-
up
Cost


$0.00
$0.00

$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
Purchase
Price/ Uni
$0.04
$0.30
$0.08
$0.05
$0.25
$0.30
$0.29
$5.00
$0.04



TOTAL COSTS
2.
SL
+ —i
S" ^
I"
-c


$1.16
$0.95

$1.28
$3.55
$0.18
$0.18
$0.18
$1.74
$0.64
Purchase
Price Net,
PIA
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

Q
	 m
	 >
Packaging Cost:
Net Cost Impact to Vehicle:
SL
si
is-
s
£


$1.16
$0.95

$1.28
$3.55
$0.18
$0.18
$0.18
$1.74
$0.64
Purchase
Price Net,
End Item
$0.04
$0.60
$0.08
$0.05
$0.25
$0.30
$0.58
$5.00
$0.04
I
$16.81
$16.81



TOOLING &
Tooling Assumptions
"X1000 "










$0
NVESTMENT
Investment Assumptions
"X1000 "










$0



Packaging Calculations


Rack/Pallet Investment Amortization:


Expendable Packaging in Piece Cost:
Packaging Cost Total:


Cost per



Cost per


$0.057












Amount



™

$0.00



Payment {%}



TierPads





Total t of Pieces



Divider Pads

$0.00



NImhs°f


60
Divider Pads

0



Rate



othem
Price Per
$0.00







Other*
Pallet/Rack
0



Pdm


$380
Others
Pric.^
$0.00


Total
Pallets/
Required


Others
A
0



Panspe,


96
0,he,«

$0.00


C stomer
ansi,
Re uiremen
ts (Weeks}

0,he,«
Pallet/Rack
0


Customer
transit
Repiremer
ts {Paris}















Pallet Option #2,
Part Size -600x1 50x1 40

Parts per Pallet = 2 Rows, 8 per row, 6
Layers = 96 Parts per Pallet





File:15 Air Induction Charging System 040109A.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                    Appendix G.1-15,8ol16
                                                                                                                                                      Form Author: G. Kolwich
                                                                                                                                                      (248)373-6000 Ext. 2411

-------
Tube Assembly-Oullel-1570D
                                                                                                      Manufacturing Assumption and Quote Summary
                                                                                                   APPENDIX G.1-15(6of11)
                                                                                                              Print Dale:9/1/2009
               Technology Level: Downsized, Turbccharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                   Vehicle Class: Compacl/Economy24 Passenger	
_OEM Operating Pattern (Weeks/Year):_

                                                                                                                                                                                          OEM Plant Location:     North America
                    Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class;
             System Description: 2007 Mini Cooper s. 1.6L 14,16V DOHC GDI Turbo
 Component Description: Tube -Elbow, Upper to Charged Air Coupler By-Pass
Component Quote Level:          Full Quolel X I
                                                                                               Part Number: 1570-N010140
                                                                                            n Quote|    |
          Annual Engine Volume (CPV):    <50,ooo
               Components per Engine:      1
            Annual Component Volume:
           Weekly Component Volume:
                Estimated Product Life:
                                                                                  North America
                                                                                                                                                                               Supplier Plant Location:
                                                                                                                                                                    	        Shipping Method:         F.O.B
                                                                                                                                                                    <50,ooo    Packaging Specification:      Retumablew.
                                                                                                                                                                             9,57<
                                                                                                                                                                                                                Expendable Separators
                                                                                                                                                                              10
GENERAL COMPONENT INFORMATION
1



Tie


Pu

1A
1B
Part Description



1 Supplier or OEM Processing
Tube - Elbow, Upper to Charged Air Coupler By

chase Part - High Impact Item

Tube (Hose) preformed
Tube (Hose) w/Clamps
Part Number



& Assembly (Full Cos
570-N0101-40

Full Cost Mapping)

1570-N0101-40-1
1570-N01 01 -40-1-1
Purchase Part - Commodity ( Value taken from Purchas















Hose Clamp
0-ring Seal Tube OD














1570-N0101-40-3














O
3:


tma
1



1
1
GENERAL MANUFACTURING INFORMATION
Primary Process
Description



pping)
Crimp End Hose Piece orto
ing


Eflrude and Form
Oerm old Clampto Hose
; Part Database)




































OEM orSuppI
%



s



s
s

s

















Material
Specification




Not Applicable



Extruded
Not Applicable


Labor Classification




General Assembly



Extruding/Drawing Operator
Extruding/Drawing Operator


Burden
Classification




Mech. Assembly, LC



CompVExl. Mold, LMC
CompVExl. Mold, LMC


MANUFACTURING RATES
Finished Pieces Pe
~*
i


240



400
240


'Syndicates Component is Supplied directly to T1 or OEM for
Final or Sub- Assembly.
'SAC'=(Supplier Accounted Costs) Indicates Component is
Supplied directly to T1 or OEM for Final or Sub-Assembly. In
addition component material cost is accounted for in T1 quote
sheet. Thus component cost will only be included for Mark-up
cuaions.
'Alpha-Numeric Character1 = Indicates purchase parts are
brought in by T2/T3 Supplier for Subassembly.





































Number of Opere
0
0)


1



1.5
1



















1
1
o-
•


0.000



0.620
0.000














T1 o




Material
Cost
Sib
(DB)




$0.00



$1.85
$0.00














Labor
Rate
ffHour
(DB)




$35.51



$54.35
$54.35














Burden
Rate
$/Hour
(DB)




$100.19



$100.04
$100.04














OEM Total Manufacturing Cost:
T1 or OEM Mark-Up Rates:
&T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:






MANUFACTURING COSTS
Material
Cost








$1.15
$0.00













Material



Labor/ Part




$0.15



$0.20
$0.23













Labor
$0.58


Burden/
Part




$0.42



$0.25
$0.42













Burden



IF
e!
H
c1
f


$0.57



$1.60
$0.64













TMC



MARK-UP COSTS
End
Item
Scrap
Rate




0.00%



0.00%
0.00%













Scrap
0.30%
$0.01

SG&A
Rate




0.00%



0.00%
0.00%













SG&A

$0.24

Profit
Rate




0.00%



0.00%
0.00%













Profit
4.00%
$0.16

ED&T/
R&D
Rate




0.00%



0.00%
0.00%













ED&T

$0.04

Total
Mark-
up
Rate




0.00%



0.00%
0.00%
Supplier
Cost
$0.00
$0.00
$0.00



$0.00
$0.00

$0.00
$0.00



Total
Mark-up
11.30%
$0.44

Total
Mark-
up
Cost




$0.00



$0.00
$0.00
Purchase
Price/ Uni
$0.25
$0.75
$0.11



$000
$000

$000
$000






TOTAL COSTS
2.
SL
+ —i
i"
s-
•£


$0.57



$1.60
$0.64
Purchase
Price Net,
PIA
$0.00
$0.00
$0.00



$0.00
$0.00

$0.00
$0.00



Q
	 »u

	 *
Packaging Cost:
Net Cost Impact to Vehicle:
SL
si
^?
£•
5


$0.57



$1.60
$0.64
Purchase
Price Net,
End Item
$0.25
$0.75
$0.11



$0.00
$0.00

$0.00
$0.00
I
I

$3.92
$3.92



	
TOOLING &
Tooling Assump
"X1000 "
0
0)
























$0
NVESTMENT
Investment Assum
"X1000 "
H
w
























$0




Rack/Pallet Investment Amortization:


Expendable Packaging in Piece Cost:
Packaging Cost Total:



Costper












$19,947
Tie, Pad

$1.00




Tie, Pads

10




Divide, Pads,

$0.00



60
Divide, Pads

0




0,e,,

$0.00




0,he,«

0



$200
«

$0.00

To,a,

100
0,he,^

0



576
0,e,«

$0.00

os;±;
ts (Weeks}

0,e,K

0

os;±;
Repiteme,
ts {Parts}





                                                                                                                                                                                                    Package Option »1
                                                                                                                                                                                                    Part Size = 200x140x90mm

                                                                                                                                                                                                    Each Layer = 4 rows of 16
                                                                                                                                                                                                    Number of Layers = 9
                                                                                                                                                                                                            ler Pallet = 576
File:15 Air Induction Charging System 040109A.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                     Appendix G.1-15,9of 16
                                                                                                           Form Author: G. Kolwich
                                                                                                           (248)373-6000 Ext. 2411

-------
Tube Inlet ETB-1570
                                                                                                   Manufacturing Assumption and Quote Summary
                                                                                                                                                                                   APPENDIXG.1-15(7of11)
                                                                                                                                                                                               Print Dale:9/1/2009
              Technology Level: Downsized, Turbccharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                  Vehicle Class: Compacl/Economy24 Passenger	
                   Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class;
            System Description: 2007 Mini Cooper s. 1.6L 14,16V DOUG GDI Turbo
        Component Description: F'
       Component Quote Level:
                                                   Part Number: i570-Noioi4i/42/43/44
Full Quolel X I
                                                n Quote|   |
_OEM Operating Pattern (Weeks/Year):      n
_       Annual Engine Volume (CPV):	
_             Components per Engine:      1
_          Annual Component Volume:    <50,ooo
_         Weekly Component Volume:     9,57<
                Estimated Product Lite:      10
    OEM Plant Location:     North America
 Supplier Plant Location:     North America
       Shipping Method:         F.o.B
Packaging Specification:
                                                                                                                                                                        Returnable w.
                                                                                                                                                                     Expendable Separators
GENERAL COMPONENT INFORMATION
1

Tie
1A
2A
3A
4A
Pu
A
2A
3A
4A
5A
6A
7A
8A
=B
Part Description

1 Supplier or OEM Processing
F ex Tube Silencer to Environment
Silencer - Charge Air By-Pass
(Tube - Charged Air Bypass to Silencer)
Tube Inlet to throttle body
chase Part - High Impact Item
Tube - Flex Elbow, Silencer to Environment
Tube - Flex Elbow, Silencer to Environment,
Silencer Outer Shell
Silencer Inner Baffle
Silencer End Cap
Tube (Hose) preformed
Tube Y-Coupler to bypass
Elbow Coupler Bypass to Throttle
(Tube-Elbow Coupler By-Pass to Throttle Body)
Elbow Coupler Bypass to Throttle w. Clamp
(Tube-Elbow Coupler By-Pass to Throttle Body)
Part Number

& Assembly (Full Cos
(1570-N010l"-44)
070-N0101-05-2
(1599-N0101-04)
070-N0101-05-5
070-N0101-05
(1570-N0101-42)
Full Cost Mapping)
070-N01 01 -05-15-1
(1570-N0101-44)
070-N01 01 -05-15-2
(1570-N0101-44)
070-N01 01 -05-2-1
070-N01 01 -05-2-1-2-3
070-N01 01 -05-2-1-2
570-N0101-40-1
070-N01 01 -05-8-1
(1570-N0101-41)
;=:*,
;,TZ,*,"
D

tma
1
1
1
1

1
-
1
1
1
1
'
-
-
GENERAL MANUFACTURING INFORMATION
Primary Process
Description

pping)
Heat Stake Cap to Flex Tube
Vibration Weld Housing
Assemble Protective Sheath
Assemble Individual Tube
Assemblies with clamps

Injection Mold
Ini-ionMold
Injection Mold
Injection Mold
Injection Mold
Extrude and Form
'**""•"
Extrude and Form
0,,,m,ldCI,mp,,H«,
Purchase Part - Commodity ( Value taken from Purchase Part Database)
1
2
3
5
7a





S,,,1,,mp,,ssinp,,c,»p,9»,,
Hose Clamp Irg end molded in place
Hose Clamp sml end
Hose Clamp





1070-N01 01 -05-16
1070-N01 01 -05-14
070-N01 01 -05-12
070-N0101-05-4





1
1
1
3
0
0
0
0








OEM or Supplier


s
s
s
s

s
s
s
s
s
s
s
s
s

s
•













Material
Specification


Not Applicable
Not Applicable
Not Applicable
Not Applicable

TPE-PP/EPDM, Inject.
*/lon6-15GF, Inject.
PBT-GF20, Inject.
PBT-GF20, Inject.
PBT-GF20, Inject.
SBR-Fiber Rein., Extrui
*/lon6-30GF, Inject.
SBR-Fiber Rein., Extrui
Not Applicable

Labor Classification


General Assembly
General Assembly
General Assembly
General Assembly

MoloyCast/Sinter Operator
Mold/Cast/Sinter Operator
Mold/Cast/Sinter Operator
vlold/Cast/Sinter Operator
Mold/Cast/Sinter Operator
Extruding/Drawing Operator
M,ld/C«,/Sin,e,Ope,,,o,
Extruding/Drawing Operator
Extruding/Drawing Operator

Burden
Classification


Mech. Assembly, LC
Mech. Assembly, LC
Mech. Assembly, LC
Mech. Assembly, LC

Inject. Mold, SMS
Inject. Mold, SMS
Inject. Mold, SMS
Inject. Mold, SMS
Inject. Mold, SMS
CompVExt. Mold, LMC
Inject. Mold, SMS
CompVExt. Mold, LMC
CompVExt. Mold, LMC

MANUFACTURING RATES
Finished Pieces Per h
1

240
240
300
120

710
720
509
986
900
383
923
343
240

'Syndicates Component is Supplied direc ly to T1 or OEM for
Final or Sub-Assembly.
'SAC'=(Supplier Accounted Costs) Indicates Component is
Supplied directly to T1 or OEM for Final or Sub-Assembly. In
addition component material cost is accounted for in T1 quote
sheet. Thus component cost will only be included for Mark-up
Calculations.
'Alpha -Numeric Character1 = Indicates purchase parts are
brought in by T2T3 Supplier for Subassembly.
























Number of Operato
ta

1
1
1
4

1
0.5
0.5
0.5
0.5
1.5
0.5
1.5
1










1
I
"

0.000
0.000
0.000
0.000

0.205
0.020
0.270
0.140
0.140
0.380
0.289
0.723
0.000





T1 o




Material
Cost
Sib
(DB)


$0.00
$0.00
$0.00
$0.00

$0.99
$1.59
$1.45
$1.45
$1.45
$1.85
$1.76
$1.85
$0.00





Labor
Rate
ffHour
(DB)


$35.51
$35.51
$35.51
$35.51

$43.52
$43.52
$43.52
$43.52
$43.52
$54.35
$43.52
$54.35
$54.35





Burden
Rate
$/Hour
(DB)


$100.19
$100.19
$100.19
$100.19

$100.01
$100.01
$100.01
$100.01
$100.01
$100.04
$100.01
$100.04
$100.04





OEM Total Manufacturing Cost:
T1 or OEM Mark-Up Rates:
&T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:



MANUFACTURING COSTS
Material
Cost


$0.00
$0.00
$0.00
$0.00

$0.20
$0.03
$0.39
$0.20
$0.20
$0.70
$0.51
$1.34
$0.00




Material




Labor/ Part


$0.15
$0.15
$0.12
$1.18

$0.06
$0.03
$0.04
$0.02
$0.02
$0.21
$0.02
$0.24
$0.23




Labor
$2.48



Burden/
Part


$0.42
$0.42
$0.33
$0.83

$0.14
$0.14
$0.20
$0.10
$0.11
$0.26
$0.11
$0.29
$0.42




Burden




IF
e!
CD
S

$0.57
$0.57
$0.45
$2.02

$0.41
$0.20
$0.63
$0.33
$0.34
$1.18
$0.64
$1.87
$0.64




TMC




MARK-UP COSTS
End
Item
Scrap
Rate


0.00%
0.00%
0.00%
0.00%

0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%




Scrap

0.30%
$0.04

SG&A
Rate


0.00%
0.00%
0.00%
0.00%

0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%




SG&A

6.00%
$0.70

Profit
Rate


0.00%
0.00%
0.00%
0.00%

0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%




Profit

4.00%
$0.47

ED&T/
R&D
Rate


0.00%
0.00%
0.00%
0.00%

0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%




ED&T
$0.00
1.00%
$0.12

Total
Mark-up
Rate


0.00%
0.00%
0.00%
0.00%

0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
Supplier
Cost
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
Total Mark
up

11.30%
$1.33

Total
Mark-up
Cost


$0.00
$0.00
$0.00
$0.00

$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
Purchase
Price/ Unit
$0.10
$0.15
$0.38
$0.12
$0.40
$0.27
$0.16
$0.00
$0.00




TOTAL COSTS
2.
SL
+ —i
1"*
%

$0.57
$0.57
$0.45
$2.02

$0.41
$0.20
$0.63
$0.33
$0.34
$1.18
$0.64
$1.87
$0.64
Net, PIA
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
E,
	 ivl-i


	 *•
Packaging Cost:
Net Cost Impact to Vehicle:
SL
It
1
5

$0.57
$0.57
$0.45
$2.02

$0.41
$0.20
$0.63
$0.33
$0.34
$1.18
$0.64
$1.87
$0.64
Net, End Item
$0.10
$0.15
$0.38
$0.12
$0.40
$0.27
$0.48
$0.00
$0.00
$0.00
$0.00
I

$11.73






TOOLING &
Tooling Assumptio
"X1000 "
0)























$0
NVESTMENT
Investment Assumpti
"X1000 "
w























$0

File:15 Air Induction Charging System 040109A.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                  Appendix G.1-15,10of 16
                                                                                                                                                                                            Form Author: G. Kolwich
                                                                                                                                                                                            (248)373-6000 Ext. 2411

-------
Tube Inlet ETB-1570
                                                                                                     Manufacturing Assumption and Quote Summary
                                                                                                                                   APPENDIXG.1-15(7of11)
                                                                                                                                               Print Date:9/1/2009
              Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                   Vehicle Class: CompaclfEconomy24 Passenger	
                    Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class;
            System Description: 2007 Mini Cooper s. 1.6L 14,16V DOHC GDI Turbo
        Component Description: F'
        Component Quote Level:
Part Number: 1570-N010141/42/43/44
                                                                                   Modification Quot<
 te|    |
_OEM Operating Pattern (Weeks/Year):_
_        Annual Engine Volume (CPV):_
_             Components per Engine:_
_          Annual Component Volume:_
_         Weekly Component Volume:_
                Estimated Product Lite:
    OEM Plant Location:
 Supplier Plant Location:
       Shipping Method:
Packaging Specification:
                                                                                                                       Returnable w.
                                                                                                                    Expendable Separators
GENERAL COMPONENT INFORMATION

1



Part Description



Part Number


O
1
CT

GENERAL MANUFACTURING INFORMATION

Primary Process
Description



EM or Supp
3


Material
Specification



Labor Classification



Burden
Classification


MANUFACTURING RATES
5"
4
ed Pieces P

i
z
berofOper
0
ta
S
1
1
5=
"

Material
Cost
Sib
IDS)



Labor
Rate
SHour
IDS)



Burden
Rate
$/Hour
IDB|


MANUFACTURING COSTS

Material
Cost



Labor/ Part



Burden/
Part


i
II

|
MARK-UP COSTS

End
Item
Scrap
Rate



SGSA
Rate



Profit
Rate



ED&T/
R&D
Rate



Total
Mark-up
Rate



Total
Mark-up
Cost


TOTAL COSTS
a
+ -)
| ""

•c
|
1 !
i
f
TOOLING &
I
gf
§|
o"
0)
NVESTMENT
1
ment Assurr
"X1000 "
"H.
3
Packaging Calculations
Rack/Pallet Investment Amortization:
Expendable Packaging in Piece Cost:
c;r

c;r
$0.00




AT::I,
$131,649
Price Per
$0.00
,»:„«)
0.00%
>'—
0
'«""»""
2,250,000
"S*
$0.00
N:r
60
»™
0
"»T
5.00%
';*:;:;
$0.00


„;,«,*
0
,ri
$220
Pptr
$0.00
ReB;C«
598
„;,«,*
0
rr
96
Packaging,
$0.00
(Weeks}

°SS'
0
~rr
57447


Packaging Cost Total:
                                                                                                                                                                                                     Pallet Options: Option « No Tier Pads, 8
                                                                                                                                                                                                     Cell Returnable Pallet Dividers
                                                                                                                                                                                                     Part Size: 600x300x100
                                                                                                                                                                                                     Parts/Layer = 2x4 = 8
                                                                                                                                                                                                     Number of Layers = 12
File:15 Air Induction Charging System 040109A.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                    Appendix G.1-15,11 of 16
                                                                                                                                           Form Author: G. Kolwich
                                                                                                                                           (248)373-6000 Ext. 2411

-------
Bracket-Support Turbo 1575
                                                                                                       Manufacturing Assumption and  Quote Summary
                                                                                                                                                                                                                                APPENDIX G.1-15(8of11)
                                                                                                                                                                                                                                           Print Dale:9/1/2009
               Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                   Vehicle Class: Compacl/Economy24 Passenger	
                    Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class;
             System Description: 2007 Mini Cooper s. 1.6L 14,16V DOHC GDI Turbo
 Component Description: Bracket -
Component Quote Level:
                                              rt, Turbo Assembly
                                            Full Quolel X I
                                                                                                 Part Number: 1575-N0101-01
                                                                                              n Quote|    |
_OEM Operating Pattern (Weeks/Year):_
_        Annual Engine Volume (CPV):_
_             Components per Engine:_
_          Annual Component Volume:_
_          Weekly Component Volume:_
                 Estimated Product Life:
                                                                                                                                                                                             OEM Plant Location:     North America
                                                                                                                                                                                  Supplier Plant Location:     North America
                                                                                                                                                                                        Shipping Method:        F.O.B
                                                                                                                                                                                 Packaging Specification:     Retumablew.
                                                                                                                                                                                                                    Expendable Separators
GENERAL COMPONENT INFORMATION
1



Tie

Part Description



1 Supplier or OEM Processing
Bracket - Support, Turbo Assembly
Part Number



& Assembly (Full Cos
1E75-N0101-01
(1275-N0101-04)
Purchase Part - Commodity ( Value taken from Purchas




































O
3:


tma
1
GENERAL MANUFACTURING INFORMATION
Primary Process
Description



pping)
Forging
; Part Database)






























OEM orSuppI
%



s
















Material
Specification




S-Steel-304, Bar


Labor Classification




Forging Operator


Burden
Classification




Cold Forge, LMC


MANUFACTURING RATES
Finished Pieces Pe
1
i


257


'Syndicates Component is Supplied directly to T1 or OEM for
Final or Sub- Assembly.
'SAC'=(Supplier Accounted Costs) Indicates Component is
Supplied directly to T1 or OEM for Final or Sub-Assembly. In
addition component material cost is accounted for in T1 quote
sheet. Thus component cost will only be included for Mark-up


'Alpha-Numeric Character1 = Indicates purchase parts are
brought in by T2/T3 Supplier for Subassembly.


































Number of Opere
0
0)


1
















1
o-
•


0.649











T1 o




Material
Cost
Sib
(DB)




$1.65











Labor
Rate
ffHour
(DB)




$33.52











Burden
Rate
$/Hour
(DB)




$100.09











OEM Total Manufacturing Cost:
T1 or OEM Mark-Up Rates:
&T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:






MANUFACTURING COSTS
Material
Cost




$1.07










Material
$1.07
0.00
1. 07
Labor/ Part




$0.15










Labor
$0.15

$0.15
Burden/
Part




$0.39










Burden



IF
e!
H
c1
S


$1.61










TMC



MARK-UP COSTS
End
Item
Scrap
Rate




0.00%










Scrap

$0.00

SG&A
Rate




0.00%










SG&A
$0.00
6.00%
$0.10

Profit
Rate




0.00%










Profit

$0.06

ED&T/
R&D
Rate




0.00%










ED&T
$0.00
0.00%
$0.00

Total
Mark-
up
Rate




0.00%
Supplier
Cost
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

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


Total
Mark-up
10.30%
$0.17

Total
Mark-
up
Cost




$0.00
Purchase
Price/ Uni
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

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





TOTAL COSTS
2.
SL
+ —1
i"
s-
•£


$1.61
Price Net,
PIA
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

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


Q
»u

	 *•
Packaging Cost:
Net Cost Impact to Vehicle:
SL
s|
£•
5


$1.61
Price Net,
End Item
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
I
I
$1.61
$1.61




TOOLING &
Tooling Assump
"X1000 "
0
0)
















$0
NVESTMENT
Investment Assum
"X1000 "
H
w




















Packaging Calculations


Rack/Pallet Investment Amortization:
Expendable Packaging in Piece Cost:

Cost per



Cost per









;:;:,


S1,596
ri
$0.00

Payment {%}



Si
0

Total , of Pieces


2,250,000
"S*
$0.00

NMomh7f


60
D;:;ss
0

"fiaT'



';*:;:;
$3.50





P..^cK
60

P^STacI


$100
';*:;:;
$0.00

Np±s,°f
Required

16
P..^cK
0

Np™se'e°f


3600
Packaging,
$0.00
Supplier,
±;
Reguiremen
ts lWeeks|

Pai^ack
0
Supplier,
transit"
Fteguiremei
ts{Pai1s|



Packaging Cost Total: $0.059
                                                                                                                                                                                                        Packaged in Expendible Card Board
                                                                                                                                                                                                        Boxes
                                                                                                                                                                                                        (Weight Consideration<40lbs)
                                                                                                                                                                                                        Card Board Box: 300x220x120
                                                                                                                                                                                                        ($3.50/Box)

                                                                                                                                                                                                        Parts per Box: 15 per layer x 4
                                                                                                                                                                                                        Layers/Box = 60 Parts/Box

                                                                                                                                                                                                        Per Pallet (1/2 Pallet), 4x5 Boxes per
                                                                                                                                                                                                        layer
                                                                                                                                                                                                        3 layers = 60 Boxes
File:15 Air Induction Charging System 040109A.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                       Appendix G.1-15,12of 16
                                                                                                                                                                                                                                        Form Author: G. Kolwich
                                                                                                                                                                                                                                        (248)373-6000 Ext. 2411

-------
                                                                                                      Manufacturing Assumption and Quote Summary
                                                                                                                                                                                        APPENDIX G.1-15(9of11)
                                                                                                                                                                                                   Print Dale:9/1/2009
              Technology Level: Downsized, Turbccharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                   Vehicle Class: Compacl/Economy24 Passenger	
                                                                                     _OEM Operating Pattern (Weeks/Year):_

                                                                                                                                                                                         OEM Plant Location:     North America
                    Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class;
             System Description: 2007 Mini Cooper s. 1.6L 14,16V DOHC GDI Turbo
        Component Description: Vacuum Reservoir-Turbo Waste Gate
        Component Quote Level:
                                                                                               Part Number: 1599-N0101-01
Full Quote] X |
                                                 n Quote|   |
                                                                                               Annual Engine Volume (CPV):    <50,ooo
                                                                                                    Components per Engine:      1
                                                                                                 Annual Component Volume:
                                                                                                 Weekly Component Volume:
                                                                                                      Estimated Product Life:
                                                                                                                                                                       North America
           Supplier Plant Location:
	        Shipping Method:        F.O.B
<50,ooo     Packaging Specification:     Retumablew.
                                                                                                                                                                            9,571
                                                                                                                                                                                                                Expendable Separators
                                                                                                                                                                             10
GENERAL COMPONENT INFORMATION
1
S

Tie
1A
Pu
1A
2A
Part Description

1 Supplier or OEM Processing
«.„„
chase Part - High Impact Item
C,_nC,p:,,™R,s™,
Part Number

& Assembly (Full Cos
7070-N0101-02
(1599-N01010-01)
Full Cost Mapping)
7070-N0101-02-1
Purchase Part - Commodity ( Value taken from Purchas
1A













O
?
CT

tma
1

1
GENERAL MANUFACTURING INFORMATION
Primary Process
Description

pping)

Inserts

PA6 GF35
PA6 GF35
; Part Database)
3
0
0
0
0
0
0
0
0
0
0
0
0
0











OEM or Supplier





s







Material
Specification





N>1on6-30GF, Inject.
*/lon6-30GF, Inject.


Labor Classification



'

Mold/Cast/Sinter Operator
Mold/Cast/Sinter Operator


Burden
Classification


Mech. Assembly, LC

Inject. Mold, SMS
Inject. Mold, SMS


MANUFACTURING RATES
Finished Pieces Per Hour


240

1037
861


'Syndicates Component is Supplied directly to T1 or OEM for
Final or Sub- Assembly.
'SAC'=(Supplier Accounted Costs) Indicates Component is
Supplied directly to T1 or OEM for Final or Sub-Assembly. In
addition component material cost is accounted for in T1 quote
sheet. Thus component cost will only be included for Mark-up
Calculations.
'Alpha-Numeric Character1 = Indicates purchase parts are
brought in by T2/T3 Supplier for Subassembly.
























Number of Operators


2

0.5
0.5







s
1
I
CT


0.000

0.158
0.454




T1 o


Material
Cost
Sib
(DB)


$0.00

$1.76
$1.76




Labor
Rate
ffHour
(DB)


$35.51

$43.52
$43.52




Burden
Rate
$/Hour
(DB)


$100.19

$100.01
$100.01




OEM Total Manufacturing Cost:
T1 or OEM Mark-Up Rates:
&T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:



MANUFACTURING COSTS
Material
Cost




$0.28
$0.80



Material

1. 08
Labor/ Part


$0.30

$0.02
$0.03



Labor
$0.34

Burden/
Part


$0.42

$0.10
$0.12



Burden


IF
$
SL
H
CD


$0.71

$0.40
$0.94



TMC


MARK-UP COSTS
End
Item
Scrap
Rate


0.00%

0.30%
0.30%



Scrap
0.50%
$0.01

SG&A
Rate


0.00%

6.00%
6.00%



SG&A
$0.14

Profit
Rate


0.00%

4.00%
4.00%



Profit
$0.13

ED&T/
R&D
Rate


0.00%

0.00%
0.00%



ED&T
$0.05

Total
Mark-
up
Rate


0.00%

10.30%
10.30%
Supplier
Cost
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

Total
Mark-up
$0.34

Total
Mark-
up
Cost


$0.00

$0.04
$0.10
Purchase
Price/ Uni
$0.04
$000
$000
$000
$000
$000
$000
$000
$000
$000
$000
$000
$000
$000



TOTAL COSTS
2.
SL
+ —1
3? ^
I"
-c


$0.71

$0.44
$1.04
Purchase
Price Net,
PIA
$0.12
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00

Q
	 m
	 *
Packaging Cost:
Net Cost Impact to Vehicle:
SL
si
is-
s
*


$0.71

$0.44
$1.04
Purchase
Price Net,
End Item
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
I
I
$2.19
$2.19

$0.10

TOOLING &
Tooling Assumptions
"X1000 "










$0
NVESTMENT
Investment Assumptions
"X1000 "










$0


Packaging Calculations
Rack/Pallet Investment Amortization:
Expendable Packaging in Piece Cost:

Piece

c;r
$0.08






Amount
$33,497
Price Per
$1.00

Payment <%}
0.00%
>'—
8

	
2,250,000
"S*
$3.00

Months
60
-™
7

Rate
5.00%
';*:;:;
$0.00



„;,«,*
0

Pallet /Racl
$200
';*:;:;
$0.00

it,
167
„;,«,*
0

,s;;,
343
Packaging,
$0.00
Supplier,
Reguiremen
ts lWeeks|

Pa«Rack
0
Supplier,
Reguiremer
ts {Paris}
57447


Packaging Cost Total: $0.101
                                                                                                                                                                                                    Pallet Option #1 w. Disposable Tier
                                                                                                                                                                                                    Pads
                                                                                                                                                                                                    PartSize:170x150x115
                                                                                                                                                                                                    Parts Layer = 7x7 =49
                                                                                                                                                                                                    Number of Layers = 7
File:15 Air Induction Charging System 040109A.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                     Appendix G.1-15,13of 16
                                                                                                                                                                                                Form Author: G. Kolwich
                                                                                                                                                                                                (248)373-6000 Ext. 2411

-------
Valve-Thrust Control 1599
                                                                                                      Manufacturing Assumption and  Quote Summary
                                                                                                 APPENDIXG.1-15(10of11)
                                                                                                               Print Date:9/1/2009
               Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                   Vehicle Class: Compacl/Economy24 Passenger	
                    Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class;
             System Description: 2007 Mini Cooper s. 1.6L 14,16V DOHC GDI Turbo
        Component Description: Value - Thrust Control, Turbo Waste Gate Pneumatic Control
        Component Quote Level:          Full (
                                                                                               Part Number: 1599-N0101-02
                                                                                    Modification Quot<
_OEM Operating Pattern (Weeks/Year):_
_        Annual Engine Volume (CPV):_
_             Components per Engine:_
_          Annual Component Volume:_
_         Weekly Component Volume:_
                 Estimated Product Lite:
                                                                                                                                                                                          OEM Plant Location:      North America
 Supplier Plant Location:     North America
       Shipping Method:        F.O.B
Packaging Specification:      Retumablew.
                                                                                                                                                                                                                 Expendable Separators
GENERAL COMPONENT INFORMATION
1



Part Description



Part Number



O
3:


GENERAL MANUFACTURING INFORMATION
Primary Process
Description




Purchase Part - Commodity ( Value taken from Purchase Part Database)
1A












Value - Thrust Control, Turbo Waste Gate












1599-N0101-02












1















(Look © Evaluating as Low















OEM orSuppI
%




8















Material
Specification







Labor Classification







Burden
Classification







MANUFACTURING RATES
Finished Pieces Pe
1
i




•Syndicates Component is Supplied directly to T1 or OEM for
Final or Sub- Assembly.
'SAC'=(Supplier Accounted Costs) Indicates Component is
Supplied directly to T1 or OEM for Final or Sub-Assembly. In
addition component material cost is accounted for in T1 quote
sheet. Thus component cost will only be included for Mark-up
a lonSi
'Alpha-Numeric Character1 = Indicates purchase parts are
brought in by T2/T3 Supplier for Subassembly.



































Number of Opere
0
0)



















1
1
o-
•














T1 o




Material
Cost
Sib
(DB)
















Labor
Rate
ffHour
(DB)
















Burden
Rate
$/Hour
(DB)
















OEM Total Manufacturing Cost:
T1 or OEM Mark-Up Rates:
&T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:






MANUFACTURING COSTS
Material
Cost















Material

0.00
>.19
Labor/ Part















Labor
$0.00

$0.00
Burden/
Part















Burden



IF
e!
H
c1
S













TMC



MARK-UP COSTS
End
Item
Scrap
Rate















Scrap

$0.03

SG&A
Rate















SG&A
6.50%
$0.34

Profit
Rate















Profit

$0.31

ED&T/
R&D
Rate















ED&T
2.50%
$0.13

Total
Mark-
up
Rate




Cost
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00


Total
Mark-up
15.50%
$0.80

Total
Mark-
up
Cost




Price/ Uni
$5.19
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00





TOTAL COSTS
2.
SL
+ —1
3? ,3
W"
s-
•£


Price Net,
PIA
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00


Q
»u

	 >
Packaging Cost:
Net Cost Impact to Vehicle:
SL
s|
£•
5


Price Net,
End Item
$5.19
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
$0.00
I
I
$5.19
$5.19




TOOLING &
Tooling Assump
"X1000 "
0
0)
















$0
NVESTMENT
Investment Assum
"X1000 "
H
w
















$0


Packaging Calculations


Rack/Pallet Investment Amortization:


Expendable Packaging in Piece Cost:
Cost per



Cost per











Total


$48,980



$0.00
Payment {%}














$0.00
Numterof


60



0
Interest



Other H

Price Per
$0.00




Others

Pallet/Rack
0
Cost per


$4,420
Other*!

Price Per
$0.00
Racks


11
Other*!

Pallet/Rack
0
N-ero,


5184
Other *3

Price Per
$0.00
os;±;

ts (Weeks}

Other *3

Pallet/Rack
0
os;±;
tepiremer
ts {Paris}





Packaging Cost Total: $0.024
                                                                                                                                                                                                     Packaging Option #3 w. Returnable
                                                                                                                                                                                                     Trays
                                                                                                                                                                                                     Part Size 80x90x50
                                                                                                                                                                                                     Parts/Layer = 6x3 = 18
                                                                                                                                                                                                     Number of Layers = 6
File:15 Air Induction Charging System 040109A.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                     Appendix G.1-15,14of 16
                                                                                                           Form Author: G. Kolwich
                                                                                                           (248)373-6000 Ext. 2411

-------
Engine Assembly 1500
                                                                                       Manufacturing Assumption and Quote Summary
                                                                                                                                                                                                                           APPENDIXG.1-15(11of11)
                                                                                                                                                                                                                                        Print Date:9/1/2009
       Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                  Vehicle Class: Compact/Economy 2-1 Passenger
                                                                                                                                             OEM Operating Pattern (Weeks/Year):
                                                                                                                                                                                                            OEM Plant Location: North America
                   Study Case#: N0101(N = New, 01 = Technology Package, 01 = Vehicle Class)
            System Description: 2007 Mini Cooper s. 1.6L n, 16V DOHC GDI Turbo
                                                                                                                                              Annual Engine Volume (CPV):   <50,ooo
                                                                                                                                                   Components per Engine: _
                                                                                                                                                                                                        Supplier Plant Location: North America
Component Description: Engine And Vehicle Assembly
Component Quote Level:   & *mc
                                                                                                           Part Number: 1500-N0101-01
                                                                                                                                                       Annual Component Volume:    <50,ooo
                                                           Modification Quote
                                                                                   ~ Differential Quote (Quote Summary includes costing fc
                                                                                                                                                       Weekly Component Volume:     9,57<
                                                                                                                                                            Estimated Product Life:
 OEM/T1 Classification: OEM Vehicle Assembly
       Shipping Method: FOB Ship Point
Packaging Specification:_NA	
GENERAL COMPONENT INFORMATION
1


Part Description


Tier 1 Supplier or OEM Processing

1A

2A
3A

4A
5A
6A
7A
8A


9A



10A


Turbo Charging Assembly

Bracket - Support, Turbo Assembly
Vacuum Reservoir- Turbo Waste Gate
I T b W
Pneumatic Control
Tube Assembly - Turbo Waste Gate Pneumatic
Cooler Assembly - Charged Air
Tube Assy w. Vehicle Tie Down Canister, Air
Tube Assy w. Vehicle Tie Down Canister, Air
Cooler Outlet


Tube - Elbow, Upper to Charged Air Coupler By


Tube: Coupler Y Branch to By-Pass/Elbow
Coupler By-Pass to Throttle Booy/Elbow
Coupler By-Pass to Throttle Booy/Tube - Flex

Part Number


D


& Assembly (Full Cost ma

501-N0101-01

575-N0101-01
599-N0101-01

599-N0101-02
570-N0101-03
«»,„-„
570-N01 01 -20/21/22
570-NO,0,-30


570-N0101-40







1

1
1

1
1
1
1
,


1



'

GENERAL MANUFACTURING INFORMATION
Primary Process
Description


pping)


ntake Manifold, 4 Nuts
Install Turbo Support Bracket, 2
Bolts
nstall Vacuum Reservoir, 2
Bolts and 1 Nut
I IIV I
No Additional Fastener
Install Waste Gate Tubing, 6
Attachment Points
Install Vehicle H/W for Charged
Air Cooler and Charged Air
Install Tube Assembly, Turbo
Assembly to Charged Air
Install Tube Assembly,
Charged Air Cooler to
Coupler/ETB bypass
Make Connection Between
Charged Air Outlet Tube and

Tube.

Body and Snap in Bypass Tube

Purchase Part - Commodity ( Value taken from Purchase Part Database)
1A
2A
3A
4A

5A
6A
7A

8A
,A


1 A
12A
13A
14A
15A
16A
17A
18A

19A
Turbo Charging Assembly
B acket - Support, Turbo Assembly
Vacuum Reservoir - Turbo Waste Gate
Value - Thrust Control, Turbo Waste Gate
Pneumatic Control
Tube Assembly - Turbo Waste Gate Pneumatic
Cooler Assembly -Charged Air
Tube Assy w. Vehicle Tie Down Canister, Air
Cooler Inlet
Tube Assy w. Vehicle Tie Down Canister, Air
Cooler Outlet
Tube - Elbow, Upper to Charged Air Coupler By
Tube: Coupler Y Branch to By-Pass/Elbow
Coupler By-Pass to Throttle Booy/Elbow
Coupler By-Pass to Throttle Booy/Tube - Flex
Nut -Exhaust Manifold to Turbo
Bolt - Bracket Support, Turbo Assembly
Bolt - Bracket Support, Turbo Assembly
Nut - Pressure Reservoir, Turbo Waste Gate
Bolt -Tube, Charge Air Cooler to Vehicle
Internal Threaded Part ( Vehicle H/W)
Isolators Veh. Mnt. Charged Air Cooler


1501-N0101-01
1575-N0101-01
1599-N0101-01
1599-N0101-02

570-N0101-03
505-N0101-01
570-N01 01 -20/21/22

570-N0101-30
570-N0101-40


280-N0101-07
580-N0101-03
580-N0101-04
580-N0101-05
580-N0101-06
580-N0101-09
NA
NA

NA
1
1
1
1

1
1
!

'
'


4
1
1
2
1
2
2
2

1

















Hardware Not Available
Hardware Not Available


Hardware Not Available
OEM/Supplier
Classification



OEM Assembly, Mark-up

Applied © Bottom.
OEM Assembly, Mark-up
Applied © Bottom.
OEM Assembly, Mark-up
Applied © Bottom.
OEM Assembly, Mark-up
Applied ©Bottom.
OEM Assembly, Mark-up
Applied ©Bottom.
OEM Assembly, Mark-up
Applied © Bottom.
OEM Assembly, Mark-up
Applied ©Bottom.
OEM Assembly, Mark-up
Applied © Bottom.


OEM Assembly, Mark-up
Applied © Bottom.


OEM Assembly, Mark-up
Applied © Bottom.


SAC
SAC
SAC
SAC

SAC
SAC
SAC

SAC
SAC


S
S
S
S
S
S
S

s
Material
Specification




Not Applicable

Not Applicable
Not Applicable

Not Applicable
Not Applicable
Not Applicable
Not Applicable
Not Applicable


Not Applicable



Not Applicable



Labor
Classification




General Assembly-OEM

General Assembly-OEM
General Assembly-OEM

General Assembly-OEM
General Assembly-OEM
General Assembly-OEM
General Assembly-OEM
General Assembly-OEM


General Assembly-OEM



General Assembly-OEM



Burden
Classification




Vehicle Operations, OEM

Vehicle Operations, OEM
Vehicle Operations, OEM

Vehicle Operations, OEM
Vehicle Operations, OEM
Vehicle Operations, OEM
Vehicle Operations, OEM
Vehicle Operations, OEM


Vehicle Operations, OEM



Vehicle Operations, OEM



MANUFACTURING RATES
| Finished Pieces Per h
1



82

97
90

240
73
49
75
61


189



92



'Syndicates Component is Supplied directly to T1 or OEM for Final or Sub-
Assembly.

•SAC'=(Supplier Accounted Costs) Indicates Component is Supplied directly to
T1 or OEM for Final or Sub-Assembly. In addition component material cost is
accounted for in T1 quote sheet. Thus component cost will only be included for
Mark-up Calculations.

'Alpha-Numeric Character1 = Indicates purchase parts are brought in by T2/T3
Supplier for Subassembly.















1

.






Number of Operatoi
ta



1

1
'

1
1
1
1
,


1



1
























Number of Lines




1

1
1

1
1
1
1
1


1



1
























I Parallel Processini
I Multiplier




1

1
1

1
1
1
1
1


1



1
























1
I
=



0.000

0.000
0.000

0.000
0.000
0.000
0.000
0.000


0.000



0.000
























Material
Cost
S/lb
(DB)




$0.00

$0.00
$0.00

$0.00
$0.00
$0.00
$0.00
$0.00


$0.00



$0.00
























Labor
Rate
$/Hour
(DB)




$83.31

$83.31
$83.31

$83.31
$83.31
$83.31
$83.31
$83.31


$83.31



$83.31
























Burden
Rate
$/Hour
(DB)




$125.21

$125.21
$125.21

$125.21
$125.21
$125.21
$125.21
$125.21


$125.21



$125.21
























Applied
Burden
Rate
$/Hour




$125.21

$125.21
$125.21

$125.21
$125.21
$125.21
$125.21
$125.21


$125.21



$125.21
























MANUFACTURING COSTS
Material
Cost




$0.00

$0.00
$0.00

$0.00
$0.00
$0.00
$0.00
$0.00


$0.00



$0.00
























Labor/ Part




$1.02

$0.86
$0.93

$0.35
$1.13
$1.71
$1.11
$1.37


$0.44



$0.90
























Burden/
Part




$1.53

$1.29
$1.39

$0.52
$1.70
$2.57
$1.67
$2.05


$0.66



$1.36
























IF
e!
1



$2.55

$2.14
$2.32

$0.87
$2.84
$4.29
$2.78
$3.42


$1.10



$2.26
























MARK-UP COSTS
End
Item
Scrap
Rate
(DB)




0.00%

0.00%
0.00%

0.00%
0.00%
0.00%
0.00%
0.00%


0.00%



0.00%
























SG&A
Rate
(DB)




0.00%

0.00%
0.00%

0.00%
0.00%
0.00%
0.00%
0.00%


0.00%



0.00%
























Profit
Rate
(DB)




0.00%

0.00%
0.00%

0.00%
0.00%
0.00%
0.00%
0.00%


0.00%



0.00%
























ED&T/
R&D
Rate
(DB)




0.00%

0.00%
0.00%

0.00%
0.00%
0.00%
0.00%
0.00%


0.00%



0.00%
























Total
Mark-
up
Rate




0.00%

0.00%
0.00%

0.00%
0.00%
0.00%
0.00%
0.00%


0.00%



0.00%

Supplier
Account
Cost
$151.85
$1.84
$2.63
$6.02

$6.12
$18.65
$9.82

$18.76
$4.39


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

$0.00
Total
Mark-
up
Cost




$0.00

$0.00
$0.00

$0.00
$0.00
$0.00
$0.00
$0.00


$0.00



$0.00

Price/ Uni
$151.85
$1.84
$2.63
$6.02

$6.12
$18.65
$9.82

$18.76
$4.39


$0.14
$0.05
$0.04
$0.05
$0.01
$0.04
$0.03
$0.08

$0.01
TOTAL COSTS
Total 2 =
Total! + Total Mark-
-°



$2.55

$2.14
$2.32

$0.87
$2.84
$4.29
$2.78
$3.42


$1.10



$2.26

Price Net,
PIA
$0.00
$0.00
$0.00
$0.00

$0.00
$0.00
$0.00

$0.00
$0.00


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

$0.00
SL
si
I"
£-



$2.55

$2.14
$2.32

$0.87
$2.84
$4.29
$2.78
$3.42


$1.10



$2.26

Price Net,
End Item
$151.85
$1.84
$2.63
$6.02

$6.12
$18.65
$9.82

$18.76
$4.39


$0.57
$0.05
$0.04
$0.09
$0.01
$0.07
$0.05
$0.16

$0.01
TOOLINGS NVESTMENT
Tooling Assumptior
"X1000 "
0)












































Investment Assumpti'
"X1000 "
w












































File:15 Air Induction Charging System 040109A.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                  APpendix G.1-15,150116
                                                                                                                                                                                                                             Form Author: G. Kolwich
                                                                                                                                                                                                                             (248)373-6000 Ext. 2411

-------
Engine Assembly 1500
                                                                                             Manufacturing Assumption and  Quote Summary
                                                                             APPENDIXG.1-15(11of11)
                                                                                          Print Dale:9/1/2009
              Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                  Vehicle Class: Compact/Economy 2-1 Pa!
                   Study Case#: N0101(N = New, 01 = Technology Package, 01 = Vehicle Class)
            System Description: 2007 Mini Cooper s. 1.6L n, 16V DOHC GDI Turbo
        Component Description: Engine And Vehicle Assembly
       Component Quote Level:   & Fuiiouote
                                                                                                          Part Number: 1500-N0101-01
                                                          Modification Quote
OEM Operating Pattern (Weeks/Year):
        Annual Engine Volume (CPV):
             Components per Engine: _
          Annual Component Volume:_
          Weekly Component Volume:
              Estimated Product Life:
                                                                                                                                                                                                         OEM Plant Location: North America
                                                                                                                                                                                                      Supplier Plant Location: North America
 OEM/T1 Classification: OEM Vehicle Assembly
       Shipping Method: FOB Ship Point
Packaging Specification:_NA	
GENERAL COMPONENT INFORMATION
1
S


20A
21A
22A




Part Description


Internal Threaded Part ( Vehicle H/W Inlet (1 pc)
& Outlet (2 pcs) Air Tube Canister Tie Down)
Bolt - Tube Charged Air Cooler Outlet
Screw Tube Intake Manifold to Attachment




Part Number


NA
NA
NA




D
?
CT

3
2
1







GENERAL MANUFACTURING INFORMATION
Primary Process
Description


«„«„„*„
HarcBare Not Available
Hardware Not Available







OEM/Supplier
Classification


s
s
s







Material
Specification












Labor
Classification












Burden
Classification












MANUFACTURING RATES
Finished Pieces P<
^
1










Number of Oper
0
0)










Number of Lin
8











Parallel Proces
Multiplier
5"











S
1
1
O"
"










Materia
Cost
S/lb
(DB)







T1 or




Labor
Rate
$/Hour
(DB)







Burden
Rate
$/Hour
(DB)







Applied
Burden
Rate
$/Hour







OEM Total Manufacturing Cost:
T1 or OEM Mark-Up Rates:
&T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:






MANUFACTURING COSTS
Material
Cost






Material


1.14
Labor/ Part






Labor
$9.81


Burden/
Part






Burden



IF
$
SL
H
c1
%




TMC



MARK-UP COSTS
End
Item
Scrap
Rate






Scrap
O.OOTo


SG&A
Rate
(DB)






SG&A



Profit
Rate
(DB)






Profit
O.OOTo


ED&T/
R&D
Rate
(DR)






ED&T



Total
Mark-
up
Rate


$0.00
$0.00
$0.00

Total
Mark-up
O.OOTo
$0.00

Total
Mark-
up
Cost


$0.02
$0.01
$0.01




TOTAL COSTS
2.
°L
+ —i
3? ^
W"
R-
•c
$0.00
$0.00
$0.00

Q
	 >\1

	 *
Packaging Cost:
Net Cost Impact to Vehicle:
SL
si
is-
s
£
$0.05
$0.02
$0.01
1
$245.77





TOOLING &
Tooling Assump
"X1000 "
o"
0)







$0
NVESTMENT
Investment Assum
"X1000 "
"H.
w







$0


PACKAGING CALCULATIONS:
No Packaging Considerations Required. Packaging
Costs for fasteners (bolts, nuts, etc.) is captured in the
piece costs.



Rack/Pallet Investment Amortization


Expendable Packaging in Piece Cost
Packaging Cost Tota

Cost per
Piece




Cost per














Total



$0
Tier Pad

$0.00


Lump Sum
Payment




Tier Pads




Total * of
Pieces




Divider Pads,

$0.00


Number of
Months



60
Divider Pads




Interest
Rate




Other *1

$0.00







Other*!




1

I

$0
Other*!

$0.00

_
jtalNumbero
Racks Requ

i

57447
Other*!



=
mberof Parts
Rack

z
e
1
Other #3

$0.00

£
|!|

B- S.
?

Other *3
Pallet/Rad


£
1 I-f

t^S
5





File:15 Air Induction Charging System 040109A.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                APpendix G.1-15,160116
                                                                                      Form Author: G. Kolwich
                                                                                      (248)373-6000 Ext. 2411

-------
                   Appendix G.1 - Subsystem 17
                        Breather Subsystem
                         Case Study #0101
                         MAQS Worksheets
File:Breather Subsystem 17 O40209.xls
EPA Contract:EP-C-07-069 WA1-3                          Appendix G.1-17,1 of 2

-------
Oil-Air Separator 1702
                                                                                              Manufacturing Assumption and  Quote Summary
                                                                             APPENDIX G.1-17(1of1)
                                                                                       Print Date:9/2/2009
                 Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                     Vehicle Class: Compact/Economy 2-1 Passenger
OEM Operating Pattern (Weeks/Year):
                                                                                                                                                                                                             OEM Plant Location: North America
                      Study Case#: N0101(N = New, 01 = Technology Package, 01 = Vehicle Class)
               System Description: 2007 Mini Cooper s. 1.6L n, 16V DOHC GDI Turbo
        Annual Engine Volume (CPV):    <50,ooo
             Components per Engine: _
                                                                                                                                                                                                         Supplier Plant Location: North America
          Component Description: Oil/Air Separator
                                                                                                             Part Number: 1702-N0101-00
          Component Quote Level:   l~ Full Quote
                                                           r Modification
                                                                                    17 Differential Quote (Quote Summary includes
          Annual Component Volume:    <50,ooo
          Weekly Component Volume:     9,57<
               Estimated Product Life:
 OEM/T1 Classification:    rtoderate Assembly Complexity
       Shipping Method:"^Ship Point
Packaging Specification:_NA	
                                                                                                                                                                                         10
GENERAL COMPONENT INFORMATION
1
S

Tie
1A
Pu
1A
2A
3A
3B
Part Description

1 Supplier or OEM Processing
Oil/Air Separator
chase Part - High Impact Item
Valve - Non Return Intake Hose & Manifold Side
Valve - Non Return Intake Hose & Manifold Side
Separator- Cyclone
Valve - Pressure Control
Part Number

& Assembly (Full Cos
702-N0101-00
Full Cost Mapping)
702-N01 01 -01/41-01
702-N01 01 -01/41-02
702-N0101-10
1702-N0101-20
D
?
CT

tma
1
0

2
2
1
1
0
GENERAL MANUFACTURING INFORMATION
Primary Process
Description

pping)
Final Assembly of PCV system

overm old Hinge
Two Shot Overmold
Injection Mold (Additional
Plastic added to Mini Cover
over GEMA cover)
Purchase Part - Commodity ( Value taken from Purchase Part Database)
1A




Hinge Flow control flap




1702-N0101-80




2
0
0
0











OEM/Supplier
Classification


T1 Assembly, Mark-up Applied
© Bottom.

T2/T3 Inject. Mold, MSMC
T2/T3 Inject. Mold, MSMC
T2/T3 Inject. Mold, MSMC
T2/T3 Inject. Mold, MSMC
T2/T3 Inject. Mold, MSMC

S





Material
Specification


Not Applicable

Nylon66-30GF, Inject.
Nylon66-30GF, Inject.
Nylon66-30GF, Inject.


Labor
Classification


GeneralAssembly

MoloyCast/Sinter Operator
MoloyCast/Sinter Operator
MoloyCast/Sinter Operator
MoloyCast/Sinter Operator
MoloyCast/Sinter Operator


'Syndicates Component is Supplied directly to T
Assembly.
•SAC'=(Supplier Accounted Costs) Indicates Com
T1 or OEM for Final or Sub-Assembly. In addition
accounted for in T1 quote sheet. Thus componen
Mark-up Calculations.
'Alpha-Numeric Charact
Supplier for Subassemb




y.


Burden
Classification


Mech Assembly, LC, Base

Inject. Mold, SMS
Inject. Mold, SMS
Inject. Mold, MLS
Inject. Mold, SMS
Inject. Mold, SMS


or OEM for Final or Sub
Donent is Supplied directly
component material cost
cost will only be included
arts are brought in by T2/


MANUFACTURING RATES
Finished Pieces Per Hour


257
am

720
800
545
391
am


to
s
for

3



Number of Operators


1
0

1
0
0
1
0
0







Number of Lines


1
1

1
1
1
1
1
1







Parallel Processing
Multiplier


1

1
1
1
1
1
1







s
1
I
CT


0.000
0.000

0.005
0.002
0.818
0.005
0.002
0.000







Material
Cost
$/lb
(DB)


$0.00


$1.54
$1.27
$1.54
$1.54
$1.27
SN/A




T1 or


Labor
Rate
$/Hour
(DB)


$35.51


$43.52
$43.52
$43.52
$43.52
$43.52
SN/A




Burden
Rate
$/Hour
(DB)


$15.00


$100.01
$100.01
$150.01
$100.01
$100.01
SN/A




Applied
Burden
Rate
$/Hour


$45.00


$100.01
$100.01
$150.01
$100.01
$100.01
SN/A




OEM Total Manufacturing Cost:
T1 or OEM Mark-Up Rates:
&T1 or OEM Mark-Up Values:
Base Cost Impact to Vehicle:



MANUFACTURING COSTS
Material
Cost


$0.00


$0.01
$0.00
$1.26
$0.01
$0.00
SN/A



Material
0.00
$1.35
Labor/ Part


$0.14


$0.06
$0.11
$0.00
SN/A



Labor
$0.37
$0.37
Burden/
Part


$0.18


$0.14
$0.13
$0.28
$0.26
$0.26
SN/A



Burden


IF
$
SL
H
CD


$0.31


$0.21
$0.13
$1.53
$0.37
$0.26
SN/A







MARK-UP COSTS
End
Item
Scrap
Rate
(DB)


0.00%


0.50%
0.50%
0.50%
0.50%
0.50%
SN/A







$ft»
SG&A
Rate
(DB)


0.00%


650%
6.50%
6.50%
650%
6.50%
SN/A





6.50%


Profit
Rate
(DB)


0.00%


6.00%
6.00%
6.00%
6.00%
6.00%
SN/A





1

ED&T/
R&D
Rate
(DB)


0.00%


1 .00%
1 .00%
1 .00%
1 .00%
1.00%
SN/A





2.50%

Total
Mark-
up
Rate


0.00%


14.00%
14.00%
14.00%
14.00%
14.00%
SN/A
Supplier
Account
Cost
$0.00
$0.00
$0.00
$0.00

Total
Mark-up
15.50%
$0.56

Total
Mark-
up
Cost


$0.00


$0.03
$0.02
$0.21
$0.05
$0.04
SN/A
Price/ Uni
$0.03
$0.00
$0.00




TOTAL COSTS
2.
SL
+ —i
s? ^
I"
-c


$0.31


$0.24
$0.15
$1.75
$0.43
$0.30
SN/A
Price Net,
PIA
$0.00
$0.00
$0.00
$0.00

Q
	 m
	 *•
Packaging Cost:
Net Cost Impact to Vehicle:
SL
si
is-
s
*


$0.31
$0.00

$0.47
$0.29
$1.75
$0.43
$0.30
$0.00
Price Net,
End Item
$0.06
$0.00
$0.00
$0.00
I

$3.61
$3.61



TOOLING &
Tooling Assumptions
"X1000 "










$0
NVESTMENT
Investment Assumptions
"X1000 "










$0

PACKAGING CALCULATIONS:
No Packaging Impact



Rack/Pallet Investment Amortization


Expendable Packaging in Piece Cost
Packaging CostTota


Piece






$0.00












A^nt


$0



$0.00


Lump Sum
Payment









Total * of
Pieces






$0.00


Number of
Months


60






Interest
Rate



Other *1
Packaging

$0.00






Other*!

Pallet/Rack


£
S
1


$0
Other*!
Packaging

$0.00
_
g-l
•i 3.

1
57447
Other*!

Pallet/Rack

=
1
II

3
1
OtherK

Price Per
$0.00
f
til


f|

OtherB

""*""'*

1
lit


I"3 i





$0.000
FfeBreather Subsystem 17 O40209.xls
EPA Contract: EP-C-07-069 WA1-3
                                                                                                                  Appendix G.1-17,2of2
                                                                                    Form Author: G. Kolwich
                                                                                    (248)373-6000 Ext. 2411

-------
                   Appendix G.1 - Subsystem 60
                   Engine Management, Engine
                     Electronic, and Electrical
                           Subsystems
                        Case Study #0101
                        MAQS Worksheets
File: Electrical Subsystem 6
EPA Contract:EP-C-07-069 WA1-3                          Appendix G.1-60,1 of 5

-------
                                                                                               Manufacturing Assumption and  Quote Summary
                                                                                                                                         APPENDIX G.1-60,(1of4)
                                                                                                                                                    Print Date:9/2/2009
                 Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class
                     Vehicle Class: Compact/Economy 2-1 Pa!
                                                           OEM Operating Pattern (Weeks/Year):
                                                                                                                                                                                                               OEM Plant Location: North America
                      Study Case#: