Light-Duty Technology Cost Analysis


   Report on Additional Case Studies
United States
Environmental Protection
Agency

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                  Light-Duty Technology Cost Analysis

                      Report on Additional Case Studies
                                  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-10-010
April 2010

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                                         CONTENTS
Section                                                                            Page

    Executive Summary	1
    1    Introduction	1-1
         1.1   Objectives	1-1
         1.2   Study Methodology	1-2
         1.3   Manufacturing Assumptions	1-5
         1.4   Subsystem Categorization	1-6
    2    Case Study Results	2-1
         2.1 Case Study #0102 Results	2-2
         2.2 Case Study #0104 Results	2-7
         2.3 Case Study #0802 Results	2-10
         2.4 Case Study #0902 Results	2-13
    3    GLOSSARY OF TERMS	3-1

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                             LIST OF APPENDICES






A. Powertrain Package Specification Proformas



B. System Cost Model Analysis Templates (CMATs)



C. Subsystem Cost Model Analysis Templates (CMATs)
                                     n

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                                 LIST OF FIGURES
Number                                                                      Page
Figure 1 -1: Cost Analysis Process Flow Steps and Document Interaction	1-4

Figure 2-1: System Cost Model Analysis Template Illustrating the Incremental Subsystem Costs
         Roll Up for V6 to 14, Turbo, GDI Downsizing, Case Study #0102	2-5

Figure 2-2: System Cost Model Analysis Template Illustrating the Incremental Subsystem Costs
         Roll Up for V8 to V6, Turbo, GDI Downsizing, Case Study #0104	2-8

Figure 2-3: System Cost Model Analysis Template Illustrating the Incremental Subsystem Costs
         Roll Up for a 6-Speed Automatic Transmission compared to a 5-Speed Automatic
         Transmission	2-12

Figure 2-4: System Cost Model Analysis Template Illustrating the Incremental Subsystem Costs
         Roll Up for a 6-Speed Wet DCT compared to a 6-Speed Automatic Transmission2-15
                                         111

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                                      LIST OF TABLES

Number                                                                      Page
Table ES-0-1: Increment Unit Cost Impact - Five (5) New Technology Configurations	2

Table 1-1: Vehicle Class and Corresponding Downsized, Turbocharged,  Stoichiometric, GDI
          Engine Case Study Evaluated	1-1

Table 1-2: Engine System, Subsystem and Sub-Subsystem Classification	1-6

Table 1-3: Transmission System, Subsystem and Sub-Subsystem Classification	1-7

Table 2-1: Location of System and Subsystem CMATs within Appendix	2-2

Table 2-2: Cost for Adding Turbocharging and GDI to a 2.0L, 14, NA, PFI engine and the
          Estimated Credit for Downsizing from a Conventional 3.0L V6 to 2.0L 14	2-6

Table 2-3: Cost for Adding Turbocharging and GDI to a 3.5L, V6, NA, PFI engine and the
          Estimated Credit for Downsizing from a Conventional 5.4L V8 to 3.5L V4	2-9
                                         IV

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                                                              Report FEV 07-069-203
                                                                    March 26, 2010

  Light-Duty Technology Cost Analysis - Report on Additional Case Studies
Executive Summary

The United States Environmental Protection Agency (EPA) contracted with FEV, Inc. to
determine the 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).

This report,  the  second  in  a  series of reports,  addresses  the direct  incremental
manufacturing cost of four (4) new powertrain configurations, relative to four (4) existing
baseline  configurations, with comparable driver performance metrics. The  complete
costing methodology used in the analysis of these configurations, as well as the pilot case
study, is described in "Light-Duty Technology Cost Analysis Pilot Study (EPA-420-R-09-
020)".

The four  (4) new powertrain technology configurations analyzed are:

   •  2.0L, 14, 4-valve, dual overhead cam (DOHC), dual variable valve timing (d-
      VVT), turbocharged, gasoline direct injection (GDI) engine, compared to an
      equivalent conventional 3.0L, V6, 4-valve, DOHC, d-VVT, naturally aspirated
      (NA), port fuel injected (PFI) engine.
   •  3.5L, V6, 4-valve, dual overhead cam (DOHC), d-VVT, turbocharged, GDI
      engine, compared to an equivalent conventional 5.4L, V8, 3-valve, single overhead
      cam (SOHC), VVT, NA, PFI engine.
   •  A  6-speed automatic transmission, compared to an equivalent 5-speed automatic
      transmission
   •  A  6-speed wet dual clutch transmission (DCT), compared to an equivalent 6-speed
      automatic transmission

The results for the four (4) case studies are shown in Table ES-0-1 along the results
previously published for case study #0101.

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  Table ES-0-1: Increment Unit Cost Impact - Five (5) New Technology Configurations
Case
Study
Reference
0101
0102
0104
0902
0802
Technology
Definition
Downsized
Turbocharged
Gasoline Direct
Injection (Engine)
Downsized
Turbocharged
Gasoline Direct
Injection (Engine)
Downsized
Turbocharged
Gasoline Direct
Injection (Engine)
6-Speed Dual Clutch
Transmission
Replacing a 6-Speed
Automatic
Transmission
6-Speed replacing a
5 -Speed Automatic
Transmission
Vehicle
Class
Compact/
Budget/
Economy Car,
Passenger. 2-4
Mid to Large
Size Car,
Passenger 4-6
Passenger +
Midsize
Towing
Capabilities
Truck & SUV
Mid to Large
Size Car,
Passenger 4-6
Mid to Large
Size Car,
Passenger 4-6
Base
Technology
CS#B0101
2.4L, 14, 4-V
DOHC, d-VVT
NA, PFI,
CS#B0102
3.0L,V6, 4-V,
DOHC, d-VVT,
NA, PFI
CS#B0104
5.4LV8, 3-V,
SOHC, VVT,
NA, PFI
CS#B0801
6-Speed
Automatic
Transmission
CS# B0802
5-Speed
Automatic
Transmission
New
Technology
CS#N0101
1.6L, 14, 4-V
DOHC, d-VVT,
Turbo, GDI
CS#N0102
2.0L, 14, 4-V,
DOHC, d-VVT
Turbo, GDI
CS#N0104
3.5LV6, 4-V,
DOHC, d-VVT
Turbo, GDI
CS#N0801
6-Speed Wet
Dual Clutch
Transmission
CS# N0802
6-Speed
Automatic
Transmission
Incremental
Unit Cost
$531.57
$68.68
$846.26
($147,34)
($105.53)(1)
(1) The 6-speed automatic transmission evaluated incorporated a Ravigneaux gear set
design, a major factor in the reduction of hardware and complexity in the 6-speed design
over the  5-speed design.  As such the 6-speed transmission was calculated to be less
costly to manufacture than the 5-speed automatic transmission.

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1   Introduction

1.1  Objectives
The  objective  of  this work  assignment was  to  determine  the  incremental direct
manufacturing  costs  for  four  (4)  new  advanced  light-duty  vehicle  technology
configurations using  the costing methodology, databases,  and supporting worksheets
developed in the previously concluded pilot study (Light-Duty Technology Cost Analysis
Pilot Study [EPA-420-R-09-020]).

For the downsized, turbocharged, stoichiometric GDI engine case studies, careful
consideration was given to the selection of vehicle classes analyzed to ensure that the
developed costing models, at any analysis level (component,  sub-subsystem, or
subsystem) could be interpolated or extrapolated to other classes, configurations and/or
content levels.
Table 1-1 exhibits the five (5) vehicle classes considered in this work assignment and
identifies those vehicles classes with  actual teardown-based cost studies.
 Table 1-1: Vehicle Class and Corresponding Downsized, Turbocharged, Stoichiometric,
                         GDI Engine Case Study Evaluated
 Vehicle Class
            Vehicle Class Description
    Completed
     Analysis
   Small Car
subcompact or compact car typically powered by an
in-line 4 cylinder engine
  Case Study #0101
  (2.4LI4» 1.6LI4)
     («175hp)
    (Pilot Study)
  Midsize Car
midsize or large passenger car typically powered
by a V6 engine
  Case Study #0102
 (3.0V6 »2.0LI4)
     (-225 hp)
    Large
 Multipurpose
    Vehicle
minivan or large cross-over vehicle with a large frontal
area, typically powered by a V6 engine, capable of
carrying ~ 6 or more passengers
(Large V6» Small V6)
  Potential to scale
 costs from #0102 &
       #0104
  Small Truck
small or mid-sized sports-utility or cross-over vehicle,
or a small pickup truck, powered by a V6 or V8 engine
  Case Study #0104
 (5.4LV8»3.5LV6)
     («330 hp)
  Large Truck
large sports-utility vehicles and large pickup trucks,
typically powered by a V8 engine
(Large V8» Small V8)
  Potential to scale
  costs from #0104
                                      1-1

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1.2  Study Methodology

The first report published, "Light-Duty Technology Cost Analysis Pilot Study (EPA-420-
R-09-020)", covers in great detail the overall costing methodology used to calculate an
incremental cost delta between various technology configurations.   In summary, the
costing methodology is heavily based on teardowns of both new and baseline technology
configurations having similar driver performance metrics. Only components identified as
being different, within the selected new and baseline technology configurations, as a
result of the new technology adaptation are evaluated for cost.   Component costs are
calculated using a ground-up costing methodology analogous to  that employed  in the
automotive industry.   All incremental costs for the new technology are calculated and
presented using transparent cost  models  consisting  of eight (8) core cost elements:
material, labor, manufacturing overhead/burden, end item scrap,  SG&A (selling general
and  administrative),  profit, ED&T  (engineering, design and testing)  and packaging.
Information on how additional associated manufacturing fixed and variable cost elements
(e.g. shipping, tooling, OEM indirect costs) are accounted for within the cost analysis are
also discussed in the initial report (EPA-420-R-09-020).

Listed below, with the  aid of Figure 1-1, is a high level summary of the ten (10) major
steps taken during the cost analysis process.   For additional information concerning the
terminology used within the ten (10) steps, please reference the glossary of terms found
at the end of this report.

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

Step 2 ; Existing vehicle models  are identified for teardown to provide the basis for
detailed incremental cost calculations.

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.

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.
                                       1-2

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Step 5; A cross functional team (CFT) reviews all the data generated from the high level
teardown and identifies which components and assumptions should be carried forward
into the cost analysis.  The CBOMs are updated to reflect the CFT input.

Step 6 ;  Phase 2 (component/assembly level)  teardowns are initiated,  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,  SG&A, profit,
ED&T, and packaging.

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 (i.e. subject matter experts) beyond the CFT.

Step 9; All costs calculated in the MAQS worksheets are automatically inputted into the
Subsystem Cost Model Analysis Templates (CMAT).   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.  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
                                       1-2

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   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 and Document Interaction
                                                1-4

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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 and are  carry-over from the pilot  study.   Listed below are the fundamental
assumptions:

    1) Manufacturing rates  are considered high  volume  (>450K  Units/Year)  and
       maintained throughout the product life.  In the four (4) case studies which follow,
       a yearly capacity planning volume (CPV) of 450,000 units was assumed.

    2) 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.

    3) OEMs  and suppliers have manufacturing equipment  and facilities capable of
       handling required manufacturing processes and capacities unless otherwise stated.

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

    5) Supplier and OEM manufacturing costs (material costs, labor rates, manufacturing
       overhead/burden rates) are based on 2008/2009 economics.

    6) Supplier mark-up rates (end-item scrap, SG&A,  profit, and ED&T) are based on
       mature technology and manufacturing methods (e.g. mature product designs, high
       production volumes, significant  marketplace  competition,  and  established
       manufacturing processes) unless otherwise specified.

    7) 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.

The specific case study assumptions are those unique to a given technology and hardware
configuration.  Listed below are  some of the case study specific considerations:

    1) Manufacturing site for defined operation or process; OEM, Tier 1 or Tier 2/3.

    2) Intellectual property expense.
                                       1-5

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    3) Neighboring system costs as a result of new technology adaptation.

    4) A new or modified, maintenance and/or end-of-life expense.

    5) Availability of significant material cost reductions (MCRs).

    6) Performance and/or cost implications of alternative new technology advances
       (NTAs).
1.4  Subsystem Categorization

As with the first case study analysis, a design based classification system was used to
group the various components and assemblies making up the technology configurations.
In general, every vehicle system (e.g. engine system, transmission system, etc) is made
up of several subsystems levels (e.g. the engine system includes a crank drive subsystem,
cylinder head subsystem, lubrication subsystem, air induction subsystem, etc),  which in-
turn, is made up of several sub-subsystem levels (e.g. the air induction subsystem may
include the following sub-subsystems: turbocharger, heat  exchanger, pipes, hoses, and
ducting). The sub-subsystem is the smallest  classification level in which all components
and assemblies are binned.

Adding  new technology to a system will also affect the  primary subsystem(s).  Also
impacted are the neighboring  subsystems which require additions and/or modification for
successful integration of the  new  technology into the system.  For example, to add a
turbocharged air induction subsystem to a naturally aspirated engine, as many as ten (10)
additional subsystems may be affected relative to cost, some in the positive direction
(added cost), others  in the negative direction (cost savings). Table 1-2 and  Table  1-3
provide  an overview of the  major subsystems and sub-subsystems  included for each
system (e.g. engine and transmission) evaluated within this analysis.   In Section 2, Case
Study Results, costs are presented for both the engine and transmission evaluations using
these design subsystem categorizations.
                                       1-6

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Table 1-2: Engine System, Subsystem and Sub-Subsystem Classification
Subsystem
Engine Frames, Mountings & Brackets
Crank Drive
Counter Balance
Cylinder Block
Cylinder Head
Valvetrain
Timing Drives
Accessory Drives
Intake
Fuel Induction
Exhaust
Lubrication
Cooling
Induction Air Charging
Breather
Electronic and Electrical
Accessory
Sub-Subsystem
Engine Frames, Engine Mountings, Hanging Hardware
Crankshaft, Flywheels/Flexplates, Connecting Rods, Pistons,
Bearing Elements
Dynamic Parts, Static Parts, Drives
Cylinder Block, Crankshaft Bearing Caps, Bedplate, Piston
Cooling
Cylinder Head, Valve Guides & Seats, Guides for Valvetrain,
Camshaft Bearing Housing, Camshaft Sensors, Camshaft
Carrier, Cylinder Head Covers.
Camshaft, Intake Valves, Exhaust Valves, Valve Springs,
Spring Retainers & Keepers & Seats,
Timing Wheels, Tensioners, Guides, Belts, Chains
Pulleys, Tensioners, Guides, Belts
Intake Manifold, Air Filter Box, Air Filters, Throttle Housing
Assembly & Supplies, Pipes/Hoses/Ducting
Fuel Rails, Fuel Injectors, Pressure Regulators & Sensors, Fuel
Injection Pumps, Pipes/Hoses, Brackets
Exhaust Manifold, Collector Pipes, Catalysts, Silencers
(Mufflers), Oxygen Sensors, Pipes/Hoses, Brackets
Oil Pans, Oil pumps, Pressure Regulators& Sensors, Oil Filters,
Pipes/Hoses, Sealing Elements, Heat Exchangers
Water Pumps, Thermostat Housing, Heat Exchangers, Pressure
Regulators, Pipes/Hoses/Ducting, Brackets
Turbochargers, Heat Exchangers, Pipes/Hoses/Ducting,
Brackets
Oil/Air Separator, Valves, Adapters, Pipes/Hoses/Ducting
Engine Management, Engine Electronic, Engine Electrical (e.g.
Wiring, Ignition, Plugs, Coils, Powertrain Control Module)
Starter Motors, Alternators, Power Steering Pumps, Air
Conditioning Compressors
                               1-7

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Table 1-3: Transmission System, Subsystem and Sub-Subsystem Classification
Subsystem
Externally Mounted Component
Case(s)
Gear Train
Internal Clutch
Launch Clutch
Oil Pump and Filter
Mechanical Control
Electrical Control
Park Mechanism
Sub-Subsystem
Lift Eye, Vent Cap, Bracket, Bolting
Transaxle Case, Transaxle Housing, Covers, Bearing
Race, Plug, Actuator
Input Shaft, Output Shaft, Transfer Shaft, Sun Gear,
Planetary Gear, Ring Gear, Counter Gear, Differential
Gear, Bearing (Roller, Needle)
Sprag Clutch, Clutch & Brake Hub, Disc and Plate,
Piston, Snap Ring, Bearing (Roller, Needle),
Synchronizer
Torque Converter, Clutch Assembly, Flexplate, Flywheel
Oil pump, Cover, Oil Filter, Oil Cooler, Oil Squirter,
Pipes/Tubes
Valve Body Assembly, Mechanical Controls (e.g. Shift
Forks), Sealing Elements, Bearing Elements, Plugs &
Cups
Controller, Solenoid, Sensor, Switches, Wiring Harness
Rod/Shaft/Pin, Spring, Pawl, Bracket, Bolt
                                  1-8

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2   Case Study Results

The results for the four (4) case studies analyzed within this work assignment. For each
case study, a brief description of the technology and its associated hardware is provided.
Additional general specifications for each case study can also be found in the Powetrain
Packaging Specification Proformas in Appendix A. A scaled-down version of the System
Cost Model Analysis Template (CMAT) is provided, summarizing the incremental direct
manufacturing costs for each major subsystem that was affected by adaptation of the new
technology.

The  full System CMATs for  each  case  study can be found  in Appendix B.  The
supporting Subsystem CMATs for each case study,  which roll-up all the component and
assembly costs for each subsystem, can be found in Appendix C. Table 2-1 provides a
cross reference between  each  case  study and the associated  system and subsystem
CMATs.

Because  each case  study consists of a large quantity of  component and assembly
Manufacturing and  Assumption Quote  Summary (MAQS) worksheets, approximately
200 pages per case study,  hard copies were not included as part of this report.  However,
electronic copies of the MAQS worksheets, as well as all other supporting case study
documents (e.g.  CBOMs, Subsystem CMATs, System  CMATs), can be accessed at
http://www.epa.go v/otaq/.
                                     2-1

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         Table 2-1: Location of System and Subsystem CMATs within Appendix
Case

Study
Numbers


NO 102

BO 102



NO 104

BO 104

N0802

B0802
N0902

B0902


Case Study Description


2.0L, 14, 4-valve, dual overhead cam (DOHC), dual
variable valve timing (d-VVT), turbocharged,
gasoline direct injection (GDI) engine, compared to
an equivalent conventional 3.0L, V6, 4-valve,
DOHC, d-VVT, naturally aspirated (NA), port fuel
injected (PFI) engine."
3.5L, V6, 4-valve, dual overhead cam (DOHC), d-
VVT, turbocharged, GDI engine, compared to an
equivalent conventional 5.4L, V8, 3-valve, single
overhead cam (SOHC), VVT, NA, PFI engine.
A 6-speed automatic transmission, compared to an
equivalent 5-speed automatic transmission

A 6-speed wet dual clutch transmission (DCT),
compared to an equivalent 6-speed automatic
transmission.
System
CMAT

Appendi
X

Section
Bl





B2



B3


B4


Subsystem
CMAT
\^-_l_V_LZl. _I_
Appendix
Section

Cl





C2



C3


C4


a For the purpose of these case studies, "equivalent" means similar performance and/or capability
                                            2-2

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2.1 Case Study #0102 Results
(V6 Downsizing to 14)

Case Study #0102 analyzed the  direct incremental manufacturing cost for downsizing
from a conventional 3.0L, V6, 4-V, DOHC, d-VVT, NA, PFI engine to a 2.0L, 14, 4-V,
DOHC, d-VVT, turbocharged, GDI engine.   The  performance specifications for both
engine configurations were considered to be equivalent with a maximum power output of
approximately 225 hp and maximum torque of approximately 210 Ib-ft.

Note that in this analysis, neither the new or base  engine actual hardware had d-VVT.
Both sets of hardware  only consisted of intake-VVT.  However, as part of the overall
study assumptions, both technologies were assumed to have d-VVT.

For the conventional/baseline engine configuration, a 2008 Ford Cyclone Duratec 35 (i.e.
3.5L V6) engine was used in combination with a 2008 Ford Mondeo Duratec 30 (i.e.,
3.0L V6) engine.  The 3.5L Duratec engine was the  principal hardware referenced in this
analysis, with the 3.0L  Duratec engine primarily used to support size and weight scaling
of the 3.5L V6 engine to a 3.0L V6 equivalent.  This approach was taken for two main
reasons: 1) the 3.5L Duratec is a relative new engine  (launched in 2007 timeframe,
winner of 2007 Ward's Top 10 Best Engines) and, as such, is considered to contain some
of the  latest design and manufacturing advances for  conventional V6  engines; and 2)
much of this same base engine cost analysis could be reused in Case  Study #0104 (5.4L
V8, NA, PFI downsized to a 3.5L V6,  Turbo, GDI engine), reducing analysis time.

For the new technology configuration, the 2007 BMW/PSA Peugeot Citroen Prince 1.6L
14,  Turbo,  GDI engine (used in the 2008 Mini Cooper, S) was selected as the lead
hardware, scaled up to a 2.0L 14, Turbo, GDI equivalent. Both the Chrysler GEMA 2.4L,
14, NA, PFI engine and GM Family II, Ecotec, 2.0L, 14, Turbocharged, GDI engine were
used for size and weight scaling (e.g. pistons,  connecting rods, cylinder head), feature
counts (e.g. valve cover  fasteners, oil sump fasteners), as  well as for  costing selected
items not captured within the 1.6L 14 BOM (e.g. balance shaft).  Because the 1.6L 14,
Prince engine was used in a previous  study (i.e. case study #0101), selected cost models
for this previously completed work  could be  reprocessed with updated function and
performance specifications, reducing analysis time.

Features of the 2.0L 14,  Turbo,  GDI fuel induction subsystem include a direct rotary
drive, swash plate, high pressure fuel pump assembly servicing four (4) side-mounted
solenoid injectors (7-hole type) with a maximum operating pressure of 150 bar.  The air
induction subsystem includes a twin-scroll turbocharger assembly, featuring a vacuum-
actuated waste gate actuator, electronically-actuated  anti-surge valve, along with a water-
cooled,  pressure-lubricated bearing housing.  The  maximum exhaust  gas temperature
permitted  at the  turbine inlet is 950°C.   Compressed air leaving the  turbocharger
assembly is cooled via an air-to-air heat exchanger prior to reaching the intake manifold.

                                       2-2

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In this cost analysis, as well as in the V8 to V6 Turbo, GDI, engine downsizing analysis,
no  additional  intellectual property  expenses  were identified  beyond  the typical
contribution included in the selling, general and administrative (SG&A) expense.  It is
acknowledged that each supplier currently manufacturing air induction components (e.g.
Honeywell-Garret, BorgWarner, Cummins) and/or high pressure fuel system components
(e.g. Bosch, Continental, Delphi) will have a large number  of patents  to protect their
intellectual property.  Because of these patents, market-leading  suppliers  can recover
some of their development costs in the short  term.  However the approach of this cost
analysis assumes that   a  competitive supplier base will develop similar  components
(which do  not infringe  on the original developer's patents), and that the value of the
originator's intellectual  property will  diminish,   resulting in more modest intellectual
property allowances as  the technology matures.   This  allowance is captured by the
assigned SG&A rate.

As  with the first  pilot  case  study (#0101),  new  technology advances (NTAs) were
identified as possible performance upgrades to the physical hardware of the turbocharged
engines. These NTAs included the following: variable geometry turbochargers, water-to-
air charge air coolers,  electric water pump (replacing the  conventional mechanical water
pump) paired with a smaller  auxiliary after-run pump.  At this time, these alternative
technologies are recorded and identified (and may be evaluated at a later date  when
representative hardware is available), but are not included in the cost analysis.

Many material cost reduction (MCR) ideas were identified in case study #0102, and these
MCRs were incorporated at the beginning  of this analysis.   For example, certain
manufacturing processes are sometimes better suited to  lower-volume products due to
lower tooling costs. An example of this would be a part manufactured using a powdered
metal process; at low production volumes, this may result in the lowest cost, but at high
production  volumes,  a  fine  blanking process  may  make  better financial sense..
Generally,  anywhere  a component design or manufacturing method  was  originally
adopted based on  low volume production, a revised design assumption and/or process
suitable for high volume mass production was selected.  A  second example of where
MCRs were directly implemented into the analysis was in the selection of "best practice"
or "upward trending" manufacturing processes. An example of this is the replacement of
a sandcast aluminum cylinder block with a diecast cylinder block.  In this particular case
study, the actual block for the 3.0L, V6, Ford Duratec block  was sandcast,  whereas the
3.5L block was diecast.  For this reason, the 3.5L, V6, Ford Duratec diecast cylinder
block was evaluated for cost and scaled down to a 3.0L V6 equivalent.

In all of the turbo, GDI,  engine  downsizing studies (case studies #0101, #0102, and
#0104), this same approach to NTA's and MCRs was utilized.

Figure 2-1  shows the net incremental direct manufacturing cost of $68.68 for downsizing
from a 3.0L V6,  NA, PFI conventional engine to a 2.0L 14, Turbo, GDI engine.  In

                                       2-3

-------
addition to the subsystem cost breakdowns showing their net contribution to costs, the
contribution from each cost element is also captured.  Major incremental cost factors for
the new technology were the  fuel induction  subsystem ($84.76) and  air induction
subsystem ($280.70).   Major incremental cost savings for the new technology due to
downsizing were the cylinder head subsystem ($158.70) and the valvetrain ($122.71).
                                       2-4

-------

Technology L®wh 01-Dcwnsiz*d, Turtxschargsd, Gasdir>s Direct Inj&et (GDI) Engine
Vehicte Class: 02- Mid to Largs Size Pasasng&r Vehicle*, 4-6 Passengers
Study Cas^: 0102 ( N0102 N*w T^chndcgj,' Configuration;!
( B0 102 Ba$$lir>$ Technology Cot-figuration)

SYSTEM & SUBSYSTEM DESCRIPTION
E
J?

£
#
|r- Subsystem Description

0100 ENGINE SYSTEM

1

2



5

6

7

8

9


1 1

12

13

14

15


17

18

19

20



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| 03 Crank Drrv* Sub*v**M-n
.
fo*y«t*
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| Cf7 Valve-train S:ub-av»t«F«

1 03 Timing Drive Subsystem

I OS> Acsoeaaory Drive Stifom^ystiwfTi

I 1 0 intalkft Subayatttm


I 12 Ixfcauat Subwyatena

| 13 Ltiferication Sufesyaterrt

I 14 Cooling Subsystem

| 15 Induction Air Charging Subsystem

| 1 S Exhaust «3a» Re^OireialatieiiHi Subsystem- Not Applicable In Analysis

	 1 	 ••» r !*•¥••••• 	
I €0 Engine Management, Engine Electronic and Electrical Subsystem*

|Tf, A<2Gease»riem@ub«y«6emi( Starter Motors. Altematom, Poiver
f® Steering Punipm, ete>

|

I

SUBSYSTEM ROLL-UP











































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
2.0L 14, DOHC, Turbo Dl
BASE TECHNOLOGY PACKAGE COST INFORMATION
3.0L V6, DOHC, NA, PFI
Minulac Hiring
Material



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Figure 2-1: System Cost Model Analysis Template Illustrating the Incremental Subsystem Costs Roll Up for V6 to 14,
                                Turbo, GDI Downsizing, Case Study #0102
                                                2-5

-------
An alternative method of binning component and assembly incremental costs is based on
their contribution to cost relative to downsizing, GDI,  or turbocharging categories. In
Table 2-2, the incremental subsystems costs are broken out into these three (3) alternative
categories.   The combined subsystems  cost of  adding  GDI to a  2.0L 14 over a
conventional  PFI subsystem  is  $213.    The combined subsystems  cost for adding
turbocharging to an 14 engine over a conventional NA subsystem is $403.  Lastly, the
credit for downsizing from a conventional V6 to a conventional 14 is $547.

  Table 2-2: Cost for Adding Turbocharging and GDI to  a 2.0L, 14, NA, PFI engine and
     the Estimated Credit for Downsizing from a Conventional 3.0L V6 to 2.0L 14.

GDI
Turbo
Downsizing
Net Incremental Cost
Combine
Subsystem
Incremental
Impact
$213
$403
(4547)
$69
Direct Subsystem
Incremental
Contribution
$85
$281


Indirect
Subsystem
Incremental
Contribution
$128
$122


                                     2-6

-------
2.2 Case Study #0104 Results
(V8 Downsizing to V6)

Case Study #0104 analyzed the direct incremental manufacturing cost for downsizing
from a conventional 5.4L, V8, 3-V, SOHC, VVT, NA, PFI engine to a 3.5L V6, 4-V,
DOHC, d-VVT, turbocharged, GDI engine.

For the conventional/baseline engine configuration, a 2008 Ford Modular 5.4L V8 engine
was selected.   Standard  features  of  this  engine include a  cast  iron block, forged
crankshaft, aluminum heads,  variable  valve timing  and hydraulic, roller  finger valve
lifters. The maximum power output rating is  300 hp @ 5000 rpm with a maximum torque
of3651b.-ft. @3750rpm.

For the new technology configuration, a 2008 Ford Cyclone Duratec 35 (i.e. 3.5L V6)
base engine was selected for the foundation  of the analysis. Utilizing the project team's
expertise, published data on Turbo, GDI, V6 engine  architectures, surrogate component
data from existing benchmarking evaluations, and previously completed cost studies (i.e.,
case study #0101 and #0102), the project team developed a 3.5L V6, Turbo, GDI engine
Bill of Materials  (BOM).  In regards to a target performance specification, the Ford
EcoBoost engine (3.5L V6, 4-V, DOHC, i-VVT, Turbo, GDI, engine) specification was
used as a surrogate; maximum 355 hp @ 5000 rpm and 350 Ib.-ft. @ 3500 rpm.

Features of the 3.5L V6, Turbo, GDI  fuel induction subsystem include a  direct  rotary
drive, swash plate  design, high-pressure  fuel pump  servicing six (6)  side-mounted
solenoid injectors  (7-hole type), with a maximum operating pressure of 150 bar. The air
induction  subsystem  features twin,  single-scroll  turbocharger  assemblies.   Each
turbocharger assembly has a vacuum-actuated waste gate, an electronically-actuated anti-
surge valve, and a water-cooled, pressure-lubricated bearing housing.  The maximum
exhaust gas inlet temperature permitted at the turbine  inlet is 950°C.  Compressed  air
leaving the turbocharger assemblies is cooled prior to reaching the intake manifold via an
air-to-air heat exchanger.

Figure  2-2  shows  the net incremental direct  manufacturing cost of  $846.26 for
downsizing from a 5.4L  V8,  NA, PFI conventional engine to a 3.5L V6, Turbo, GDI
engine.  Major incremental cost factors for the new technology were the fuel induction
subsystem ($124.59) and air induction subsystem ($448.79).  The downsizing of many
subsystems (e.g. intake, crank drive, cylinder block) resulted in a cost savings of $155.
                                      2-7

-------

Technology Lewi; 01-Dcwnstz*d, Turteochargfsd, Gasoline Dir*ci Inj&el (GDI) Engine
Vehicle Class; 04-Small lo Midsize Truck, Pas&sngsr + Midsize Towing Capability
Study Casfr*: 0104 ( N0104 N«w TschrxJcg^' Configurationt
( BQ 1 04 Bass>)ir>§ Technology C

£ t.oe

£ a. ie

£ S.1T

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£ O.11

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Figure 2-2: System Cost Model Analysis Template Illustrating the Incremental Subsystem Costs Roll Up for V8 to V6,
                                Turbo, GDI Downsizing, Case Study #0104
                                                2-8

-------
Similar to the V6 to 14 downsizing  analysis, Table 2-3 breaks down the incremental
component and subsystems costs into downsizing, GDI, and turbocharging categories. As
shown in  the table, the combined subsystem  cost for adding GDI to  a V6 (over a
conventional  PFI  subsystem) is  $321.   The  combined subsystem costs for adding
turbocharging to a V6 engine over a conventional NA subsystem is $681. Lastly, the
credit for downsizing from a conventional V8 to a conventional V6 is $155.

 Table 2-3: Cost for Adding Turbocharging and GDI to a 3.5L, V6, NA, PFI engine and
     the Estimated Credit for Downsizing from a Conventional 5.4L V8 to 3.5L V4.

GDI
Turbo
Downsizing
Net Incremental Cost
Combine
Subsystem
Incremental
Impact
$321
$681
(-$155)
$846
Direct Subsystem
Incremental
Contribution
$125
$449


Indirect
Subsystem
Incremental
Contribution
$196
$232


                                    2-9

-------
2.3 Case Study #0802 Results
(6-Speed versus 5-Speed Automatic Transmission)

Case Study #0802 analyzed the direct incremental manufacturing cost for updating from
a conventional  5-speed automatic transmission to  a next generation 6-speed automatic
transmission.

The 5-speed automatic transmission selected for the analysis was the  Toyota U151E
FWD transmission.   This transmission was used  in various applications including the
Toyota  Camry through  the  2005-2006  timeframe.   The  main  construction of the
transmission includes three (3) full planetary gear sets.  The front and rear planetary gear
sets are positioned in series along a common intermediate shaft assembly.  Adjacent to
the front and rear planetary sets, and mounted in series to the  counter shaft assembly, is a
third underdrive planetary  set.   The transmission contains a total of nine  (9) shift
elements, four (4) disc clutches, three (3) disc brakes, and two (2) one-way-clutches. The
hydraulic valve body assembly, containing  a total of seven  (7) shift solenoid valves is
controlled directly by the  engine  control  module (ECM). The  total  weight of the
transmission, including Automatic Transmission Fluid (ATF), is approximately 221 Ibs.
The maximum output torque rating for the U15 IE is 258 Ib-ft.

The 6-speed automatic transmission  selected for the analysis was the replacement
transmission to the Toyota  5-speed.  The Toyota  6-speed FWD transmission  (U660E)
was a complete redesign of the existing U151E transmission,  which launched in the 2007
timeframe.  Employing a Ravigneaux and underdrive planetary gear set, positioned along
a common  intermediate  shaft assembly, the U660E  gear  driveline is much  simpler
compared to its predecessor.  Only six (6) shift elements are required for operation of the
transmission; two (2) disc clutches, three (3) disc brakes, and one (1) one-way-clutch.
The U660E  valve body assembly also contains a total of seven (7) shift  solenoid valves
interfacing with an exterior-mount transmission control module (TCM), which in-turn
communicates  with the  engine control module  (ECM).   The  total  weight of the
transmission, including ATF, is 208 Ibs.  The maximum output torque rating for the
U660E is 295 Ib.-ft.

As  discussed in the initial report (EPA-420-R-09-020), the costing methodology employs
an  exclusion approach to costing.  Following completion  of the  comparison bill of
materials (CBOMs), the cross functional  team  began the process of rationalizing
similarities   and differences  between hardware  on the five (5)  and  six (6) speed
transmissions. A combination of component function and content exclusion analysis was
conducted, eliminating the majority of components which required costing.  Since the 5-
speed transmission contained more hardware (i.e., approximately 150 more parts), and
was generally more complex,  the 6-speed established a zero cost baseline from which an
incremental  cost for the  5-speed was established.   The majority of incremental cost
                                      2-10

-------
increase of the five 5-speed over the 6-speed was associated with the two (2) additional
clutch packs, the need for a counter shaft assembly, and some additional gearing.

According  to the  SAE Technical  Paper  2006-01-0847  ("Toyota's New 6-Speed
Automatic  Transaxle U660E for FWD Vehicles"), the U660E's  transmission geartrain
structure, consisting of a Ravigneaux gear set and simpler planetary  set, was Toyota's
original invention.  As such, there was no patent royalty fee penalization assessed against
the 6-speed design.  The patent rights for similar 6-speed transmission designs (e.g.
Lepelletier) are due to expire in 2010.  Therefore we do not expect royalty fees to be a
significant part of the cost for 6-speed transmissions.

For the 6-speed automatic transmission, there were no NTA or MCR ideas identified as
part of the cost analysis.  It was obvious from the transmission teardown assessment that
in addition to Toyota's goal for improving overall performance with their new 6-speed
automatic transmission relative to the 5-speed predecessor, keeping costs at or below the
existing manufacturing  cost was a key metric.   In regard to  the 5-speed automatic
transmission, many of innovative ideas implemented into the 6-speed automatic  could
have been  incorporated into a new 5-speed if it  were to be redesigned).    The most
obvious NTA would be  adopting a similar Ravigneaux geartrain design, which  could
conceivably have the same financial benefit recognized by the 6-speed automatic.  As
part of this analysis, no  additional work was conducted to determine what the financial
impact would be on the 5-speed automatic by employing some of these NTA and MCRs
concepts.  As such, the net incremental direct manufacturing cost shown below is  solely
based on the physical hardware evaluated.

Figure 2-3  shows the net incremental direct manufacturing cost between the six (6) and
five (5) speed automatic transmissions.  In evaluating the physical hardware, the 6-speed
automatic was analyzed to be less expensive to manufacture by approx $105. Note that
when the 6-speed transmission  was redesigned, several other functional and performance
updates not driven  by the added 6th-gear ratio were incorporated (e.g. modified hydraulic
control strategy, spool valve material, and friction discs, as well as a newly-developed
torque converter).  These modifications were not  costed in the  analysis since they are
independent of the  gear ratio addition and modifications.
                                      2-11

-------

T«chnology Lewi: 08 - 6 Sp**sd Automatic versus 5 St^^rl Automatic Transmission
Y*hick* Class; 02 - Mid to Larg* Siz* Passenger V^Hcte, 4-6 Passencprs
Study Ca»4; 0802 ( NO£O2 N«w T«chr>okx^ Configuration)
( B0602 Ratlins Technology Cctf iguration)

SYSTEM & SUBSYSTEM DESCRIPTION
,1

£
4t
Subsystem Description

0200 TRANSMISSION SYSTEM

i

2

3

4

E

6

7

8

9

10

11

12




EXT E RNAL COMPONENT S: ConEsi sts of installation of oil coolers,
lift ey^n, vent caF*s,


„» CA@B[S>: lncktd«s patt»a«d jrt comp@nenft« (i«^ bearing na^ttn),
pNj^n, and asaoe^A^ l^t^warai.


GEAR TRAIN: Includes Input Shaft*. Output Shafts, Differential and
adl aaacH? laced ggears aed b»ariEtgs c%n the anwft.


INTERIM L CLUTCHES: Internal (01 Gears, Synchronizers, Bands,
etc.


05 LAUNCH CLUTCHES: Torque Converter




OIL PUMP & FILTER: Includes Pump, Pump Shaft/Drive Mechanism.
Oil Fi Iters ( In1e rnal or Ex ternaC , Pick-up Tube, and Oil Baffles.

07 MECHANICAL CONTROLS


03 ELECTRICAL CONTROLS


og PARK MECHANISM: Includes Park i, Lock Pawl Mechanism and
Actuating Levers



1O MISCELLANEOUS:

I





SUBSYSTEM ROLL-UP































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
6 Sp&ed Automatic Transmission: 2Q07-2009 Toyota Camry
BASE TECHNOLOGY PACKAGE COST INFORMATION
5 Speed Automatic Transmission: 20O4-2006 Toyota Camry
Manufacturing
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Figure 2-3: System Cost Model Analysis Template Illustrating the Incremental Subsystem Costs Roll Up for a 6-Speed
                    Automatic Transmission compared to a 5-Speed Automatic Transmission
                                                2-12

-------
2.4 Case Study #0902 Results
(6-Speed Wet Dual Clutch Transmission versus 6-Speed Automatic Transmission)

Case Study #0902 analyzed the direct incremental manufacturing cost for updating from
a conventional 6-speed automatic transmission to a 6-speed, wet, dual clutch
transmission.

The baseline technology configuration selected for the analysis was the Toyota 6-speed
automatic transmission (U660E) of case study #0802. General design parameters of the
U660E transmission can be found in section 2.3 of this report.

The new technology configuration selected for the analysis was the Volkswagen (VW)
six 6-speed, wet, dual clutch transmission (DCT); model number DQ250. Other industry
naming conventions for this technology configuration include twin-clutch gearbox or
dual shift gearbox (DSG).   The basic components of the DCT include a twin clutch pack
assembly driving two (2) coaxial input shafts. Power from the engine is transmitted to
the input shafts through a dual-mass flywheel which is connected in series to the twin-
clutch pack. Each input shaft, dependent on the selected gear,  is designed to mesh with
one (1) of two (2) output shafts.   Upon reverse gear selection, there is an intermediate
shaft which engages with both input shaft one (1) and output shaft two (2). There are
four (4) shift forks, two (2) on each output shaft, hydraulically activated into one of two
positions from their neutral home position. The controls for the DCT, which include the
hydraulic controls,  electronic controls, and various sensors and actuators, are integrated
into a single module VW refers to as a Mechatronic unit.  The total weight of the
transmission module, including the dual-mass flywheel, is approximately 207 Ibs. The
maximum output torque rating for the DQ250 transmission is 258 Ib.-ft.

Relative to intellectual property costs, no additional allowances were  provided, outside
the general allowance covered as part of the selling, general and administrative (SG&A)
expense, for protecting intellectual property.  It is acknowledged that each supplier
currently making a version of a DCT (e.g. BorgWarner, Getrag, ZF, LuK) will have a
large number of patents on their own technology. Because of these patents, suppliers
who are considered to be market leaders in DCT technology will certainly recover some
of their development costs in the short term.  However, it is assumed that as the supplier
base and associated technologies mature, the value (i.e. function/cost) each supplier
provides will begin to equalize, resulting in a diminishing intellectual property cost
allowance for each design.

As part of the hardware review and evaluation, no NTA or MCR ideas were considered
in the final cost analysis. The evaluation team felt that in general, both transmissions
were robustly designed, with each consisting of a high level of component and function
integration, which resulted in two financially competitive solutions.
                                     2-13

-------
In this analysis, approximately seventy-five (75) percent of the components on both the
6-speed automatic transmission and 6-speed wet DCT were evaluated for cost.  This
level of analysis was required due to the inherent differences between the automatic
versus DCT components. The only subsystems identified as common in function and
cost between the two (2) transmissions were the oil pump, filter, park mechanism, and
external components.

Figure 2-4 shows the net, incremental, direct manufacturing cost between the 6-speed wet
DCT and 6-speed automatic transmissions.  In evaluating the physical hardware, the 6-
speed wet DCT was analyzed to be less expensive to manufacture by approx $147.  The
major cost increment of the  6-speed wet DCT was the launch clutch system ($64.79),
which included a dual-mass flywheel and twin clutch assembly.  The major incremental
cost savings  for  the new technology were  the  internal  clutches ($132.35) and the
geartrain ($38.04).
                                      2-14

-------

T«c hnology L«wl : 09 - 6 Sp&^d Automatic versus 6 Sf»$d Direct Slit Tta^misston
Vshicte Class: 02- Mid to Laijp Sizs Pas.»rijsr Vshicte, 4-6 Passengers
Stuch/ Caaw*; 0902 ( N0»2 New Technology Configu-atbn)
( B0902 Basslins Technology Corf iguiaHcn)

SYSTEM 8. SUBSYSTEM DESCRIPTION
1

I
^mD^ion

0200 TRANSMISSION SYSTEM

i

2

3

4

5

e

7

e

a

10

1 1

12





M EXTERNALCOMPOHENTS:Consistsof imtallatiDIl of oilcootets,
lift eyes, ve]^ ^aps.




.^ CAS^S): biekid&s ^resaed in components {I.** bearing tac«3},
pNags, and associated hardwara^

GEAR TR AIN: Includes Input Shafts, Output Shafts. Differential and
ait assoo iated gears and bearings on th> sha ft.


INTERNAL CLUTCHES: Internal lor Sears, Synchronizers, Bands,


OS LAUNCH CLUTCHES: Torque Converter


ML PUMP & FILTER: Includes Pump, Pump Shall Dt rve Mechanism,
Oil Filters {Internal OF External; . pick-up Tube, and Oil Baffles.


Or MECHANICAL CONTROLS


08 ELECTRICAL COHTROLS


PARK MECHANISM: Include s Park & Lock Pawl Hechanism and


19 MISCELLANEOUS:





SUBSYSTEM ROLL-UP































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagen
BASE TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Automatic Transmission: 2Q07-20Q9 Toyota Camry
Manufacturing
Material



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Figure 2-4: System Cost Model Analysis Template Illustrating the Incremental Subsystem Costs Roll Up for a 6-Speed Wet
                              DCT compared to a 6-Speed Automatic Transmission
                                                 2-15

-------
3   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 implications 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 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.

                                      3-1

-------
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 for some of the existing
hardware under evaluation.  These advanced technologies,  through improved function
                                       3-2

-------
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 Cl ass 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).
                                       3-2

-------
System CMAT (Cost Mode 1 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.
                                      3-4

-------
                            APPENDIX A
                POWERTRAIN PACKAGE PROFORMAS

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

   •  Appendix A. 1: Powertrain Package Proforma for Case Study #0102, 3 .OL,
      V6, 4-V, DOHC, d-VVT, NA, PFI engine compared to a 2.0L, 14, 4-V,
      DOHC, d-VVT, turbocharged, GDI engine

   •  Appendix A.2: Powertrain Package Proforma for Case Study #0104, 5.4L,
      V8, 3-V, SOHC, VVT, NA,  PFI engine compared to a 3.5L V6, 4-V,
      DOHC, d-VVT, turbocharged, GDI engine

   •  Appendix A.3: Powertrian Package Proforma for Case Study #0802,
      conventional 5-speed automatic transmission compared to a next generation
      6-speed automatic transmission

   •  Appendix A.4: Powertrain Package Proforma for Case Study #0902,
      conventional 6-speed automatic transmission compared to a 6-speed, wet,
      dual clutch transmission
                                 A-0

-------
                                       APPENDIX A.1 -POWERTRAIN PACKAGE SPECIFICATION PROFORMA
                                                                 CASE STUDY #0102
                                                                             Printed: 3/29/2010
    CASE STUDY: 0102

    TECHNOLOGY:
    Downsized, turbocharged, gasoline direct
    injection (GDI) Engine versus Port-fuel
    injected, 4-valve, naturally aspirated gasoline
    engine.

    VEHICLE CLASS:
    Mid to Large Size Passenger Car
    Passenger Seating: 4 -6
                                                     Surrogate Image of Duratec 3.0 V6 Engine
                                                                                                          Mini Cooper S, 1.6114, Turbo GDI

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27

Characteristics
Engine Name/Code
Engine Type
Displacement, cc (CID)
Aspiration
Compression Ratio
Variable Valve Timing (VVT)
Variable Valve Lift
Multi Displacement System
Variable Intake Manifold
Bore (mm)
Stroke (mm)
Fuel System
Block Material
Cylinder Head Material
Cylinder Liner Material
Connecting Rod Material
Intake Manifold Material
Horse Power @ RPM
Torgue (Ib-ft) @ rpm (normal)
Transmission
Fuel Economy (City/Highway)
Emission Certification
Fuel Octane
North American Applications
Manufacturer
Plant Locations
Annual Engine Volume


2008 Ford Mondeo Duratec 30
V6, 4 Valve, DOHC
3.0L
Naturally Aspirated
10:1
Hardware: Intake -VVT, Study Assumption: Dual-VVT
No
No
No
89
79.5
Seguential multi-port electronic injection
Hardware: Aluminum Sand Castr, Study Assumption: Aluminum Diecast
Aluminum
Cast Iron
PM Steel Forged/Cracked
Composite (Aluminum & Glassed Reinforced Nylon)
221 @ 6250
205 @ 4750 rpm
Electronic 6-speed automatic with overdrive
18/26
Tier 2, Bin4/LEV-2 ULEV
Unleaded regular/E85
Ford Fusion
Ford Motor Company
Mexico
Actual: Approximately 300K, Study Assumption 450K


Theoretical engine scaled off Prince/N14B16
(Mini Cooper S Engine)
14, 4-Valve, DOHC
2.0L
Turbocharged (Twin Scroll, Wastegate)
10:1
Dual-VVT
No
No
No
85.9
85.9
Direct Injection, Side Mounted Solenoid (7 Hole), < 150 bar
Aluminum Die Cast
Aluminum
Cast Iron
PM Steel Forged/Cracked
Glass Reinforced Nylon
Est. 225 @ 4000/6000
Est. 205 @ 2000/4000
Electronic 6-speed automatic with overdrive
NA
Tier 2, Bin 5 / LEV-2 (Based on Mini Cooper S)
87/91 (Based on Mini Cooper S)
n/a
n/a
n/a
450K

File:PT Package Spec. Proforma 032610.xls
EPA Contract: EP-C-07-069 WA1-3
Apdx. A.1 PT-Pkge.Proforma 0102,
                              of4
    Author: G. Kolwich
(248) 373-6000, Ext.2411

-------
                                       APPENDIX A.2 -POWERTRAIN PACKAGE SPECIFICATION PROFORMA
                                                                 CASE STUDY #0104
                                                                             Printed: 3/29/2010
    CASE STUDY: 0104

    TECHNOLOGY:
    Downsized, turbocharged, gasoline direct
    injection (GDI) Engine versus Port-fuel
    injected, 3-valve, naturally aspirated gasoline
    engine.

    VEHICLE CLASS:
    Mid to Large Car and Light Duty Truck
    Passenger Seating: 4 -5
                                                         Ford Triton 5.4L, V8, NA, PFI
                                                                                                           Ford EcoBoost 3.5L, V6, Turbo, GDI

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27

Characteristics
Engine Name/Code
Engine Type
Displacement, cc (CID)
Aspiration
Compression Ratio
Variable Valve Timing (VVT)
Variable Valve Lift
Multi Displacement System
Variable Intake Manifold
Bore (mm)
Stroke (mm)
Fuel System
Block Material
Cylinder Head Material
Cylinder Liner Material
Connecting Rod Material
Intake Manifold Material
Horse Power @ RPM
Torque (Ib-ft) @ rpm (normal)
Transmission
Fuel Economy (City/Highway)
Emission Certification
Fuel Octane
North American Application(s)
Manufacturer
Plant Locations
Annual Engine Volume


Triton / 5.4L 3V NA
5.4L 3-valve SOHC V8
5,407.7 cc (330)
Naturally Aspirated
9.8:1
VVT
No
No
No
90.17
105.92
Sequential multi-port electronic injection
Cast Iron
Aluminum
Steel
PM Steel Forged/Cracked
Composite
31 0@ 5000 rpm
390 @ 3500 rpm
Electronic 6-speed automatic with overdrive
4x2 14/20,4x4 14/18
LEV-2
Unleaded regular/E85
Ford F-Series Light Duty Truck
Ford Motor Company
Ford Windsor Engine Plant I, Windsor, ONT
Actual: 2008 Approximately 41 OK, Study Assumption: 450K

New Technology Package
Theoretical engine based off Ford EcoBoost / 3.5L GTDI iVCT
3.5L EcoBoost™ 24-valve DOHC V6
3500 cc (21 3. 5)
Twin-Turbocharged
10.0:1
Actual Hardware: Intake-VVT, Study Assumption: Dual-VVT
No
No
No
92.5
88.7
Direct Injection
Aluminum
Aluminum
Cast Iron
PM Steel Forged/Cracked
Cast Aluminum (costed as composite)
355 @ 5700 rpm
350 @ 3500 rpm
6-speed electronically controlled automatic overdrive with paddle activation
17/25 (AWD standard equipment)
LEV-2
91 Octane (recommended)
Ford Flex and Taurus SHO and Lincoln MKS and MKX
Ford Motor Company
Ford Cleveland Engine Plant I, Brook Park, OH
Study Assumption: 450K

File:PT Package Spec. Proforma 032610.xls
EPA Contract: EP-C-07-069 WA1-3
Apdx. A.2 PT-Pkge.Proforma 0104, Page 2 of 4
    Author: G. Kolwich
(248) 373-6000, Ext.2411

-------
                                     APPENDIX A.3 -POWERTRAIN PACKAGE SPECIFICATION PROFORMA
                                                              CASE STUDY #0802
                                                                         Printed: 3/29/2010
 CASE STUDY: 0802

 TECHNOLOGY:
 6-Speed Automatic Transmission compared to
 an equivalent 5-Speed Automatic Transmission

 VEHICLE CLASS:
 Mid to Large Size Passenger Car
 Passenger Seating: 4 -6

1
2
3
4
5
6
7
8









9
10
11
12

Characteristics
Transmission Name / Code
Transmission Type
Control System
Geartrain
Internal Clutches
Launch Clutch Subsystem
Engine Connection
Gear Ratios
First
Second
Third
Fourth
Fifth
Sixth
Reverse
Final I
Final II
Maximum Torque Capacity
Approximate Weight (with Automatic Transmission Fluid)
North American Application(s)
Annual Case Study Volume Assumption:

Baseline Technology Package
2004/2006 Toyota 5-Speed Automatic Transmission, U1 51 E
5-Speed Automatic Transmission for FWD Mid to Large Size Passenger
Vehicles
Electric-Hydraulic
3 Planetary Sets: Front, Rear and Underdrive
4 Disc Clutches, 3 Disc Brakes, and 2 Sprags all Electro-Hydraulically
Controlled.
Electro-Hydraulically Controlled Torque Converter with Lock-up Clutch
Flex Plate Assembly
(Ratio Data Published per SAE 2002-01-0936)
3.938
2.194
1.411
0.973
0.703
n/a
3.141
n/a
n/a
258 Ib-ft
221 Ibs
Camry, Solara, Sienna, Avalon
450K

New Technology Package
2007-Present, Toyota 6-Speed Automatic Transmission, U660E
6-Speed Automatic Transmission for FWD Mid to Large Size Passenger
Vehicles
Electric-Hydraulic
One Ravigneaux Planetary and One Underdrive Planetary
2 Disc Clutches, 3 Disc Brakes, and 1 Sprag all Electro-Hydraulically
Controlled.
Electro-Hydraulically Controlled Torque Converter with Lock-up Clutch
Flex Plate Assembly
(Ratio Data Published per SAE 2006-01-0847)
3.300
1.900
1.420
1.000
0.713
0.608
4.148
n/a
n/a
295 Ib-ft
208 Ibs
Camry, Lexus ES-350, Avalon
450K

File:PT Package Spec. Proforma 032610.xls
EPA Contract: EP-C-07-069 WA1-3
Apdx. A.3 PT-Pkge.Proforma 0802, Page 3 of 4
    Author: G. Kolwich
(248) 373-6000, Ext.2411

-------
                                     APPENDIX A.4 -POWERTRAIN PACKAGE SPECIFICATION PROFORMA
                                                              CASE STUDY #0902
                                                                         Printed: 3/29/2010
 CASE STUDY: 0902

 TECHNOLOGY:
 6-Speed Wet Dual Clutch Transmission
 compared to an equivalent 6-Speed Automatic
 Transmission

 VEHICLE CLASS:
 Mid to Large Size Passenger Car
 Passenger Seating: 4 -6

1
2
3
4
5
6
7
8









9
10
11
12

Characteristics
Transmission Name / Code
Transmission Type
Control System
Geartrain
Internal Clutches
Launch Clutch Subsystem
Engine Connection
Gear Ratio
First
Second
Third
Fourth
Fifth
Sixth
Reverse
Final I
Final II
Maximum Torque Capacity
Approximate Weight (with Transmission Fluid)
North American Application(s)
Annual Case Study Volume Assumption:


2007-Present, Toyota 6-Speed Automatic Transmission, U660E
6-Speed Automatic Transmission for FWD Mid to Large Size Passenger
Vehicles
Electric-Hydraulic
One Ravigneaux Planetary and One Underdrive Planetary
2 Disc Clutches, 3 Disc Brakes, and 1 Sprag all Electro-Hydraulically
Controlled
Electro-Hydraulically Controlled Torque Converter with Lock-up Clutch
Flex Plate Assembly
(Ratio Data Published per SAE 2006-01-0847)
3.30
1.90
1.42
1.00
0.71
0.61
4.15
n/a
n/a
295 Ib-ft
208 Ibs
Camry, Lexus ES-350, Avalon
2450K


Volkswagen Direct Shift Gearbox (DSG)/Dual Clutch Transmission, DQ250
6-Speed, Twin Wet Clutch Transmission for FWD Mid Size Passenger
Vehicles
Electric-Hydraulic
Two Coaxial Input Gear Shaft Assemblies, Two Output Gear Shaft
Assemblies, and a Intermediate Gear Shaft Assembly for Reverse Gear.
Four Electro-Hydraulically Controlled Shift Fork and Synchronizer Gear
Assemblies
Two Eectro-Hydraulically Controlled, Oil-Cooled Multi-Plate
Clutches
Dual-mass Flywheel assembly
(Calculated Ratios)
3.36
2.09
1.47
1.10
1.09
0.92
3.99
3.94
3.14
258 Ib-ft
207
Jetta Sports Wagon
2450K

File:PT Package Spec. Proforma 032610.xls
EPA Contract: EP-C-07-069 WA1-3
Apdx. A.4 PT-Pkge.Proforma 0902, Page 4 of 4
    Author: G. Kolwich
(248) 373-6000, Ext.2411

-------
                             APPENDIX B
           SYSTEM COST MODEL ANALYSIS TEMPLATES

The System Cost Model Analysis Template (CMAT) 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 CBOM.

   •  Appendix B.I: System CMAT for Case Study #0102, 3.OL, V6, 4-V,
      DOHC, d-VVT, NA, PFI engine compared to a 2.0L, 14, 4-V, DOHC, d-
      VVT, turbocharged, GDI engine

   •  Appendix B.2: System CMAT for Case Study #0104, 5.4L, V8, 3-V,
      SOHC, VVT, NA, PFI engine compared to a 3.5L V6, 4-V, DOHC, d-VVT,
      turbocharged, GDI engine

   •  Appendix B.3: System CMAT for Case Study #0802, conventional 5-speed
      automatic transmission compared to a next generation 6-speed automatic
      transmission

   •  Appendix B.4: System CMAT for Case Study #0902, conventional 6-speed
      automatic transmission compared to a 6-speed, wet, dual clutch
      transmission
                                  B-0

-------
                                                   APPENDIX B.1 - SYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                              CASE STUDY #0102
                                                                                                                                                                         Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case*: 0102 ( N0102 New Technology Configuration)
                      ( B0102 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
o>
>• Subsystem Description
.a
CO

0100 ENGINE SYSTEM

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20



|02 Engine Frames, Mountings & Brackets Subsystem

I 03 Crank Drive Subsystem

| 04 Counter Balance Subsystem

I 05 Cylinder Block Subsystem

I 06 Cylinder Head Subsystem

I 07 Valvetrain Subsystem

| 08 Timing Drive Subsystem

I 09 Accessory Drive Subsystem

I 10 Intake Subsystem

I 1 1 Fuel Subsystem

I 12 Exhaust Subsystem

I 13 Lubrication Subsystem

I 14 Cooling Subsystem

I 15 Induction Air Charging Subsystem

| 16 Exhaust Gas Re-Circulation Subsystem- Not Applicable In Analysis

I 17 Breather Subsystem

I 60 Engine Management, Engine Electronic and Electrical Subsystems

I Accessories Subsystem (Starter Motors, Alternators, Power
Steering Pumps, etc)

I

I

SUBSYSTEM ROLL-UP














































NEW TECHNOLOGY PACKAGE COST INFORMATION
2.0L 14, DOHC, Turbo Dl
Manufacturing
Material





$ 50.89

$ 10.37

$ 81.47

$ 91.27

$ 83.52

$ 10.10

$ 29.00

$ 11.04

$ 37.51

$ 144.60

$ 11.91

$ 18.49

$ 98.15

$

$ 9.14

$ 51.36

$ 3.44

$

$

$ 742.58
Labor



$

$ 24.65

$ 6.22

$ 25.86

$ 18.16

$ 1 5.83

$

$

$ 0.92

$ 1 8.45

$ 31.84

$ 6.43

$ 6.29

$ 51.97

$

$ 2.42

$ 22.00

$ 2.55

$

$

$ 233.59
Burden



$

$ 65.62

$ 10.89

$ 135.54

$ 108.15

$ 59.40

$

$

$ 2.15

$ 55.50

$ 98.14

$ 1 2.74

$ 10.55

$ 73.38

$

$ 7.38

$ 38.90

$ 7.45

$

$

$ 685.46
Total
Cost
(Component/
Assembly)



$

$ 141.16

$ 27.47

$ 242.87

$ 217.58

$ 158.75

$ 10.10

$ 29.00

$ 14.11

$ 111.46

$ 274.57

$ 31.08

$ 35.33

$ 223.50

$

$ 18.94

$ 112.26

$ 1 3.45

$

$

$ 1,661.62
Markup
End Item
Scrap



$

$ 1.50

$ 0.84

$ 7.83

$ 4.33

$ 0.51

$

$

$ 0.07

$ 1.15

$ 11.06

$ 0.14

$ 0.20

$ 7.36

$

$ 0.06

$ 0.62

$ 0.09

$

$

$ 35.75
SGSA



$

$ 6.27

$ 3.16

$ 1 1 .75

$ 7.37

$ 6.24

$

$

$ 0.92

$ 1 1 .45

$ 17.24

$ 2.15

$ 2.40

$ 20.61

$

$ 1.23

$ 8.11

$ 1.35

$

$

$ 100.23
Profit



$

$ 6.27

$ 2.92

$ 1 2.61

$ 8.10

$ 6.01

$

$

$ 0.85

$ 11.48

$ 16.27

$ 1.76

$ 2.48

$ 20.71

$

$ 0.82

$ 7.47

$ 1.10

$

$

$ 98.83
EDST-RSD



$

$ 2.12

$ 0.91

$ 2.89

$ 2.25

$ 2.41

$

$

$ 0.35

$ 4.41

$ 6.94

$ 0.49

$ 1.06

$ 7.75

$

$ 0.21

$ 3.11

$ 0.30

$

$

$ 35.19
Total Markup
Cost
(Component/
Assembly)



$

$ 16.15

$ 7.83

$ 35.07

$ 22.05

$ 15.17

$

$

$ 2.19

$ 28.48

$ 51.51

$ 4.55

$ 6.15

$ 56.44

$

$ 2.32

$ 19.30

$ 2.84

$

$

$ 270.01
Total
Packaging
Cost
(Component/
Assembly)



$

$ 0.60

$ 0.05

$ 1.14

$ 0.48

$ 0.26

$

$

$ 0.18

$ 0.25

$ 0.59

$ 0.33

$ 0.11

$ 0.76

$

$ 0.05

$ 0.07

$ 0.09

$

$

$ 4.99
Net
Component/
Assembly Cosl
Impact to OEM



$

$ 1 57.91

$ 35.36

$ 279.08

$ 240.12

$ 174.18

$ 10.10

$ 29.00

$ 16.48

$ 140.19

$ 326.67

$ 35.96

$ 41.59

$ 280.70

$

$ 21.31

$ 131.64

$ 1 6.38

$

$

$ 1,936.62
File: System CMAT- RPT2-032009.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                              Appendix B.1 (CS#0102), , Page: 1 of 12
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                   APPENDIX B.1 - SYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                              CASE STUDY #0102
                                                                                                                                                                         Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case*: 0102 ( N0102 New Technology Configuration)
                      ( B0102 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
o>
>• Subsystem Description
.a
CO

0100 ENGINE SYSTEM

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20



|02 Engine Frames, Mountings & Brackets Subsystem

I 03 Crank Drive Subsystem

| 04 Counter Balance Subsystem

I 05 Cylinder Block Subsystem

I 06 Cylinder Head Subsystem

I 07 Valvetrain Subsystem

| 08 Timing Drive Subsystem

I 09 Accessory Drive Subsystem

I 10 Intake Subsystem

I 1 1 Fuel Subsystem

I 12 Exhaust Subsystem

I 13 Lubrication Subsystem

I 14 Cooling Subsystem

I 15 Induction Air Charging Subsystem

| 16 Exhaust Gas Re-Circulation Subsystem- Not Applicable In Analysis

I 17 Breather Subsystem

I 60 Engine Management, Engine Electronic and Electrical Subsystems

I Accessories Subsystem (Starter Motors, Alternators, Power
Steering Pumps, etc)

I

I

SUBSYSTEM ROLL-UP














































BASE TECHNOLOGY PACKAGE COST INFORMATION
3.0L V6, DOHC, NA, PR
Manufacturing
Material



$

$ 56.77

$

$ 97.26

$ 148.96

$ 120.32

$ 49.34

$ 22.00

$ 21.72

$ 8.16

$ 135.37

$ 1 4.77

$

$

$

$ 1.21

$ 40.21

$

$

$

$ 715.90
Labor



$

$ 32.52

$

$ 21 .04

$ 31.81

$ 31 .27

$ 5.99

$

$ 4.31

$ 9.17

$ 43.46

$ 2.87

$

$

$

$ 0.43

$ 23.22

$

$

$

$ 206.07
Burden



$

$ 90.55

$

$ 119.50

$ 182.67

$ 115.65

$ 11.58

$

$ 12.04

$ 28.18

$ 121.81

$ 18.14

$

$

$

$ 0.59

$ 32.81

$

$

$

$ 733.66
Total
Cost
(Component/
Assembly)



$

$ 179.84

$

$ 237.81

$ 363.44

$ 267.24

$ 66.90

$ 22.00

$ 38.07

$ 45.51

$ 300.63

$ 35.77

$

$

$

$ 2.23

$ 96.24

$

$

$

$ 1,655.63
Markup
End Item
Scrap



$

$ 1.11

$

$ 6.95

$ 6.61

$ 0.97

$ 0.59

$

$ 0.18

$ 0.34

$ 7.63

$ 0.18

$

$

$

$ 0.00

$ 0.42

$

$

$

$ 24.98
SGSA



$

$ 7.91

$

$ 1 1 .06

$ 11.63

$ 11.97

$ 1.56

$

$ 2.37

$ 3.83

$ 18.81

$ 2.35

$

$

$

$ 0.09

$ 6.34

$

$

$

$ 77.91
Profit



$

$ 7.86

$

$ 1 2.04

$ 12.70

$ 11.54

$ 1.04

$

$ 2.19

$ 3.94

$ 18.08

$ 2.14

$

$

$

$ 0.06

$ 5.16

$

$

$

$ 76.76
EDST-RSD



$

$ 2.67

$

$ 2.98

$ 3.59

$ 4.65

$ 0.24

$

$ 0.91

$ 1.66

$ 7.84

$ 0.87

$

$

$

$ 0.02

$ 1.85

$

$

$

$ 27.28
Total Markup
Cost
(Component/
Assembly)



$

$ 19.56

$

$ 33.02

$ 34.53

$ 29.1 3

$ 3.43

$

$ 5.65

$ 9.77

$ 52.36

$ 5.54

$

$

$

$ 0.17

$ 13.77

$

$

$

$ 206.92
Total
Packaging
Cost
(Component/
Assembly)



$

$ 0.91

$

$ 0.74

$ 0.86

$ 0.52

$ 0.38

$

$ 0.42

$ 0.15

$ 0.98

$ 0.32

$

$

$

$ 0.02

$ 0.07

$

$

$

$ 5.38
Net
Component/
Assembly Cosl
Impact to OEM



$

$ 200.31

$

$ 271.57

$ 398.82

$ 296.90

$ 70.71

$ 22.00

$ 44.15

$ 55.43

$ 353.97

$ 41.63

$

$

$

$ 2.42

$ 110.07

$

$

$

$ 1,867.93
File: System CMAT- RPT2-032009.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                              Appendix B.1 (CS#0102), , Page: 2 of 12
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                           APPENDIX B.1 - SYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                 CASE STUDY #0102
                                                                                                                                              Printed: 3/2 6/2010

Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
Study Case*: 0102 ( N0102 New Technology Configuration)
( B0102 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

E
o>
>• Subsystem Description
.a
CO

0100 ENGINE SYSTEM

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20



|02 Engine Frames, Mountings & Brackets Subsystem

I 03 Crank Drive Subsystem

| 04 Counter Balance Subsystem

I 05 Cylinder Block Subsystem

I 06 Cylinder Head Subsystem

I 07 Valvetrain Subsystem

| 08 Timing Drive Subsystem

I 09 Accessory Drive Subsystem

I 10 Intake Subsystem

I 1 1 Fuel Subsystem

I 12 Exhaust Subsystem

I 13 Lubrication Subsystem

I 14 Cooling Subsystem

I 15 Induction Air Charging Subsystem

| 16 Exhaust Gas Re-Circulation Subsystem- Not Applicable In Analysis

I 17 Breather Subsystem

I 60 Engine Management, Engine Electronic and Electrical Subsystems

I Accessories Subsystem (Starter Motors, Alternators, Power
Steering Pumps, etc)

I

I

SUBSYSTEM ROLL-UP















































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
2.0L 14, DOHC, Turbo Dl
BASE TECHNOLOGY PACKAGE COST INFORMATION
3.0L V6, DOHC, NA, PFI
Manufacturing
Material



$

t (5.88)

$ 10.37

$ (15.80)

$ (57.68!

t (36.81)

$ (39.24|

$ 7.00

$ (1 0.69)

$ 29.35

$ 9.22

$ (2.88)

$ 18.49

$ 98.15

$

$ 7.93

$ 11.16

$ 3.44

$

$

$ 26.67
Labor



$

$ (7.87)

$ 6.22

$ 4.82

$ (1 3.65J

$ (15.43)

$ (5.99!

$

$ (3.38!

$ 9.28

$ (1 1 .62!

$ 3.56

$ 6.29

$ 51.97

$

$ 1.99

$ (1.22J

$ 2.55

$

$

$ 27.51
Burden



$

$ (24.93)

$ 10.89

$ 16.04

$ (74.52)

$ (56.25)

$ (11.58J

$

$ (9.89)

$ 27.31

$ (23.67J

$ (5,40)

$ 10.55

$ 73.38

$

$ 6.80

$ 6.09

$ 7.45

$

$

$ (48,19)
Total
Cost
(Component/
Assembly)



$

$ (38.88)

$ 27.47

$ 5.06

$ (145.85)

$ (108.49)

$ (56.SOJ

$ 7.00

$ (23.96)

$ 65.94

$ (26.055

$ (4,69)

$ 35.33

$ 223.50

$

$ 1 6.71

$ 16.03

$ 1 3.45

$

$

$ 5.99
Markup
End Item
Scrap



$

$ 0.38

$ 0.84

$ 0.88

$ (2.28)

$ (0.47)

$ (0.59J

$

$ (0.11)

$ 0.81

$ 3.43

$ (0.04)

$ 0.20

$ 7.36

$

$ 0.06

$ 0.21

$ 0.09

$

$

$ 10.77
SGSA



$

$ (1.64)

$ 3.16

$ 0.69

$ (4.26!

$ (5.72)

$ (1.56!

$

$ (1.45)

$ 7.62

$ (1.57)

$ (0.20)

$ 2.40

$ 20.61

$

$ 1.14

$ 1.76

$ 1.35

$

$

$ 22.33
Profit



$

$ (1.60)

$ 2.92

$ 0.57

$ (4.60!

$ (5.53)

$ (1 .04!

$

$ (1.34!

$ 7.53

$ (1 .80)

$ (0.38)

$ 2.48

$ 20.71

$

$ 0.76

$ 2.31

$ 1.10

$

$

$ 22.08
EDST-RSD



$

$ (0.58)

$ 0.91

$ (0.09)

$ (1.34J

$ (2,24)

$ (0.24)

$

$ (0.56J

$ 2.75

$ (0.91)

$ (0.37)

$ 1.06

$ 7.75

$

$ 0.19

$ 1.25

$ 0.30

$

$

$ 7.91
Total Markup
Cost
(Component/
Assembly)



$

$ (3.41)

$ 7.83

$ 2.04

$ (12.48)

$ (13.96)

$ (3.43)

$

$ (3.46J

$ 18.71

$ (0.85)

$ (0.99)

$ 6.15

$ 56.44

$

$ 2.15

$ 5.53

$ 2.84

$

$

$ 63.08
Total
Packaging
Cost
(Component/
Assembly)



$

t (0.31)

$ 0.05

$ 0.40

$ (0.37J

$ (0.26)

$ (0.38!

$

$ (0.24J

$ 0.10

$ (0.39!

$ 0.02

$ 0.11

$ 0.76

$

$ 0.03

$ 0.01

$ 0.09

$

$

$ (0,39)
Net
Component/
Assembly Cosl
Impact to OEM



$

t (42.40)

$ 35.36

$ 7.51

$ (1 58.70!

t (122.71)

$ (60.61!

$ 7.00

$ (27.66!

$ 84.76

$ (27.30!

$ (5.68)

$ 41.59

$ 280.70

$

$ 1 8.89

$ 21.57

$ 1 6.38

$

$

$ 68.68
File: System CMAT- RPT2-032009.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                 Appendix B.1 (CS#0102), , Page: 3 of 12
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                   APPENDIX B.2 - SYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                              CASE STUDY #0104
                                                                                                                                                                          Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
        Study Case*: 0104 ( N0104 New Technology Configuration)
                      ( B0104 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
o>
>• Subsystem Description
.a
CO

0100 ENGINE SYSTEM

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20



|02 Engine Frames, Mountings & Brackets Subsystem

I 03 Crank Drive Subsystem

| 04 Counter Balance Subsystem

I 05 Cylinder Block Subsystem

I 06 Cylinder Head Subsystem

I 07 Valvetrain Subsystem

| 08 Timing Drive Subsystem

I 09 Accessory Drive Subsystem

I 10 Intake Subsystem

I 1 1 Fuel Subsystem

I 12 Exhaust Subsystem

I 13 Lubrication Subsystem

I 14 Cooling Subsystem

I 15 Induction Air Charging Subsystem

| 16 Exhaust Gas Re-Circulation Subsystem- Not Applicable In Analysis

I 17 Breather Subsystem

I 60 Engine Management, Engine Electronic and Electrical Subsystems

I Accessories Subsystem (Starter Motors, Alternators, Power
Steering Pumps, etc)

I

I

SUBSYSTEM ROLL-UP














































NEW TECHNOLOGY PACKAGE COST INFORMATION
3.5L.V6 DOHC, Turbo Dl
Manufacturing
Material



$

$ 70.67

$

$ 1 05.58

$ 161.65

$ 1 20.77

$ 29.50

$ 33.00

$ 56.49

$ 52.08

$ 76.95

$ 44.25

$ 24.98

$ 1 46.26

$

$ 15.99

$ 75.20

$ 4.11





_#
Labor



$

$ 33.19

$

$ 21.77

$ 32.63

$ 31.34

$ 5.72

$

$ 3.78

$ 25.81

$ 3.47

$ 1 6.54

$ 7.54

$ 76.44

$

$ 4.24

$ 32.70

$ 2.92





$ 297.96
Burden



$

$ 96.75

$

$ 128.38

$ 210.03

$ 115.98

$ 11.39

$

$ 5.66

$ 79.08

$ 14.41

$ 39.30

$ 12.56

$ 106.36

$

$ 12.92

$ 58.06

$ 8.67





$ 900.20
Total
Cost
(Component/
Assembly)



$

$ 200.61

$

$ 255.72

$ 404.31

$ 268.10

$ 46.61

$ 33.00

$ 65.93

$ 1 56.98

$ 94.83

$ 1 00.09

$ 45.08

$ 329.41

$

$ 33.14

$ 165.95

$ 15.69

$

$

$ 2,216.05
Markup
End Item
Scrap



$

$ 2.22

$

$ 7.11

$ 7.37

$ 0.98

$ 0.58

$

$ 0.16

$ 1.55

$ 3.98

$ 0.37

$ 0.25

$ 1 7.87

$

$ 0.11

$ 0.92

$ 0.11





$ 43.60
SGSA



$

$ 8.86

$

$ 12.65

$ 12.73

$ 12.06

$ 1.36

$

$ 1.64

$ 15.81

$ 6.16

$ 5.03

$ 3.07

$ 38.21

$

$ 2.15

$ 11.98

$ 1.62





$ 133.46
Profit



$

$ 8.78

$

$ 1 3.21

$ 13.96

$ 1 1 .62

$ 0.90

$

$ 1.88

$ 1 5.79

$ 6.96

$ 4.52

$ 3.14

$ 40.86

$

$ 1.44

$ 11.08

$ 1.32





$ 135.56
EDST-RSD



$

$ 3.02

$

$ 3.04

$ 3.91

$ 4.69

$ 0.23

$

$ 0.47

$ 6.05

$ 3.38

$ 1.75

$ 1.31

$ 16.27

$

$ 0.36

$ 4.63

$ 0.37





$ 49.49
Total Markup
Cost
(Component/
Assembly)



$

$ 22.88

$

$ 36.02

$ 37.96

$ 29.36

$ 3.07

$

$ 4.15

$ 39.21

$ 20.48

$ 11.67

$ 7.78

$ 113.21

$

$ 4.05

$ 28.61

$ 3.41

$

$

$ 362.11
Total
Packaging
Cost
(Component/
Assembly)



$

$ 0.83

$

$ 0.80

$ 0.86

$ 0.52

$ 0.38

$

$ 1.11

$ 0.39

$ 0.29

$ 1.26

$ 0.18

$ 6.17

$

$ 0.05

$ 0.11

$ 0.11





$ 13.08
Net
Component/
Assembly Cost
Impact to OEM



$

$ 224.31

$

$ 292.55

$ 443.13

$ 297.98

$ 50.06

$ 33.00

$ 71.20

$ 1 96.58

$ 115.60

$ 113.02

$ 53.04

$ 448.79

$

$ 37.25

$ 194.68

$ 19.22

$

$

$ 2,591.24
File: System CMAT- RPT2-032009.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                              Appendix B.2 (CS#0104), Page: 4 of 12
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                   APPENDIX B.2 - SYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                              CASE STUDY #0104
                                                                                                                                                                          Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
        Study Case*: 0104 ( N0104 New Technology Configuration)
                      ( B0104 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
o>
>• Subsystem Description
.a
CO

0100 ENGINE SYSTEM

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20



|02 Engine Frames, Mountings & Brackets Subsystem

I 03 Crank Drive Subsystem

| 04 Counter Balance Subsystem

I 05 Cylinder Block Subsystem

I 06 Cylinder Head Subsystem

I 07 Valvetrain Subsystem

| 08 Timing Drive Subsystem

I 09 Accessory Drive Subsystem

I 10 Intake Subsystem

I 1 1 Fuel Subsystem

I 12 Exhaust Subsystem

I 13 Lubrication Subsystem

I 14 Cooling Subsystem

I 15 Induction Air Charging Subsystem

| 16 Exhaust Gas Re-Circulation Subsystem- Not Applicable In Analysis

I 17 Breather Subsystem

I 60 Engine Management, Engine Electronic and Electrical Subsystems

I Accessories Subsystem (Starter Motors, Alternators, Power
Steering Pumps, etc)

I

I

SUBSYSTEM ROLL-UP














































BASE TECHNOLOGY PACKAGE COST INFORMATION
5.4L V8, SOHC, NA, PR
Manufacturing
Material



$

$ 75.77

$

$ 96.03

$ 170.31

$ 183.67

$ 40.60

$ 22.00

$ 76.05

$ 11.04

$ 21.97

$ 7.70

$

$

$

$ 1.21

$ 42.49

$





$ 748.84
Labor



$

$ 38.48

$

$ 19.85

$ 30.32

$ 1 8.74

$ 5.72

$

$ 6.48

$ 1 1 .29

$ 2.77

$ 1.39

$

$

$

$ 0.43

$ 23.81

$





$ 159.29
Burden



$

$ 109.25

$

$ 164.51

$ 193.96

$ 70.32

$ 11.39

$

$ 10.63

$ 36.58

$ 13.61

$ 6.29

$

$

$

$ 0.59

$ 41.91

$





$ 659.78
Total
Cost
(Component/
Assembly)



$

$ 223.50

$

$ 280.40

$ 394.60

$ 272.73

$ 57.71

$ 22.00

$ 93.16

$ 58.92

$ 38.35

$ 1 5.38

$

$

$

$ 2.23

$ 108.22

$

$

$

$ 1,567.91
Markup
End Item
Scrap



$

$ 1.43

$

$ 7.10

$ 8.04

$ 0.63

$ 0.69

$

$ 0.35

$ 0.45

$ 1.18

$ 0.07

$

$

$

$ 0.00

$ 0.50

$





$ 20.44
SGSA



$

$ 1 0.32

$

$ 1 1 .63

$ 13.91

$ 7.87

$ 1.48

$

$ 3.49

$ 5.03

$ 2.30

$ 0.94

$

$

$

$ 0.09

$ 7.29

$





$ 64.39
Profit



$

$ 1 0.20

$

$ 1 2.90

$ 15.24

$ 7.50

$ 0.99

$

$ 3.99

$ 5.21

$ 2.12

$ 0.87

$

$

$

$ 0.06

$ 6.10

$





$ 65.24
EDST-RSD



$

$ 3.51

$

$ 3.29

$ 4.27

$ 2.88

$ 0.25

$

$ 1.00

$ 2.20

$ 0.88

$ 0.36

$

$

$

$ 0.02

$ 2.27

$





$ 20.95
Total Markup
Cost
(Component/
Assembly)



$

$ 25.46

$

$ 34.93

$ 41.46

$ 18.88

$ 3.41

$

$ 8.83

$ 12.89

$ 6.48

$ 2.24

$

$

$

$ 0.17

$ 16.16

$

$

$

$ 171.02
Total
Packaging
Cost
(Component/
Assembly)



$

$ 1.06

$

$ 1.46

$ 0.86

$ 0.27

$ 0.38

$

$ 1.15

$ 0.18

$ 0.35

$ 0.18

$

$

$

$ 0.02

$ 0.15

$





$ 6.05
Net
Component/
Assembly Cosl
Impact to OEM



$

$ 250.01

$

$ 31 6.79

$ 436.92

$ 291.87

$ 61.50

$ 22.00

$ 103.13

$ 71.99

$ 45.18

$ 1 7.79

$

$

$

$ 2.42

$ 124.52

$

$

$

$ 1,744.98
File: System CMAT- RPT2-032009.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                              Appendix B.2 (CS#0104), Page: 5 of 12
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                           APPENDIX B.2 - SYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                 CASE STUDY #0104
                                                                                                                                              Printed: 3/2 6/2010

Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
Study Case*: 0104 ( N0104 New Technology Configuration)
( B0104 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

E
o>
>• Subsystem Description
.a
CO

0100 ENGINE SYSTEM

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20



|02 Engine Frames, Mountings & Brackets Subsystem

I 03 Crank Drive Subsystem

| 04 Counter Balance Subsystem

I 05 Cylinder Block Subsystem

I 06 Cylinder Head Subsystem

I 07 Valvetrain Subsystem

| 08 Timing Drive Subsystem

I 09 Accessory Drive Subsystem

I 10 Intake Subsystem

I 1 1 Fuel Subsystem

I 12 Exhaust Subsystem

I 13 Lubrication Subsystem

I 14 Cooling Subsystem

I 15 Induction Air Charging Subsystem

| 16 Exhaust Gas Re-Circulation Subsystem- Not Applicable In Analysis

I 17 Breather Subsystem

I 60 Engine Management, Engine Electronic and Electrical Subsystems

I Accessories Subsystem (Starter Motors, Alternators, Power
Steering Pumps, etc)

I

I

SUBSYSTEM ROLL-UP















































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
3.5L.V6 DOHC, Turbo Dl
BASE TECHNOLOGY PACKAGE COST INFORMATION
5.4L V8, SOHC, NA, PFI
Manufacturing
Material



$

$ (8,10)

$

$ 9.55

$ (8.66)

$ (62.89)

$ (11.10)

$ 11.00

$ (19.56)

$ 41.04

$ 54.98

$ 36.55

$ 24.98

$ 146.26

$

$ 1 4.78

$ 32.70

$ 4.11

$

$

$ 268.64
Labor



$

$ (5.29)

$

$ 1.91

$ 2.31

$ 1 2.60

$

$

$ (2.70)

$ 1 4.52

$ 0.70

$ 1 5.1 6

$ 7.54

$ 76.44

$

$ 3.80

$ 8.88

$ 2.92

$

$

$ 138.78
Burden



$

t (1 2.50)

$

$ (36.1 3)

$ 16.07

$ 45.66

$

$

$ (4.96)

$ 42.50

$ 0.80

$ 33.00

$ 12.56

$ 106.36

$

$ 1 2.33

$ 16.15

$ 8.67

$

$

$ 240.51
Total
Cost
(Component/
Assembly)



$

t (22.88)

$

$ (24.67)

$ 9.71

t (4,63)

$ (11.10)

$ 11.00

$ (27,23)

$ 98.06

$ 56.49

$ 84.71

$ 45.08

$ 329.41

$

$ 30.91

$ 57.73

$ 1 5.69

$

$

$ 648.28
Markup
End Item
Scrap



$

$ 0.79

$

$ 0.01

$ (0.67)

$ 0.35

$ 10.115

$

$ (0.1 8)

$ 1.11

$ 2.80

$ 0.30

$ 0.25

$ 1 7.87

$

$ 0.10

$ 0.43

$ 0.11

$

$

$ 23.16
SGSA



$

t (1.45)

$

$ 1.02

$ (1.18)

$ 4.20

$ (0.13)

$

$ (1.85)

$ 1 0.78

$ 3.86

$ 4.09

$ 3.07

$ 38.21

$

$ 2.06

$ 4.69

$ 1.62

$

$

$ 69.00
Profit



$

t (1 ,43)

$

$ 0.31

$ (1.29)

$ 4.12

$ (0.08)

$

$ (2.11)

$ 1 0.58

$ 4.84

$ 3.65

$ 3.14

$ 40.86

$

$ 1.38

$ 4.98

$ 1.32

$

$

$ 70.27
EDST-RSD



$

1 (0.49)

$

t (0,25)

$ (0.38)

$ 1.81

$ (0.02)

$

$ (0.53)

$ 3.85

$ 2.50

$ 1.38

$ 1.31

$ 1 6.27

$

$ 0.34

$ 2.35

$ 0.37

$

$

$ 28.54
Total Markup
Cost
(Component/
Assembly)



$

I (2,58)

$

$ 1.09

$ (3.49)

$ 10.48

$ (0.34)

$

$ (4.6?)

$ 26.32

$ 14.00

$ 9.43

$ 7.78

$ 113.21

$

$ 3.88

$ 12.46

$ 3.41

$

$

$ 190.97
Total
Packaging
Cost
(Component/
Assembly)



$

$ (0,23)

$

t (0.68)

$ (0.01 j

$ 0.26

$

$

$ (0.03)

$ 0.21

$ (0.06)

$ 1.08

$ 0.18

$ 6.17

$

$ 0.03

$ (0.04)

$ 0.11

$

$

$ 7.02
Net
Component/
Assembly Cosl
Impact to OEM



$

$ (25,70)

$

$ (24,24)

$ 6.21

$ 6.11

$ (11.44)

$ 11.00

$ (31 .94)

$ 1 24.59

$ 70.43

$ 95.22

$ 53.04

$ 448.79

$

$ 34.83

$ 70.15

$ 1 9.22

$

$

$ 846.27
File: System CMAT- RPT2-032009.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                 Appendix B.2 (CS#0104), Page: 6 of 12
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                           APPENDIX B.3 - SYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                 CASE STUDY #0802
                                                                                                                                             Printed: 3/2 6/2010
Technology Level: 08 - 6 Speed Automatic versus 5 Speed Automatic Transmission
Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
Study Case#: 0802 ( N0802 New Technology Configuration)
( B0802 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

Subsystem
Subsystem Description

0200 TRANSMISSION SYSTEM

1

2

3

4

5

6

7

8

9

10

11

12




01 EXTERNAL COMPONENTS: Consists of installation of oil coolers,
lift eyes, vent caps.


CASE(S): Includes pressed in components (i.e., bearing races),
plugs, and associated hardware.


Q3 GEAR TRAIN: Includes Input Shafts, Output Shafts, Differential and
all associated gears and bearings on the shaft.


INTERNAL CLUTCHES: Internal for Gears, Synchronizers, Bands,
etc.




05 LAUNCH CLUTCHES: Torque Converter

OIL PUMP & FILTER: Includes Pump, Pump Shaft/Drive Mechanism,
Oil Filters (Internal or External), Pick-up Tube, and Oil Baffles.


07 MECHANICAL CONTROLS


08 ELECTRICAL CONTROLS


og PARK MECHANISM: Includes Park & Lock Pawl Mechanism and
Actuating Levers


10 MISCELLANEOUS:

1



SUBSYSTEM ROLL-UP

NEW TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Automatic Transmission: 2007-2009 Toyota Camry
Manufacturing
Material



$

$

$

$

$

$

$

$

$

$





#_
Labor



$

$

$

$

$

$

$

$

$

$





$ 297.96
Burden



$

$

$

$

$

$

$

$

$

$





$ 900.20
Total
Manufacturing
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$





$ 2,216.05
Markup
End Item
Scrap



$

$

$

$

$

$

$

$

$

$





$ 43.60
SGSA



$

$

$

$

$

$

$

$

$

$





$ 133.46
Profit



$

$

$

$

$

$

$

$

$

$





$ 135.56
EDST-RSD



$

$

$

$

$

$

$

$

$

$





$ 49.49
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$





$ 362.11
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$





$ 13.08
Net
Component/
Assembly Cost
Impact to OEM



$

$

$

$

$

$

$

$

$

$





$ 2,591.24
File: System CMAT- RPT2-032009.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                 Appendix B.3 (CS#0802), Page: 7 of 12
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                  APPENDIX B.3 - SYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0802
                                                                                                                                                                       Printed: 3/2 6/2010
     Technology Level: 08 - 6 Speed Automatic versus 5 Speed Automatic Transmission
        Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case#: 0802  ( N0802 New Technology Configuration)
                     ( B0802 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

Subsystem
Subsystem Description

0200 TRANSMISSION SYSTEM

1

2

3

4

5

6

7

8

9

10

11

12




01 EXTERNAL COMPONENTS: Consists of installation of oil coolers,
lift eyes, vent caps.


CASE(S): Includes pressed in components (i.e., bearing races),
plugs, and associated hardware.


Q3 GEAR TRAIN: Includes Input Shafts, Output Shafts, Differential and
all associated gears and bearings on the shaft.


INTERNAL CLUTCHES: Internal for Gears, Synchronizers, Bands,
etc.


05 LAUNCH CLUTCHES: Torque Converter


OIL PUMP & FILTER: Includes Pump, Pump Shaft/Drive Mechanism,
Oil Filters (Internal or External), Pick-up Tube, and Oil Baffles.


07 MECHANICAL CONTROLS


08 ELECTRICAL CONTROLS


og PARK MECHANISM: Includes Park & Lock Pawl Mechanism and
Actuating Levers


10 MISCELLANEOUS:

1




SUBSYSTEM ROLL-UP






























BASE TECHNOLOGY PACKAGE COST INFORMATION
5 Speed Automatic Transmission: 2004-2006 Toyota Camry
Manufacturing
Material



$

$ 0.83

$ 1.83

$ 19.46

$

$

$ 0.17

$

$

$





$ 22.23
Labor



$

$ 0.53

$ 4.69

$ 8.87

$

$

$ 0.52

$

$

$





$ 14.46
Burden



$

$ 4.68

$ 13.67

$ 34.46

$

$

$ 0.50

$

$

$





$ 53.42
Total
Cost
(Component/
Assembly)



$

$ 6.03

$ 20.19

$ 62.80

$

$

$ 1.19

$

$

$





$ 90.11
Markup
End Item
Scrap



$

$

$ 0.14

$ 0.47

$

$

$ 0.00

$

$

$





$ 0.62
SGSA



$

$

$ 1.45

$ 4.27

$

$

$ 0.04

$

$

$





$ 5.78
Profit



$

$

$ 1.64

$ 4.28

$

$

$ 0.03

$

$

$





$ 5.99
EDST-RSD



$

$

$ 0.81

$ 1.90

$

$

$ 0.01

$

$

$





$ 2.74
Total Markup
Cost
(Component/
Assembly)



$

$

$ 4.05

$ 10.91

$

$

$ 0.07

$

$

$





$ 15.13
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$ 0.26

$

$

$ 0.02

$

$

$





$ 0.28
Net
Component/
Assembly Cosl
Impact to OEM



$

$ 6.03

$ 24.24

$ 73.98

$

$

$ 1.28

$

$

$





$ 105.53
File: System CMAT- RPT2-032009.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                             Appendix B.3 (CS#0802), Page: 8 of 12
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
ff-|
APPENDIX B.3 - SYSTEM COST MODEL ANALYSIS TEMPLATE
                      CASE STUDY #0802
                                                                                                                                              Printed: 3/2 6/2010

Technology Level: 08 - 6 Speed Automatic versus 5 Speed Automatic Transmission
Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
Study Case#: 0802 ( N0802 New Technology Configuration)
( B0802 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

Subsystem
Subsystem Description

0200 TRANSMISSION SYSTEM

1

2

3

4

5

6

7

8

9

10

11

12




01 EXTERNAL COMPONENTS: Consists of installation of oil coolers,
lift eyes, vent caps.


CASE(S): Includes pressed in components (i.e., bearing races),
plugs, and associated hardware.


Q3 GEAR TRAIN: Includes Input Shafts, Output Shafts, Differential and
all associated gears and bearings on the shaft.


INTERNAL CLUTCHES: Internal for Gears, Synchronizers, Bands,
etc.


05 LAUNCH CLUTCHES: Torque Converter


OIL PUMP & FILTER: Includes Pump, Pump Shaft/Drive Mechanism,
Oil Filters (Internal or External), Pick-up Tube, and Oil Baffles.


07 MECHANICAL CONTROLS


08 ELECTRICAL CONTROLS


og PARK MECHANISM: Includes Park & Lock Pawl Mechanism and
Actuating Levers


10 MISCELLANEOUS:

1



SUBSYSTEM ROLL-UP































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Automatic Transmission: 2007-2009 Toyota Camry
BASE TECHNOLOGY PACKAGE COST INFORMATION
5 Speed Automatic Transmission: 2004-2006 Toyota Camry
Manufacturing
Material



$

$ (0.83)

$ (1.83)

$ (1 9.46!

$

$

$ (0.17)

$

$

$





$ (22,29)
Labor



$

$ (0.53)

$ (4.69!

$ (8.87)

$

$

$ (0.52!

$

$

$





$ (14,61)
Burden



$

$ (4.68)

$ (13,8?!

$ (34.48J

$

$

$ (0.50J

$

$

$





$ (53,32)
Total
Manufacturing
Cost
(Component/
Assembly)



$

$ (6,03)

$ (20,19!

$ (62.SOJ

$

$

$ (1.19)

$

$

$





$ (90,22)
Markup
End Item
Scrap



$

$

$ (0.14!

$ (0.47!

$

$

$ (o.ooj

$

$

$





$ (0,61)
SGSA



$

$

$ (1.45)

$ (4.2?!

$

$

$ (0.04!

$

$

$





$ (5,76)
Profit



$

$

$ (1.84)

$ (4.28)

$

$

$ (0.03J

$

$

$





$ (5,95)
EDST-RSD



$

$

$ (0.81)

$ (1.90)

$

$

$ (0.01)

$

$

$





$ (2,71)
Total Markup
Cost
(Component/
Assembly)



$

$

$ (4.05!

$ (10.91J

$

$

$ (0.0?)

$

$

$





$ (15,04)
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$ (0.28J

$

$

$ (0.02!

$

$

$





$ (0,28)
Net
Component/
Assembly Cosl
Impact to OEM



$

% (6.03)

$ (24.24!

$ (73.9SJ

$

$

$ (1.28!

$

$

$





$ (105,53)
File: System CMAT- RPT2-032009.xls
EPA Contract:EP-C-07-069 WAI -3
                                                                  Appendix B.3 (CS#0802), Page: 9 of 12
                                                                                                   Author: G. Kolwich
                                                                                                (248)373-6000 Ext. 2411

-------
                                                   APPENDIX B.4 - SYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0902
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 09 - 6 Speed Automatic versus 6 Speed Direct Shift Transmission
        Vehicle Class: 02- Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case#: 0902  ( N0902 New Technology Configuration)
                     ( B0902 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

Subsystem
Subsystem Description

0200 TRANSMISSION SYSTEM

1

2

3

4

5

6

7

8

9

10

11

12




01 EXTERNAL COMPONENTS: Consists of installation of oil coolers,
lift eyes, vent caps.


CASE(S): Includes pressed in components (i.e., bearing races),
plugs, and associated hardware.


Q3 GEAR TRAIN: Includes Input Shafts, Output Shafts, Differential and
all associated gears and bearings on the shaft.


INTERNAL CLUTCHES: Internal for Gears, Synchronizers, Bands,
etc.


05 LAUNCH CLUTCHES: Torque Converter


OIL PUMP & FILTER: Includes Pump, Pump Shaft/Drive Mechanism,
Oil Filters (Internal or External), Pick-up Tube, and Oil Baffles.


07 MECHANICAL CONTROLS


08 ELECTRICAL CONTROLS


og PARK MECHANISM: Includes Park & Lock Pawl Mechanism and
Actuating Levers


10 MISCELLANEOUS:

1




SUBSYSTEM ROLL-UP






























NEW TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagen
Manufacturing
Material



$

$ 64.85

$ 57.31

$ 10.81

$ 46.61

$

$ 23.85

$ 95.75

$ 0.10

$





$ 299.27
Labor



$

$ 7.28

$ 25.22

$ 15.21

$ 28.52

$

$ 23.71

$ 6.38

$ 0.85

$





$ 107.18
Burden



$

$ 13.09

$ 75.67

$ 29.71

$ 61 .55

$

$ 42.44

$ 8.95

$ 0.76

$





$232.17
Total
Cost
(Component/
Assembly)



$

$ 85.22

$ 158.20

$ 55.73

$ 1 36.68

$

$ 90.00

$ 111.09

$ 1.71

$





$ 638.62
Markup
End Item
Scrap



$

$ 4.05

$ 0.93

$ 0.26

$ 0.99

$

$ 0.96

$ 0.01

$ 0.01

$





$ 7.21
SGSA



$

$ 5.30

$ 9.31

$ 3.35

$ 7.94

$

$ 5.68

$ 0.11

$ 0.11

$





$ 31.81
Profit



$

$ 4.89

$ 10.64

$ 3.09

$ 7.48

$

$ 5.12

$ 0.10

$ 0.13

$





$ 31.45
EDST-RSD



$

$ 0.81

$ 2.66

$ 0.51

$ 1.31

$

$ 0.83

$ 0.02

$ 0.10

$





$ 6.24
Total Markup
Cost
(Component/
Assembly)



$

$ 1 5.05

$ 23.55

$ 7.20

$ 1 7.71

$

$ 12.61

$ 0.23

$ 0.35

$





$ 76.70
Total
Packaging
Cost
(Component/
Assembly)



$

$ 0.95

$ 2.45

$ 0.55

$ 0.72

$

$ 0.63

$ 0.01

$

$





$ 5.30
Net
Component/
Assembly Cost
Impact to OEM



$

$ 1 01 .21

$ 184.21

$ 63.48

$ 1 55.1 1

$

$ 103.23

$ 111.33

$ 2.06

$





$ 720.63
File: System CMAT- RPT2-032009.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                             Appendix B.4 (CS#0902), Page: 10 of 12
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                   APPENDIX B.4 - SYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0902
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 09 - 6 Speed Automatic versus 6 Speed Direct Shift Transmission
        Vehicle Class: 02- Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case#: 0902  ( N0902 New Technology Configuration)
                     ( B0902 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

Subsystem
Subsystem Description

0200 TRANSMISSION SYSTEM

1

2

3

4

5

6

7

8

9

10

11

12




01 EXTERNAL COMPONENTS: Consists of installation of oil coolers,
lift eyes, vent caps.


CASE(S): Includes pressed in components (i.e., bearing races),
plugs, and associated hardware.


Q3 GEAR TRAIN: Includes Input Shafts, Output Shafts, Differential and
all associated gears and bearings on the shaft.


INTERNAL CLUTCHES: Internal for Gears, Synchronizers, Bands,
etc.


05 LAUNCH CLUTCHES: Torque Converter


OIL PUMP & FILTER: Includes Pump, Pump Shaft/Drive Mechanism,
Oil Filters (Internal or External), Pick-up Tube, and Oil Baffles.


07 MECHANICAL CONTROLS


08 ELECTRICAL CONTROLS


og PARK MECHANISM: Includes Park & Lock Pawl Mechanism and
Actuating Levers


10 MISCELLANEOUS:

1




SUBSYSTEM ROLL-UP





























0
BASE TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Automatic Transmission: 2007-2009 Toyota Camry
Manufacturing
Material



$

$ 59.04

$ 47.93

$ 54.86

$ 89.44

$

$ 15.44

$ 104.86

$ 0.30

$





$371.87
Labor



$

$ 1 0.47

$ 42.72

$ 37.85

$ 0.46

$

$ 31.49

$ 3.94

$ 1.02

$





$127.95
Burden



$

$ 45.95

$ 91.92

$ 67.45

$ 0.83

$

$ 41.23

$ 6.01

$ 0.72

$





$254.12
Total
Cost
(Component/
Assembly)



$

$ 115.46

$ 182.57

$ 160.16

$ 90.74

$

$ 88.16

$ 114.82

$ 2.03

$





$ 753.94
Markup
End Item
Scrap



$

$ 0.55

$ 2.92

$ 1.57

$

$

$ 0.59

$ 0.02

$ 0.01

$





$ 5.67
SGSA



$

$ 7.18

$ 16.39

$ 16.17

$

$

$ 7.66

$ 0.24

$ 0.12

$





$ 47.76
Profit



$

$ 6.62

$ 14.85

$ 16.15

$

$

$ 7.07

$ 0.22

$ 0.14

$





$ 45.05
EDST-RSD



$

$ 2.76

$ 2.35

$ 4.81

$

$

$ 1.18

$ 0.04

$ 0.10

$





$ 11.24
Total Markup
Cost
(Component/
Assembly)



$

$ 17.11

$ 36.51

$ 38.70

$

$

$ 16.50

$ 0.51

$ 0.38

$





$ 109.71
Total
Packaging
Cost
(Component/
Assembly)



$

$ 0.56

$ 0.69

$ 2.81

$

$

$ 0.26

$ 0.01

$

$





$ 4.32
Net
Component/
Assembly Cosl
Impact to OEM



$

$ 133.12

$ 219.77

$ 201.67

$ 90.74

$

$ 104.92

$ 1 1 5.34

$ 2.41

$





$ 867.97
File: System CMAT- RPT2-032009.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                             Appendix B.4 (CS#0902), Page: 11 of 12
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                           APPENDIX B.4 - SYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                 CASE STUDY #0902
                                                                                                                                             Printed: 3/2 6/2010

Technology Level: 09 - 6 Speed Automatic versus 6 Speed Direct Shift Transmission
Vehicle Class: 02- Mid to Large Size Passenger Vehicle, 4-6 Passengers
Study Case#: 0902 ( N0902 New Technology Configuration)
( B0902 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

Subsystem
Subsystem Description

0200 TRANSMISSION SYSTEM

1

2

3

4

5

6

7

8

9

10

11

12




01 EXTERNAL COMPONENTS: Consists of installation of oil coolers,
lift eyes, vent caps.


CASE(S): Includes pressed in components (i.e., bearing races),
plugs, and associated hardware.


Q3 GEAR TRAIN: Includes Input Shafts, Output Shafts, Differential and
all associated gears and bearings on the shaft.


INTERNAL CLUTCHES: Internal for Gears, Synchronizers, Bands,
etc.


05 LAUNCH CLUTCHES: Torque Converter


OIL PUMP & FILTER: Includes Pump, Pump Shaft/Drive Mechanism,
Oil Filters (Internal or External), Pick-up Tube, and Oil Baffles.


07 MECHANICAL CONTROLS


08 ELECTRICAL CONTROLS


og PARK MECHANISM: Includes Park & Lock Pawl Mechanism and
Actuating Levers


10 MISCELLANEOUS:

1



SUBSYSTEM ROLL-UP































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagen
BASE TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Automatic Transmission: 2007-2009 Toyota Camry
Manufacturing
Material



$

$ 5.82

$ 9.38

$ (44.06)

$ (42.83)

$

$ 8.41

t (9.12)

t (0.20)

$





$ (72,60)
Labor



$

$ (3.19)

$ (17.50)

$ (22.63!

$ 28.06

$

$ (7.79!

$ 2.44

$ (0:16)

$





$ (20,77)
Burden



$

$ (32.88)

$ (16.25J

$ (37.74J

$ 60.71

$

$ 1.21

$ 2.94

$ 0.04

$





$ (2195)
Total
Manufacturing
Cost
(Component/
Assembly)



$

$ (30.24)

$ (24.37J

$ (1 04.43J

$ 45.94

$

$ 1.83

$ (3-73)

$ (0-32)

$





$ (115,32)
Markup
End Item
Scrap



$

$ 3.49

$ (1.99J

$ (1.32J

$ 0.99

$

$ 0.37

$ (0.01)

$ (0.00)

$





$ 1.54
SGSA



$

$ (1.88)

$ (7.0SJ

$ (12.82!

$ 7.94

$

$ (1.98J

$ (0.13)

$ (0.01)

$





$ (15,95)
Profit



$

$ (1 .73)

$ (4.20!

$ (13.06)

$ 7.48

$

$ (1.95)

$ (0.12)

$ (0.01)

$





$ (13,60)
EDST-RSD



$

$ (1.94)

$ 0.31

$ (4.30)

$ 1.31

$

$ (0.34)

$ (0.02)

$ (0.01)

$





$ (4,99)
Total Markup
Cost
(Component/
Assembly)



$

$ (2.08)

$ (12.96!

$ (31.49!

$ 17.71

$

$ (3.89)

$ (0.28)

$ (0.03)

$





$ (33,00)
Total
Packaging
Cost
(Component/
Assembly)



$

$ 0.39

$ 1.76

$ (2.26!

$ 0.72

$

$ 0.37

$ 0.00

$

$





$ 0.98
Net
Component/
Assembly Cosl
Impact to OEM



$

$ (31,91)

$ (35.57J

$ (138.19J

$ 64.37

$

$ (1.69J

$ (4-01)

t (0-34)

$





$ (147,34)
File: System CMAT- RPT2-032009.xls
EPA Contract:EP-C-07-069 WAI -3
                                                                 Appendix B.4 (CS#0902), Page: 12 of 12
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                            APPENDIX C
         SUBSYSTEM COST MODEL ANALYSIS TEMPLATES

The Subsystem Cost Model Analysis Template (CMAT) 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.

   •  Appendix C.I: Subsystem CMATs for Case Study #0102, 3.OL, V6, 4-V,
      DOHC, d-VVT, NA, PFI engine compared to a 2.0L, 14, 4-V, DOHC, d-
      VVT, turbocharged, GDI engine

   •  Appendix C.2: Subsystem CMATs for Case Study #0104, 5.4L, V8, 3-V,
      SOHC, VVT, NA, PFI engine compared to a 3.5L V6, 4-V, DOHC, d-VVT,
      turbocharged, GDI engine

   •  Appendix C.3: Subsystem CMATs for Case Study #0802, conventional 5-
      speed automatic transmission compared to a next generation 6-speed
      automatic transmission

   •  Appendix C.4: Subsystem CMATs for Case Study #0902, conventional 6-
      speed automatic transmission compared to a 6-speed, wet, dual clutch
      transmission
                                 C-0

-------
                                                APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0102
                                                                                                                                                                       Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case*: 0102  ( N0102 New Technology Configuration)
                     ( B0102 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0103 Crank Drive Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15




|01 Crank Shaft

|02 Flywheels

|03 Connect Rods (Assemblies: Connecting Rod, Connecting Rod Cap)

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

|05 Drive for Accessory Drives (Down force, Flywheel side)

|06 Drive for Timing Drive (Down force, Flywheel side)

1 65 Adaptors

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings: Connecting-Rod Bolts

|85 Sealing Elements

h Bearing Elements (Connecting Rod Bearing Shells, Connecting Rod
Bushing)

|95 Tools

|99 Miscellaneous

|00 Engine & Vehicle Assembly


SUB-SUBSYSTEM ROLL-UP





































NEW TECHNOLOGY PACKAGE COST INFORMATION
2.0L 14, DOHC, Turbo Dl
Manufacturing
Material



$ 28.70

$

$ 5.25

$ 5.43

$

$

$

$

$

$

$

$

$

$

$ 11.52


$ 50.89
Labor



$ 9.08

$

$ 6.40

$ 6.16

$

$

$

$

$

$

$

$

$

$

$ 3.01


$ 24.65
Burden



$ 24.94

$

$ 16.09

$ 18.98

$

$

$

$

$

$

$

$

$

$

$ 5.60


$ 65.62
Total
Cost
(Component/
Assembly)



$ 62.72

$

$ 27.74

$ 30.57

$

$

$

$

$

$

$

$

$

$

$ 20.13


$ 141.16
Markup
End Item
Scrap



$ 0.24

$

$ 0.14

$ 1.11

$

$

$

$

$

$

$

$

$

$

$


$ 1.50
SGSA



$ 2.44

$

$ 1.80

$ 2.03

$

$

$

$

$

$

$

$

$

$

$


$ 6.27
Profit



$ 2.79

$

$ 1.66

$ 1.81

$

$

$

$

$

$

$

$

$

$

$


$ 6.27
EDST-RSD



$ 0.70

$

$ 0.69

$ 0.73

$

$

$

$

$

$

$

$

$

$

$


$ 2.12
Total Markup
Cost
(Component/
Assembly)



$ 6.17

$

$ 4.30

$ 5.68

$

$

$

$

$

$

$

$

$

$

$


$ 16.15
Total
Packaging
Cost
(Component/
Assembly)



$ 0.14

$

$ 0.07

$ 0.38

$

$

$

$

$

$

$

$

$

$

$


$ 0.60
Net
Component/
Assembly Cosl
Impact to OEM



$ 69.03

$

$ 32.12

$ 36.64

$

$

$

$

$

$

$

$

$

$

$ 20.13


$ 157.91
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                              Apdx. C.1 Crank Drive, Page: 1 of 48
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0102
                                                                                                                                                                       Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case*: 0102  ( N0102 New Technology Configuration)
                     ( B0102 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0103 Crank Drive Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15




|01 Crank Shaft

|02 Flywheels

|03 Connect Rods (Assemblies: Connecting Rod, Connecting Rod Cap)

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

|05 Drive for Accessory Drives (Down force, Flywheel side)

|06 Drive for Timing Drive (Down force, Flywheel side)

1 65 Adaptors

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings: Connecting-Rod Bolts

|85 Sealing Elements

h Bearing Elements (Connecting Rod Bearing Shells, Connecting Rod
Bushing)

|95 Tools

|99 Miscellaneous

|00 Engine & Vehicle Assembly


SUB-SUBSYSTEM ROLL-UP





































BASE TECHNOLOGY PACKAGE COST INFORMATION
3.0L V6, DOHC, NA, PR
Manufacturing
Material



$ 32.74

$

$ 6.70

$ 7.31

$

$

$

$

$

$

$

$

$

$

$ 10.02


$ 56.77
Labor



$ 11.49

$

$ 9.60

$ 7.81

$

$

$

$

$

$

$

$

$

$

$ 3.61


$ 32.52
Burden



$ 39.80

$

$ 24.14

$ 20.64

$

$

$

$

$

$

$

$

$

$

$ 5.96


$ 90.55
Total
Cost
(Component/
Assembly)



$ 84.04

$

$ 40.44

$ 35.77

$

$

$

$

$

$

$

$

$

$

$ 19.59


$ 179.84
Markup
End Item
Scrap



$ 0.30

$

$ 0.20

$ 0.62

$

$

$

$

$

$

$

$

$

$

$


$ 1.11
SGSA



$ 2.95

$

$ 2.63

$ 2.33

$

$

$

$

$

$

$

$

$

$

$


$ 7.91
Profit



$ 3.38

$

$ 2.43

$ 2.06

$

$

$

$

$

$

$

$

$

$

$


$ 7.86
EDST-RSD



$ 0.84

$

$ 1.01

$ 0.82

$

$

$

$

$

$

$

$

$

$

$


$ 2.67
Total Markup
Cost
(Component/
Assembly)



$ 7.47

$

$ 6.27

$ 5.82

$

$

$

$

$

$

$

$

$

$

$


$ 19.56
Total
Packaging
Cost
(Component/
Assembly)



$ 0.14

$

$ 0.19

$ 0.58

$

$

$

$

$

$

$

$

$

$

$


$ 0.91
Net
Component/
Assembly Cosl
Impact to OEM



$ 91.65

$

$ 46.90

$ 42.17

$

$

$

$

$

$

$

$

$

$

$ 19.59


$ 200.31
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                              Apdx. C.1 Crank Drive, Page: 2 of 48
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                        APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                CASE STUDY #0102
                                                                                                                                             Printed: 3/2 6/2010

Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
Study Case*: 0102 ( N0102 New Technology Configuration)
( B0102 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0103 Crank Drive Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15




|01 Crank Shaft

|02 Flywheels

|03 Connect Rods (Assemblies: Connecting Rod, Connecting Rod Cap)

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

|05 Drive for Accessory Drives (Down force, Flywheel side)

|06 Drive for Timing Drive (Down force, Flywheel side)

1 65 Adaptors

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings: Connecting-Rod Bolts

|85 Sealing Elements

h Bearing Elements (Connecting Rod Bearing Shells, Connecting Rod
Bushing)

|95 Tools

|99 Miscellaneous

|00 Engine & Vehicle Assembly


SUB-SUBSYSTEM ROLL-UP






































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
2.0L 14, DOHC, Turbo Dl
BASE TECHNOLOGY PACKAGE COST INFORMATION
3.0L V6, DOHC, NA, PFI
Manufacturing
Material



$ J4.Q4S

$

$ (1.45)

$ |*1 .88)

$

$

$

$

$

$

$

$

$

$

$ 1.50


$ (5,88)
Labor



$ JZ425

$

$ J3.20J

$ (1.65)

$

$

$

$

$

$

$

$

$

$

$ J0.80S


$ (7,87)
Burden



$ (1 4,88)

$

$ (8.05)

$ (1.66)

$

$

$

$

$

$

$

$

$

$

$ (0.36)


$ (24,93)
Total
Manufacturing
Cost
(Component/
Assembly)



f, (21,32)

$

f (1 2.70J

$ (5.20)

$

$

$

$

$

$

$

$

$

$

$ 0.54


$ (38,68)
Markup
End Item
Scrap



f, (0.05)

$

$ (0.08)

$ 0.50

$

$

$

$

$

$

$

$

$

$

$


$ 0.38
SGSA



$ (0.51)

$

$ (0.83)

$ (0.30)

$

$

$

$

$

$

$

$

$

$

$


$ (1,64)
Profit



$ (0.59)

$

$ J0.78)

$ (0.25)

$

$

$

$

$

$

$

$

$

$

$


$ (1,60)
EDST-RSD



$ (0.15)

$

f, (0.32)

$ (0.09)

$

$

$

$

$

$

$

$

$

$

$


$ (0,56)
Total Markup
Cost
(Component/
Assembly)



$ 1*1.30)

$

$ (1.97)

$ 1*0.14)

$

$

$

$

$

$

$

$

$

$

$


$ (3,41)
Total
Packaging
Cost
(Component/
Assembly)



$

$

$ (0.12)

$ 1*0.19)

$

$

$

$

$

$

$

$

$

$

$


$ (0,31)
Net
Component/
Assembly Cosl
Impact to OEM



$ 1*22.82)

$

$ (14.79)

$ (5.53)

$

$

$

$

$

$

$

$

$

$

$ 0.54


$ (42,40)
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                  Apdx. C.1 Crank Drive, Page: 3 of 48
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.1  - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0102
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case*: 0102  ( N0102 New Technology Configuration)
                     ( B0102 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0104 Counter Balance Subsystem

1

2

3

4

5

6

7

8

9

10

11

12



| 01 Dynamic Parts

I 02 Static Parts

I 03 Drives

I 65 Adapters

| 70 Pipes, Hoses, Ducting

I 75 Brackets

| 80 Connecting Elements

I 85 Sealing Elements

| 90 Bearing Elements

I 95 Tools

I 99 Misc.

I 00 Vehicle and Engine Assembly

SUB-SUBSYSTEM ROLL-UP






























NEW TECHNOLOGY PACKAGE COST INFORMATION
2.0L 14, DOHC, Turbo Dl
Manufacturing
Material



$ 8.53

$

$

$

$

$

$

$

$

$

$

$ 1.83

$ 10.37
Labor



$ 5.83

$

$

$

$

$

$

$

$

$

$

$ 0.39

$ 6.22
Burden



$ 10.18

$

$

$

$

$

$

$

$

$

$

$ 0.71

$ 10.89
Total
Cost
(Component/
Assembly)



$ 24.54

$

$

$

$

$

$

$

$

$

$

$ 2.93

$ 27.47
Markup
End Item
Scrap



$ 0.84

$

$

$

$

$

$

$

$

$

$

$

$ 0.84
SGSA



$ 3.16

$

$

$

$

$

$

$

$

$

$

$

$ 3.16
Profit



$ 2.92

$

$

$

$

$

$

$

$

$

$

$

$ 2.92
EDST-RSD



$ 0.91

$

$

$

$

$

$

$

$

$

$

$

$ 0.91
Total Markup
Cost
(Component/
Assembly)



$ 7.83

$

$

$

$

$

$

$

$

$

$

$

$ 7.83
Total
Packaging
Cost
(Component/
Assembly)



$ 0.05

$

$

$

$

$

$

$

$

$

$

$

$ 0.05
Net
Component/
Assembly Cosl
Impact to OEM



$ 32.42

$

$

$

$

$

$

$

$

$

$

$ 2.93

$ 35.36
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                             Apdx. C.1 Counter Balance, Page: 4 of 48
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.1  - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0102
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case*: 0102  ( N0102 New Technology Configuration)
                     ( B0102 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0104 Counter Balance Subsystem

1

2

3

4

5

6

7

8

9

10

11

12



| 01 Dynamic Parts

I 02 Static Parts

I 03 Drives

I 65 Adapters

| 70 Pipes, Hoses, Ducting

I 75 Brackets

| 80 Connecting Elements

I 85 Sealing Elements

| 90 Bearing Elements

I 95 Tools

I 99 Misc.

I 00 Vehicle and Engine Assembly

SUB-SUBSYSTEM ROLL-UP






























BASE TECHNOLOGY PACKAGE COST INFORMATION
3.0L V6, DOHC, NA, PR
Manufacturing
Material



$

$

$

$

$

$

$

$

$

$

$

$

$ -
Labor



$

$

$

$

$

$

$

$

$

$

$

$

$ -
Burden



$

$

$

$

$

$

$

$

$

$

$

$

$ -
Total
Manufacturing
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$
Markup
End Item
Scrap



$

$

$

$

$

$

$

$

$

$

$

$

$ -
SGSA



$

$

$

$

$

$

$

$

$

$

$

$

$ -
Profit



$

$

$

$

$

$

$

$

$

$

$

$

$ -
EDST-RSD



$

$

$

$

$

$

$

$

$

$

$

$

$ -
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$
Net
Component/
Assembly Cosl
Impact to OEM



$

$

$

$

$

$

$

$

$

$

$

$

$
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                             Apdx. C.1 Counter Balance, Page: 5 of 48
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                        APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                 CASE STUDY #0102
                                                                                                                                              Printed: 3/2 6/2010

Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
Study Case*: 0102 ( N0102 New Technology Configuration)
( B0102 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0104 Counter Balance Subsystem

1

2

3

4

5

6

7

8

9

10

11

12



| 01 Dynamic Parts

I 02 Static Parts

I 03 Drives

I 65 Adapters

| 70 Pipes, Hoses, Ducting

I 75 Brackets

| 80 Connecting Elements

I 85 Sealing Elements

| 90 Bearing Elements

I 95 Tools

I 99 Misc.

I 00 Vehicle and Engine Assembly

SUB-SUBSYSTEM ROLL-UP































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
2.0L 14, DOHC, Turbo Dl
BASE TECHNOLOGY PACKAGE COST INFORMATION
3.0L V6, DOHC, NA, PFI
Manufacturing
Material



$ 8.53

$

$

$

$

$

$

$

$

$

$

$ 1.83

$ 10.37
Labor



$ 5.83

$

$

$

$

$

$

$

$

$

$

$ 0.39

$ 6.22
Burden



$ 10.18

$

$

$

$

$

$

$

$

$

$

$ 0.71

$ 10.89
Total
Manufacturing
Cost
(Component/
Assembly)



$ 24.54

$

$

$

$

$

$

$

$

$

$

$ 2.93

$ 27.47
Markup
End Item
Scrap



$ 0.84

$

$

$

$

$

$

$

$

$

$

$

$ 0.84
SGSA



$ 3.16

$

$

$

$

$

$

$

$

$

$

$

$ 3.16
Profit



$ 2.92

$

$

$

$

$

$

$

$

$

$

$

$ 2.92
EDST-RSD



$ 0.91

$

$

$

$

$

$

$

$

$

$

$

$ 0.91
Total Markup
Cost
(Component/
Assembly)



$ 7.83

$

$

$

$

$

$

$

$

$

$

$

$ 7.83
Total
Packaging
Cost
(Component/
Assembly)



$ 0.05

$

$

$

$

$

$

$

$

$

$

$

$ 0.05
Net
Component/
Assembly Cosl
Impact to OEM



$ 32.42

$

$

$

$

$

$

$

$

$

$

$ 2.93

$ 35.36
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                 Apdx. C.1 Counter Balance, Page: 6 of 48
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.1  - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0102
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case*: 0102  ( N0102 New Technology Configuration)
                     ( B0102 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0105 Cylinder Block Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15



I 01 Cylinder Block

I 02 Crankshaft Bearing Caps

I 03 Bedplates

I 04 Piston Cooling

I 65 Crankcase Adaptor

I 66 Water Jacket

I 67 Cylinder Barrel

I 70 Pipes, Hoses, Ducting

I 75 Brackets

I 80 Boltings/Dowel Pins/Plugs/Studs Etc

I 85 Sealing Elements

I 90 Bearing Elements: Crankshaft bearing shells

I 95 Tools

I 99 Miscellaneous

| 00 Engine & Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP




































NEW TECHNOLOGY PACKAGE COST INFORMATION
2.0L 14, DOHC, Turbo Dl
Manufacturing
Material



$ 45.55

$

$ 21.68

$ 2.60

$

$

$

$

$

$

$

$

$

$ 0.68

$ 10.96

$ 81.47
Labor



$ 11.14

$

$ 10.10

$ 0.64

$

$

$

$

$

$

$

$

$

$ 0.37

$ 3.61

$ 25.86
Burden



$ 80.67

$

$ 48.15

$ 3.61

$

$

$

$

$

$

$

$

$

$ 0.87

$ 2.24

$ 135.54
Total
Cost
(Component/
Assembly)



$ 137.36

$

$ 79.94

$ 6.85

$

$

$

$

$

$

$

$

$

$ 1.91

$ 16.81

$ 242.87
Markup
End Item
Scrap



$ 4.65

$

$ 3.12

$ 0.04

$

$

$

$

$

$

$

$

$

$ 0.01

$

$ 7.83
SGSA



$ 6.45

$

$ 4.31

$ 0.86

$

$

$

$

$

$

$

$

$

$ 0.11

$

$ 11.75
Profit



$ 7.20

$

$ 4.75

$ 0.58

$

$

$

$

$

$

$

$

$

$ 0.08

$

$ 12.61
EDST-RSD



$ 1.74

$

$ 1.13

$

$

$

$

$

$

$

$

$

$

$ 0.02

$

$ 2.89
Total Markup
Cost
(Component/
Assembly)



$ 20.05

$

$ 13.32

$ 1.48

$

$

$

$

$

$

$

$

$

$ 0.22

$

$ 35.07
Total
Packaging
Cost
(Component/
Assembly)



$ 0.57

$

$ 0.48

$ 0.04

$

$

$

$

$

$

$

$

$

$ 0.05

$

$ 1.14
Net
Component/
Assembly Cosl
Impact to OEM



$ 157.98

$

$ 93.74

$ 8.38

$

$

$

$

$

$

$

$

$

$ 2.17

$ 16.81

$ 279.08
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                             Apdx. C.1 Cylinder Block, Page: 7 of 48
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.1  - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0102
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case*: 0102  ( N0102 New Technology Configuration)
                     ( B0102 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0105 Cylinder Block Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15



I 01 Cylinder Block

I 02 Crankshaft Bearing Caps

I 03 Bedplates

I 04 Piston Cooling

I 65 Crankcase Adaptor

I 66 Water Jacket

I 67 Cylinder Barrel

I 70 Pipes, Hoses, Ducting

I 75 Brackets

I 80 Boltings/Dowel Pins/Plugs/Studs Etc

I 85 Sealing Elements

I 90 Bearing Elements: Crankshaft bearing shells

I 95 Tools

I 99 Miscellaneous

| 00 Engine & Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP




































BASE TECHNOLOGY PACKAGE COST INFORMATION
3.0L V6, DOHC, NA, PR
Manufacturing
Material



$ 77.42

$ 3.49

$

$

$

$

$

$

$

$

$

$

$

$ 4.05

$ 12.31

$ 97.26
Labor



$ 13.17

$ 1.50

$

$

$

$

$

$

$

$

$

$

$

$ 2.16

$ 4.21

$ 21.04
Burden



$ 106.22

$ 4.99

$

$

$

$

$

$

$

$

$

$

$

$ 5.48

$ 2.82

$119.50
Total
Cost
(Component/
Assembly)



$ 196.81

$ 9.98

$

$

$

$

$

$

$

$

$

$

$

$ 1 1 .68

$ 19.34

$ 237.81
Markup
End Item
Scrap



$ 6.88

$ 0.01

$

$

$

$

$

$

$

$

$

$

$

$ 0.06

$

$ 6.95
SGSA



$ 9.54

$ 0.75

$

$

$

$

$

$

$

$

$

$

$

$ 0.76

$

$ 11.06
Profit



$ 10.64

$ 0.70

$

$

$

$

$

$

$

$

$

$

$

$ 0.70

$

$ 12.04
EDST-RSD



$ 2.57

$ 0.12

$

$

$

$

$

$

$

$

$

$

$

$ 0.29

$

$ 2.98
Total Markup
Cost
(Component/
Assembly)



$ 29.64

$ 1.57

$

$

$

$

$

$

$

$

$

$

$

$ 1.81

$

$ 33.02
Total
Packaging
Cost
(Component/
Assembly)



$ 0.57

$ 0.12

$

$

$

$

$

$

$

$

$

$

$

$ 0.05

$

$ 0.74
Net
Component/
Assembly Cosl
Impact to OEM



$ 227.02

$ 11.67

$

$

$

$

$

$

$

$

$

$

$

$ 1 3.54

$ 19.34

$ 271.57
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                             Apdx. C.1 Cylinder Block, Page: 8 of 48
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                        APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                 CASE STUDY #0102
                                                                                                                                             Printed: 3/2 6/2010

Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
Study Case*: 0102 ( N0102 New Technology Configuration)
( B0102 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0105 Cylinder Block Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15



I 01 Cylinder Block

I 02 Crankshaft Bearing Caps

I 03 Bedplates

I 04 Piston Cooling

I 65 Crankcase Adaptor

I 66 Water Jacket

I 67 Cylinder Barrel

I 70 Pipes, Hoses, Ducting

I 75 Brackets

I 80 Boltings/Dowel Pins/Plugs/Studs Etc

I 85 Sealing Elements

I 90 Bearing Elements: Crankshaft bearing shells

I 95 Tools

I 99 Miscellaneous

| 00 Engine & Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP





































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
2.0L 14, DOHC, Turbo Dl
BASE TECHNOLOGY PACKAGE COST INFORMATION
3.0L V6, DOHC, NA, PFI
Manufacturing
Material



$ (31 .87)

$ (3,49)

$ 21.68

$ 2.60

$

$

$

$

$

$

$

$

$

$ (3.37)

$ (1.35)

$ (15,80)
Labor



$ (2.03)

$ (1 ,50)

$ 10.10

$ 0.64

$

$

$

$

$

$

$

$

$

$ (1.79)

$ (0.80)

$ 4.82
Burden



$ (25.55)

t (4,99)

$ 48.15

$ 3.61

$

$

$

$

$

$

$

$

$

$ (4,61)

$ (0.58)

$ 16.04
Total
Manufacturing
Cost
(Component/
Assembly)



$ (S9..45)

t (9,93)

$ 79.94

$ 6.85

$

$

$

$

$

$

$

$

$

t (9,77)

$ (2.53)

$ 5.06
Markup
End Item
Scrap



$ (2.23)

t (0,01)

$ 3.12

$ 0.04

$

$

$

$

$

$

$

$

$

t (0,05)

$

$ 0.88
SGSA



$ (3.09)

t (0.75)

$ 4.31

$ 0.86

$

$

$

$

$

$

$

$

$

t (0,64)

$

$ 0.69
Profit



$ (3.44)

1 (0,70)

$ 4.75

$ 0.58

$

$

$

$

$

$

$

$

$

t (0,62)

$

$ 0.57
EDST-RSD



$ (0.83)

* (0,12)

$ 1.13

$

$

$

$

$

$

$

$

$

$

$ (0,27)

$

$ (0,09)
Total Markup
Cost
(Component/
Assembly)



$ (9.59)

$ (1,57)

$ 13.32

$ 1.48

$

$

$

$

$

$

$

$

$

1 (1 ,59)

$

$ 2.04
Total
Packaging
Cost
(Component/
Assembly)



$

$ (0,1 2)

$ 0.48

$ 0.04

$

$

$

$

$

$

$

$

$

$ (0,00)

$

$ 0.40
Net
Component/
Assembly Cosl
Impact to OEM



$ (89.04)

t (11,67)

$ 93.74

$ 8.38

$

$

$

$

$

$

$

$

$

$ (11,37)

S (2.53;

$ 7.51
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                 Apdx. C.1 Cylinder Block, Page: 9 of 48
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0102
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case*: 0102  ( N0102 New Technology Configuration)
                     ( B0102 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0106 Cylinder Head Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17



|01 Cylinder Head

|02 Valve Guides. Valve Seats

|03 Guides for Valve Train

|06 Camshaft Bearing Housing

|07 Cam Shaft Speed Sensor

|08 Camshaft Carrier

|09 Other Parts for Cylinder Head

|20 Cylinder Head Covers

|65 Adapter

|70 Pipes

|75 Brackets

|60 Boltings: Cylinder Head, Cylinder Head Cover, Manifold

|85 Sealing Elements: Cylinder Head, Cylinder Head Cover, ....

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Vehicle and Engine Assembly

SUB-SUBSYSTEM ROLL-UP








































NEW TECHNOLOGY PACKAGE COST INFORMATION
2.0L 14, DOHC, Turbo Dl
Manufacturing
Material



$ 57.25

$

$

$

$

$

$

$ 13.15

$

$

$

$

$

$

$

$

$ 24.26

$ 94.65
Labor



$ 13.00

$

$

$

$

$

$

$ 1.85

$

$

$

$

$

$

$

$

$ 3.01

$ 17.86
Burden



$ 92.13

$

$

$

$

$

$

$ 7.41

$

$

$

$

$

$

$

$

$ 5.53

$ 105.07
Total
Cost
(Component/
Assembly)



$ 162.38

$

$

$

$

$

$

$ 22.41

$

$

$

$

$

$

$

$

$ 32.79

$ 217.59
Markup
End Item
Scrap



$ 4.22

$

$

$

$

$

$

$ 0.11

$

$

$

$

$

$

$

$

$

$ 4.33
SGSA



$ 5.91

$

$

$

$

$

$

$ 1.46

$

$

$

$

$

$

$

$

$

$ 7.37
Profit



$ 6.75

$

$

$

$

$

$

$ 1.34

$

$

$

$

$

$

$

$

$

$ 8.10
EDST-RSD



$ 1.69

$

$

$

$

$

$

$ 0.56

$

$

$

$

$

$

$

$

$

$ 2.25
Total Markup
Cost
(Component/
Assembly)



$ 18.57

$

$

$

$

$

$

$ 3.47

$

$

$

$

$

$

$

$

$

$ 22.05
Total
Packaging
Cost
(Component/
Assembly)



$ 0.27

$

$

$

$

$

$

$ 0.22

$

$

$

$

$

$

$

$

$

$ 0.48
Net
Component/
Assembly Cosl
Impact to OEM



$ 181.22

$

$

$

$

$

$

$ 26.10

$

$

$

$

$

$

$

$

$ 32.79

$ 240.12
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                             Apdx. C.1 Cylinder Head, Page: 10 of 48
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0102
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case*: 0102  ( N0102 New Technology Configuration)
                     ( B0102 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0106 Cylinder Head Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17



|01 Cylinder Head

|02 Valve Guides. Valve Seats

|03 Guides for Valve Train

|06 Camshaft Bearing Housing

|07 Cam Shaft Speed Sensor

|08 Camshaft Carrier

|09 Other Parts for Cylinder Head

|20 Cylinder Head Covers

|65 Adapter

|70 Pipes

|75 Brackets

|60 Boltings: Cylinder Head, Cylinder Head Cover, Manifold

|85 Sealing Elements: Cylinder Head, Cylinder Head Cover, ....

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Vehicle and Engine Assembly

SUB-SUBSYSTEM ROLL-UP








































BASE TECHNOLOGY PACKAGE COST INFORMATION
3.0L V6, DOHC, NA, PR
Manufacturing
Material



$ 80.85

$

$

$

$

$

$

$ 22.83

$

$

$

$

$

$

$

$

$ 45.28

$ 148.96
Labor



$ 23.63

$

$

$

$

$

$

$ 3.97

$

$

$

$

$

$

$

$

$ 4.21

$ 31.81
Burden



$ 149.18

$

$

$

$

$

$

$ 14.13

$

$

$

$

$

$

$

$

$ 19.36

$ 182.67
Total
Cost
(Component/
Assembly)



$ 253.66

$

$

$

$

$

$

$ 40.93

$

$

$

$

$

$

$

$

$ 68.85

$ 363.44
Markup
End Item
Scrap



$ 6.40

$

$

$

$

$

$

$ 0.20

$

$

$

$

$

$

$

$

$

$ 6.61
SGSA



$ 8.97

$

$

$

$

$

$

$ 2.66

$

$

$

$

$

$

$

$

$

$ 11.63
Profit



$ 10.25

$

$

$

$

$

$

$ 2.46

$

$

$

$

$

$

$

$

$

$ 12.70
EDST-RSD



$ 2.56

$

$

$

$

$

$

$ 1.02

$

$

$

$

$

$

$

$

$

$ 3.59
Total Markup
Cost
(Component/
Assembly)



$ 28.18

$

$

$

$

$

$

$ 6.34

$

$

$

$

$

$

$

$

$

$ 34.53
Total
Packaging
Cost
(Component/
Assembly)



$ 0.54

$

$

$

$

$

$

$ 0.32

$

$

$

$

$

$

$

$

$

$ 0.86
Net
Component/
Assembly Cosl
Impact to OEM



$ 282.38

$

$

$

$

$

$

$ 47.59

$

$

$

$

$

$

$

$

$ 68.85

$ 398.82
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                             Apdx. C.1 Cylinder Head, Page: 11 of 48
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                        APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                 CASE STUDY #0102
                                                                                                                                             Printed: 3/2 6/2010

Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
Study Case*: 0102 ( N0102 New Technology Configuration)
( B0102 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0106 Cylinder Head Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17



|01 Cylinder Head

|02 Valve Guides. Valve Seats

|03 Guides for Valve Train

|06 Camshaft Bearing Housing

|07 Cam Shaft Speed Sensor

|08 Camshaft Carrier

|09 Other Parts for Cylinder Head

|20 Cylinder Head Covers

|65 Adapter

|70 Pipes

|75 Brackets

|60 Boltings: Cylinder Head, Cylinder Head Cover, Manifold

|85 Sealing Elements: Cylinder Head, Cylinder Head Cover, ....

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Vehicle and Engine Assembly

SUB-SUBSYSTEM ROLL-UP









































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
2.0L 14, DOHC, Turbo Dl
BASE TECHNOLOGY PACKAGE COST INFORMATION
3.0L V6, DOHC, NA, PFI
Manufacturing
Material



$ (23.80S

$

$

$

$

$

$

$ {9.68}

$

$

$

$

$

$

$

$

$ (21.02)

$ (54,30)
Labor



$ (1 0.83S

$

$

$

$

$

$

$ (2.12)

$

$

$

$

$

$

$

$

$ (1.20)

$ (13,95)
Burden



$ (57,05)

$

$

$

$

$

$

$ (6,72)

$

$

$

$

$

$

$

$

$ (1 3,83)

$ (77,80)
Total
Manufacturing
Cost
(Component/
Assembly)



$ (51,28)

$

$

$

$

$

$

$ (IS, 52)

$

$

$

$

$

$

$

$

$ (38,05)

$ (145,85)
Markup
End Item
Scrap



$ (2.1 8)

$

$

$

$

$

$

$ (0.09)

$

$

$

$

$

$

$

$

$

$ (2,28)
SGSA



$ (3.08)

$

$

$

$

$

$

$ (1.20)

$

$

$

$

$

$

$

$

$

$ (4,28)
Profit



$ (3.48)

$

$

$

$

$

$

t (1.11)

$

$

$

$

$

$

$

$

$

$ (4,80)
EDST-RSD



$ (0.87)

$

$

$

$

$

$

t (0-46)

$

$

$

$

$

$

$

$

$

$ (1,34)
Total Markup
Cost
(Component/
Assembly)



$ (9.61)

$

$

$

$

$

$

$ (2.87)

$

$

$

$

$

$

$

$

$

$ (12,48)
Total
Packaging
Cost
(Component/
Assembly)



$ (0.27)

$

$

$

$

$

$

$ (0.10)

$

$

$

$

$

$

$

$

$

$ (0,37)
Net
Component/
Assembly Cosl
Impact to OEM



$ (1 01 .1 6)

$

$

$

$

$

$

$ (21.49)

$

$

$

$

$

$

$

$

$ (36.05)

$ (158,70)
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                 Apdx. C.1 Cylinder Head, Page: 12 of 48
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0102
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case*: 0102  ( N0102 New Technology Configuration)
                     ( B0102 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0107 Valvetrain Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16



|01 Intake Valves

|02 Exhaust Valves

|03 Valve Springs

|04 Spring Retainers & Keepers, Spring Seats

t Valve Actuation Elements: Rockers, Finger Followers, Hydraulic
Lash Adjusters,...

|06 Camshafts

|08 Camshaft Phaser and/or Cam Sprockets

|65 Adapters

1 70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings

|85 Sealings: e.g. Valve-stem, Seals

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

lOO Engine and Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP






































NEW TECHNOLOGY PACKAGE COST INFORMATION
2.0L 14, DOHC, Turbo Dl
Manufacturing
Material



$ 9.20

$ 26.00

$ 4.80

$ 9.12

$ 12.80

$ 6.06

$ 12.20

$

$

$

$ 0.30

$

$

$

$ 3.97

$

$ 84.44
Labor



$

$

$

$

$

$ 4.57

$ 5.23

$

$

$

$

$

$

$

$ 2.38

$ 3.61

$ 15.79
Burden



$

$

$

$

$

$ 1 7.21

$ 17.43

$

$

$

$

$

$

$

$ 9.52

$ 13.18

$ 57.34
Total
Cost
(Component/
Assembly)



$ 9.20

$ 26.00

$ 4.80

$ 9.12

$ 12.80

$ 27.84

$ 34.85

$

$

$

$ 0.30

$

$

$

$ 15.87

$ 1 6.79

$ 157.58
Markup
End Item
Scrap



$

$

$

$

$

$ 1.40

$ 0.17

$

$

$

$

$

$

$

$ 0.11

$

$ 1.68
SGSA



$

$

$

$

$

$ 2.87

$ 2.27

$

$

$

$

$

$

$

$ 1.11

$

$ 6.25
Profit



$

$

$

$

$

$ 2.65

$ 2.09

$

$

$

$

$

$

$

$ 1.27

$

$ 6.01
EDST-RSD



$

$

$

$

$

$ 0.90

$ 0.87

$

$

$

$

$

$

$

$ 0.63

$

$ 2.41
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$ 7.82

$ 5.40

$

$

$

$

$

$

$

$ 3.13

$

$ 16.35
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$ 0.08

$ 0.10

$

$

$

$

$

$

$

$ 0.08

$

$ 0.26
Net
Component/
Assembly Cosl
Impact to OEM



$ 9.20

$ 26.00

$ 4.80

$ 9.12

$ 12.80

$ 35.75

$ 40.35

$

$

$

$ 0.30

$

$

$

$ 19.08

$ 1 6.79

$ 174.19
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                              Apdx. C.1 Valvetrain, Page: 13 of 48
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0102
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case*: 0102  ( N0102 New Technology Configuration)
                     ( B0102 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0107 Valvetrain Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16



|01 Intake Valves

|02 Exhaust Valves

|03 Valve Springs

|04 Spring Retainers & Keepers, Spring Seats

t Valve Actuation Elements: Rockers, Finger Followers, Hydraulic
Lash Adjusters,...

|06 Camshafts

|08 Camshaft Phaser and/or Cam Sprockets

|65 Adapters

1 70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings

|85 Sealings: e.g. Valve-stem, Seals

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

lOO Engine and Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP






































BASE TECHNOLOGY PACKAGE COST INFORMATION
3.0L V6, DOHC, NA, PR
Manufacturing
Material



$ 12.48

$ 27.24

$ 7.20

$ 1 3.68

$ 19.20

$ 7.97

$ 25.31

$

$

$

$ 0.60

$

$

$

$ 7.94

$

$121.61
Labor



$

$

$

$

$

$ 8.44

$ 10.85

$

$

$

$

$

$

$

$ 4.76

$ 7.22

$ 31.27
Burden



$

$

$

$

$

$ 31.49

$ 36.15

$

$

$

$

$

$

$

$ 19.05

$ 25.73

$112.41
Total
Cost
(Component/
Assembly)



$ 12.48

$ 27.24

$ 7.20

$ 1 3.68

$ 19.20

$ 47.89

$ 72.30

$

$

$

$ 0.60

$

$

$

$ 31.75

$ 32.95

$ 265.29
Markup
End Item
Scrap



$

$

$

$

$

$ 2.34

$ 0.36

$

$

$

$

$

$

$

$ 0.22

$

$ 2.92
SGSA



$

$

$

$

$

$ 5.05

$ 4.70

$

$

$

$

$

$

$

$ 2.22

$

$ 11.97
Profit



$

$

$

$

$

$ 4.66

$ 4.34

$

$

$

$

$

$

$

$ 2.54

$

$ 11.54
EDST-RSD



$

$

$

$

$

$ 1.58

$ 1.81

$

$

$

$

$

$

$

$ 1.27

$

$ 4.65
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$ 13.62

$ 11.21

$

$

$

$

$

$

$

$ 6.25

$

$ 31.08
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$ 0.16

$ 0.20

$

$

$

$

$

$

$

$ 0.16

$

$ 0.52
Net
Component/
Assembly Cosl
Impact to OEM



$ 12.48

$ 27.24

$ 7.20

$ 1 3.68

$ 19.20

$ 61.68

$ 83.71

$

$

$

$ 0.60

$

$

$

$ 38.16

$ 32.95

$ 296.89
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                              Apdx. C.1 Valvetrain, Page: 14 of 48
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                        APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                 CASE STUDY #0102
                                                                                                                                             Printed: 3/2 6/2010

Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
Study Case*: 0102 ( N0102 New Technology Configuration)
( B0102 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0107 Valvetrain Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16



|01 Intake Valves

|02 Exhaust Valves

|03 Valve Springs

|04 Spring Retainers & Keepers, Spring Seats

t Valve Actuation Elements: Rockers, Finger Followers, Hydraulic
Lash Adjusters,...

|06 Camshafts

|08 Camshaft Phaser and/or Cam Sprockets

|65 Adapters

1 70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings

|85 Sealings: e.g. Valve-stem, Seals

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

lOO Engine and Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP







































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
2.0L 14, DOHC, Turbo Dl
BASE TECHNOLOGY PACKAGE COST INFORMATION
3.0L V6, DOHC, NA, PFI
Manufacturing
Material



$ (3.28)

$ (1.24)

$ (2.40)

$ (4.56)

$ (8.40!

$ (LSI)

$ (13.11!

$

$

$

$ (0.30!

$

$

$

$ (3.97!

$

$ (37,17)
Labor



$

$

$

$

$

$ (3-87)

$ (5.62)

$

$

$

$

$

$

$

$ (2.38!

$ (3.81)

$ (15,48)
Burden



$

$

$

$

$

$ (14.27)

$ (18.73)

$

$

$

$

$

$

$

$ (9.52)

$ I'lZSSJ

$ (55,07)
Total
Manufacturing
Cost
(Component/
Assembly)



$ (3.28)

$ (1-24)

$ (2.40)

$ (4,56)

$ (6.40)

$ (20.05)

$ (37.45)

$

$

$

$ (0.30)

$

$

$

$ (15.8?)

$ (16.16)

$ (107,71)
Markup
End Item
Scrap



$

$

$

$

$

t (0.94)

$ (0.19!

$

$

$

$

$

$

$

$ (0.11)

$

$ (1,24)
SGSA



$

$

$

$

$

$ (2.18)

$ (2.43!

$

$

$

$

$

$

$

$ (1.11)

$

$ (5,72)
Profit



$

$

$

$

$

$ (2,01)

$ (2.25)

$

$

$

$

$

$

$

$ (1.2?!

$

$ (5,53)
EDST-RSD



$

$

$

$

$

$ (0.6?J

$ (0.94)

$

$

$

$

$

$

$

$ (0.83)

$

$ (2,24)
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$ (5.SO)

$ (5.80!

$

$

$

$

$

$

$

$ (3.13)

$

$ (14,73)
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$ (0-08)

$ (0.10!

$

$

$

$

$

$

$

$ (0.08!

$

$ (0,28)
Net
Component/
Assembly Cosl
Impact to OEM



$ (3.28)

$ (1-24)

$ (2.40)

$ (4,56)

$ (8.40)

$ (25.93)

$ (43.35)

$

$

$

$ (0.30)

$

$

$

$ (19.08!

$ (16.16)

$ (122,70)
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                  Apdx. C.1 Valvetrain, Page: 15 of 48
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.1  - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0102
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case*: 0102  ( N0102 New Technology Configuration)
                     ( B0102 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0108 Timing Drive Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14



|01 Timing Wheels (Sprockets)

|02 Tensioners

|03 Guides

|05 Belts, Chains

|06 Covers

|65 Adaptors

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings

|85 Sealings

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine Assembly

SUB-SUBSYSTEM ROLL-UP


































NEW TECHNOLOGY PACKAGE COST INFORMATION
2.0L 14, DOHC, Turbo Dl
Manufacturing
Material



$ 1.60

$

$

$ 8.50

$

$

$

$

$

$

$

$

$

$

$ 10.10
Labor



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
Burden



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
Total
Manufacturing
Cost
(Component/
Assembly)



$ 1.60

$

$

$ 8.50

$

$

$

$

$

$

$

$

$

$

$ 10.10
Markup
End Item
Scrap



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
SGSA



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
Profit



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
EDST-RSD



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Net
Component/
Assembly Cosl
Impact to OEM



$ 1.60

$

$

$ 8.50

$

$

$

$

$

$

$

$

$

$

$ 10.10
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                             Apdx. C.1 Timing Drives, Page: 16 of 48
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.1  - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0102
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case*: 0102  ( N0102 New Technology Configuration)
                     ( B0102 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0108 Timing Drive Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14



|01 Timing Wheels (Sprockets)

|02 Tensioners

|03 Guides

|05 Belts, Chains

|06 Covers

|65 Adaptors

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings

|85 Sealings

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine Assembly

SUB-SUBSYSTEM ROLL-UP


































BASE TECHNOLOGY PACKAGE COST INFORMATION
3.0L V6, DOHC, NA, PR
Manufacturing
Material



$

$ 26.00

$

$ 1 2.00

$ 9.75

$

$

$

$

$

$

$

$

$ 1.59

$ 49.34
Labor



$

$

$

$

$ 4.18

$

$

$

$

$

$

$

$

$ 1.81

$ 5.99
Burden



$

$

$

$

$ 9.77

$

$

$

$

$

$

$

$

$ 1.81

$ 11.58
Total
Cost
(Component/
Assembly)



$

$ 26.00

$

$ 1 2.00

$ 23.70

$

$

$

$

$

$

$

$

$ 5.20

$ 66.90
Markup
End Item
Scrap



$

$

$

$

$ 0.59

$

$

$

$

$

$

$

$

$

$ 0.59
SGSA



$

$

$

$

$ 1.56

$

$

$

$

$

$

$

$

$

$ 1.56
Profit



$

$

$

$

$ 1.04

$

$

$

$

$

$

$

$

$

$ 1.04
EDST-RSD



$

$

$

$

$ 0.24

$

$

$

$

$

$

$

$

$

$ 0.24
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$ 3.43

$

$

$

$

$

$

$

$

$

$ 3.43
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$ 0.38

$

$

$

$

$

$

$

$

$

$ 0.38
Net
Component/
Assembly Cosl
Impact to OEM



$

$ 26.00

$

$ 1 2.00

$ 27.51

$

$

$

$

$

$

$

$

$ 5.20

$ 70.71
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                             Apdx. C.1 Timing Drives, Page: 17 of 48
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                        APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                 CASE STUDY #0102
                                                                                                                                             Printed: 3/2 6/2010

Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
Study Case*: 0102 ( N0102 New Technology Configuration)
( B0102 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0108 Timing Drive Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14



|01 Timing Wheels (Sprockets)

|02 Tensioners

|03 Guides

|05 Belts, Chains

|06 Covers

|65 Adaptors

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings

|85 Sealings

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine Assembly

SUB-SUBSYSTEM ROLL-UP



































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
2.0L 14, DOHC, Turbo Dl
BASE TECHNOLOGY PACKAGE COST INFORMATION
3.0L V6, DOHC, NA, PFI
Manufacturing
Material



$ 1.60

$ (26.00)

$

$ {3.50}

$ (9.75)

$

$

$

$

$

$

$

$

$ (1.59)

$ (39,24)
Labor



$

$

$

$

$ (4.1 8)

$

$

$

$

$

$

$

$

$ (1.81)

$ (5,99)
Burden



$

$

$

$

$ (9.7?)

$

$

$

$

$

$

$

$

$ (1.81)

$ (11,58)
Total
Manufacturing
Cost
(Component/
Assembly)



$ 1.60

$ (26.00)

$

$ (3.50)

$ (23.70)

$

$

$

$

$

$

$

$

$ (5.20)

$ (56,80)
Markup
End Item
Scrap



$

$

$

$

$ (0.59)

$

$

$

$

$

$

$

$

$

$ (0,59)
SGSA



$

$

$

$

$ (1.56)

$

$

$

$

$

$

$

$

$

$ (1,56)
Profit



$

$

$

$

$ (1.04)

$

$

$

$

$

$

$

$

$

$ (1,04)
EDST-RSD



$

$

$

$

$ (0.2*)

$

$

$

$

$

$

$

$

$

$ (0,24)
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$ (3.435

$

$

$

$

$

$

$

$

$

$ (3,43)
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$ (0.38)

$

$

$

$

$

$

$

$

$

$ (0,38)
Net
Component/
Assembly Cosl
Impact to OEM



$ 1.60

$ (26.00)

$

$ (3,50)

$ (27.51)

$

$

$

$

$

$

$

$

$ (5.20)

$ (60, 61)
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                 Apdx. C.1 Timing Drives, Page: 18 of 48
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.1  - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0102
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case*: 0102  ( N0102 New Technology Configuration)
                     ( B0102 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0109 Accessory Drive Subsystem

1

2

3

4

5

6

7

8

9

10

11



I 01 Pulleys

I 02 Tensioners

I 03 Guides

I 05 Belts

| 65 Adaptors

I 70 Pipes, Hoses, Ducting

I 85 Sealing Elements

I 90 Bearing Elements

I 95 Tools

I 99 Miscellaneous

| 00 Engine & Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP




























NEW TECHNOLOGY PACKAGE COST INFORMATION
2.0L 14, DOHC, Turbo Dl
Manufacturing
Material



$ 29.00

$

$

$

$

$

$

$

$

$

$

$ 29.00
Labor



$

$

$

$

$

$

$

$

$

$

$

$
Burden



$

$

$

$

$

$

$

$

$

$

$

$
Total
Manufacturing
Cost
(Component/
Assembly)



$ 29.00

$

$

$

$

$

$

$

$

$

$

$ 29.00
Markup
End Item
Scrap



$

$

$

$

$

$

$

$

$

$

$

$ -
SGSA



$

$

$

$

$

$

$

$

$

$

$

$
Profit



$

$

$

$

$

$

$

$

$

$

$

$
EDST-RSD



$

$

$

$

$

$

$

$

$

$

$

$ -
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$
Net
Component/
Assembly Cosl
Impact to OEM



$ 29.00

$

$

$

$

$

$

$

$

$

$

$ 29.00
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                            Apdx. C.1 Accessory Drives, Page: 19 of 48
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.1  - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0102
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case*: 0102  ( N0102 New Technology Configuration)
                     ( B0102 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
o>
-g Sub-Subsystem Description
CO
.a
CO

0109 Accessory Drive Subsystem

1

2

3

4

5

6

7

8

9

10

11



I 01 Pulleys

I 02 Tensioners

I 03 Guides

I 05 Belts

| 65 Adaptors

I 70 Pipes, Hoses, Ducting

I 85 Sealing Elements

I 90 Bearing Elements

I 95 Tools

I 99 Miscellaneous

| 00 Engine & Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP




























BASE TECHNOLOGY PACKAGE COST INFORMATION
3.0L V6, DOHC, NA, PR
Manufacturing
Material



$ 22.00

$

$

$

$

$

$

$

$

$

$

$ 22.00
Labor



$

$

$

$

$

$

$

$

$

$

$

$
Burden



$

$

$

$

$

$

$

$

$

$

$

$
Total
Cost
(Component/
Assembly)



$ 22.00

$

$

$

$

$

$

$

$

$

$

$ 22.00
Markup
End Item
Scrap



$

$

$

$

$

$

$

$

$

$

$

$ -
SGSA



$

$

$

$

$

$

$

$

$

$

$

$
Profit



$

$

$

$

$

$

$

$

$

$

$

$
EDST-RSD



$

$

$

$

$

$

$

$

$

$

$

$ -
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$
Net
Component/
Assembly Cosl
Impact to OEM



$ 22.00

$

$

$

$

$

$

$

$

$

$

$ 22.00
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                            Apdx. C.1 Accessory Drives, Page: 20 of 48
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                         APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                 CASE STUDY #0102
                                                                                                                                              Printed: 3/2 6/2010

Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
Study Case*: 0102 ( N0102 New Technology Configuration)
( B0102 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0109 Accessory Drive Subsystem

1

2

3

4

5

6

7

8

9

10

11



I 01 Pulleys

I 02 Tensioners

I 03 Guides

I 05 Belts

| 65 Adaptors

I 70 Pipes, Hoses, Ducting

I 85 Sealing Elements

I 90 Bearing Elements

I 95 Tools

I 99 Miscellaneous

| 00 Engine & Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP





























INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
2.0L 14, DOHC, Turbo Dl
BASE TECHNOLOGY PACKAGE COST INFORMATION
3.0L V6, DOHC, NA, PFI
Manufacturing
Material



$ 7.00

$

$

$

$

$

$

$

$

$

$

$ 7.00
Labor



$

$

$

$

$

$

$

$

$

$

$

$
Burden



$

$

$

$

$

$

$

$

$

$

$

$
Total
Manufacturing
Cost
(Component/
Assembly)



$ 7.00

$

$

$

$

$

$

$

$

$

$

$ 7.00
Markup
End Item
Scrap



$

$

$

$

$

$

$

$

$

$

$

$ -
SGSA



$

$

$

$

$

$

$

$

$

$

$

$
Profit



$

$

$

$

$

$

$

$

$

$

$

$
EDST-RSD



$

$

$

$

$

$

$

$

$

$

$

$ -
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$
Net
Component/
Assembly Cosl
Impact to OEM



$ 7.00

$

$

$

$

$

$

$

$

$

$

$ 7.00
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                 Apdx. C.1 Accessory Drives, Page: 21 of 48
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0102
                                                                                                                                                                       Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case*: 0102  ( N0102 New Technology Configuration)
                     ( B0102 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0110 Intake Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13



|01 Intake Manifolds

|02 Air Filter Box

|03 Air Filters

|05 Throttle Housing Assembly; including Supplies

|65 Adapters: Flanges for Port Shut-off

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Bolting & Clamps

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine and Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP
































NEW TECHNOLOGY PACKAGE COST INFORMATION
2.0L 14, DOHC, Turbo Dl
Manufacturing
Material



$ 11.04

$

$

$

$

$

$

$

$

$

$

$

$

$ 11.04
Labor



$ 0.92

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.92
Burden



$ 2.15

$

$

$

$

$

$

$

$

$

$

$

$

$ 2.15
Total
Cost
(Component/
Assembly)



$ 14.11

$

$

$

$

$

$

$

$

$

$

$

$

$ 14.11
Markup
End Item
Scrap



$ 0.07

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.07
SGSA



$ 0.92

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.92
Profit



$ 0.85

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.85
EDST-RSD



$ 0.35

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.35
Total Markup
Cost
(Component/
Assembly)



$ 2.19

$

$

$

$

$

$

$

$

$

$

$

$

$ 2.19
Total
Packaging
Cost
(Component/
Assembly)



$ 0.18

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.18
Net
Component/
Assembly Cosl
Impact to OEM



$ 16.48

$

$

$

$

$

$

$

$

$

$

$

$

$ 16.48
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                               Apdx. C.1 Intake, Page: 22 of 48
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0102
                                                                                                                                                                       Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case*: 0102  ( N0102 New Technology Configuration)
                     ( B0102 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0110 Intake Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13



|01 Intake Manifolds

|02 Air Filter Box

|03 Air Filters

|05 Throttle Housing Assembly; including Supplies

|65 Adapters: Flanges for Port Shut-off

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Bolting & Clamps

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine and Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP
































BASE TECHNOLOGY PACKAGE COST INFORMATION
3.0L V6, DOHC, NA, PR
Manufacturing
Material



$ 21.42

$

$

$

$

$

$

$

$

$

$

$

$ 0.30

$ 21.72
Labor



$ 3.71

$

$

$

$

$

$

$

$

$

$

$

$ 0.60

$ 4.31
Burden



$ 11.32

$

$

$

$

$

$

$

$

$

$

$

$ 0.72

$ 12.04
Total
Cost
(Component/
Assembly)



$ 36.45

$

$

$

$

$

$

$

$

$

$

$

$ 1.62

$ 38.07
Markup
End Item
Scrap



$ 0.18

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.18
SGSA



$ 2.37

$

$

$

$

$

$

$

$

$

$

$

$

$ 2.37
Profit



$ 2.19

$

$

$

$

$

$

$

$

$

$

$

$

$ 2.19
EDST-RSD



$ 0.91

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.91
Total Markup
Cost
(Component/
Assembly)



$ 5.65

$

$

$

$

$

$

$

$

$

$

$

$

$ 5.65
Total
Packaging
Cost
(Component/
Assembly)



$ 0.42

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.42
Net
Component/
Assembly Cosl
Impact to OEM



$ 42.52

$

$

$

$

$

$

$

$

$

$

$

$ 1.62

$ 44.15
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                               Apdx. C.1 Intake, Page: 23 of 48
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                        APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                CASE STUDY #0102
                                                                                                                                            Printed: 3/2 6/2010

Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
Study Case*: 0102 ( N0102 New Technology Configuration)
( B0102 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0110 Intake Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13



|01 Intake Manifolds

|02 Air Filter Box

|03 Air Filters

|05 Throttle Housing Assembly; including Supplies

|65 Adapters: Flanges for Port Shut-off

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Bolting & Clamps

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine and Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP

































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
2.0L 14, DOHC, Turbo Dl
BASE TECHNOLOGY PACKAGE COST INFORMATION
3.0L V6, DOHC, NA, PFI
Manufacturing
Material



$ (10.39)

$

$

$

$

$

$

$

$

$

$

$

$ (0.30S

$ (10,69)
Labor



$ (2.78)

$

$

$

$

$

$

$

$

$

$

$

$ (0.80S

$ (3,38)
Burden



$ (9,17)

$

$

$

$

$

$

$

$

$

$

$

$ (0.72)

$ (9,89)
Total
Manufacturing
Cost
(Component/
Assembly)



$ (22.34)

$

$

$

$

$

$

$

$

$

$

$

$ (1.S2)

$ (23,96)
Markup
End Item
Scrap



f, (0.11)

$

$

$

$

$

$

$

$

$

$

$

$

$ (0,11)
SGSA



$ (1.45)

$

$

$

$

$

$

$

$

$

$

$

$

$ (1,45)
Profit



$ (1.34)

$

$

$

$

$

$

$

$

$

$

$

$

$ (1,34)
EDST-RSD



$ (0.56)

$

$

$

$

$

$

$

$

$

$

$

$

$ (0,56)
Total Markup
Cost
(Component/
Assembly)



$ (3.48)

$

$

$

$

$

$

$

$

$

$

$

$

$ (3,46)
Total
Packaging
Cost
(Component/
Assembly)



$ (0.245

$

$

$

$

$

$

$

$

$

$

$

$

$ (0,24)
Net
Component/
Assembly Cosl
Impact to OEM



$ (26.04,S

$

$

$

$

$

$

$

$

$

$

$

$ (1.82)

$ (27,66)
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                  Apdx. C.1 Intake, Page: 24 of 48
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.1  - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0102
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case*: 0102  ( N0102 New Technology Configuration)
                     ( B0102 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0111 Fuel Induction Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13



|01 Fuel Rails

|04 Fuel Injectors

|06 Pressure Regulators

|07 Fuel Injection Pumps

|65 Adaptors

|70 Pipes, Hoses: Low Pressure, High Pressure

|75 Brackets

|60 Bolting

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine Assembly

SUB-SUBSYSTEM ROLL-UP
































NEW TECHNOLOGY PACKAGE COST INFORMATION
2.0L 14, DOHC, Turbo Dl
Manufacturing
Material



$ 11.17

$ 8.75

$

$ 1 6.99

$

$ 0.39

$

$

$

$

$

$

$ 0.21

$ 37.51
Labor



$ 1.81

$ 5.88

$

$ 8.01

$

$ 0.34

$

$

$

$

$

$

$ 2.41

$ 18.45
Burden



$ 4.04

$ 23.89

$

$ 24.95

$

$ 0.71

$

$

$

$

$

$

$ 1.91

$ 55.50
Total
Cost
(Component/
Assembly)



$ 17.01

$ 38.53

$

$ 49.94

$

$ 1.44

$

$

$

$

$

$

$ 4.53

$ 111.46
Markup
End Item
Scrap



$ 0.05

$ 0.41

$

$ 0.68

$

$ 0.00

$

$

$

$

$

$

$

$ 1.15
SGSA



$ 1.02

$ 4.47

$

$ 5.88

$

$ 0.09

$

$

$

$

$

$

$

$ 11.45
Profit



$ 0.68

$ 4.77

$

$ 5.97

$

$ 0.06

$

$

$

$

$

$

$

$ 11.48
EDST-RSD



$ 0.17

$ 1.91

$

$ 2.32

$

$ 0.01

$

$

$

$

$

$

$

$ 4.41
Total Markup
Cost
(Component/
Assembly)



$ 1.92

$ 11.55

$

$ 14.84

$

$ 0.16

$

$

$

$

$

$

$

$ 28.48
Total
Packaging
Cost
(Component/
Assembly)



$ 0.08

$ 0.05

$

$ 0.11

$

$ 0.01

$

$

$

$

$

$

$

$ 0.25
Net
Component/
Assembly Cosl
Impact to OEM



$ 19.02

$ 50.13

$

$ 64.90

$

$ 1.61

$

$

$

$

$

$

$ 4.53

$ 140.19
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                             Apdx. C.1 Fuel Induction, Page: 25 of 48
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.1  - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0102
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case*: 0102  ( N0102 New Technology Configuration)
                     ( B0102 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0111 Fuel Induction Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13



|01 Fuel Rails

|04 Fuel Injectors

|06 Pressure Regulators

|07 Fuel Injection Pumps

|65 Adaptors

|70 Pipes, Hoses: Low Pressure, High Pressure

|75 Brackets

|60 Bolting

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine Assembly

SUB-SUBSYSTEM ROLL-UP
































BASE TECHNOLOGY PACKAGE COST INFORMATION
3.0L V6, DOHC, NA, PR
Manufacturing
Material



$ 1.85

$ 6.20

$

$

$

$

$

$

$

$

$

$

$ 0.12

$ 8.16
Labor



$ 2.24

$ 5.73

$

$

$

$

$

$

$

$

$

$

$ 1.20

$ 9.17
Burden



$ 3.25

$ 24.10

$

$

$

$

$

$

$

$

$

$

$ 0.83

$ 28.18
Total
Cost
(Component/
Assembly)



$ 7.33

$ 36.03

$

$

$

$

$

$

$

$

$

$

$ 2.15

$ 45.51
Markup
End Item
Scrap



$ 0.02

$ 0.32

$

$

$

$

$

$

$

$

$

$

$

$ 0.34
SGSA



$ 0.44

$ 3.39

$

$

$

$

$

$

$

$

$

$

$

$ 3.83
Profit



$ 0.29

$ 3.65

$

$

$

$

$

$

$

$

$

$

$

$ 3.94
EDST-RSD



$ 0.07

$ 1.59

$

$

$

$

$

$

$

$

$

$

$

$ 1.66
Total Markup
Cost
(Component/
Assembly)



$ 0.83

$ 8.94

$

$

$

$

$

$

$

$

$

$

$

$ 9.77
Total
Packaging
Cost
(Component/
Assembly)



$ 0.08

$ 0.07

$

$

$

$

$

$

$

$

$

$

$

$ 0.15
Net
Component/
Assembly Cosl
Impact to OEM



$ 8.24

$ 45.04

$

$

$

$

$

$

$

$

$

$

$ 2.15

$ 55.43
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                             Apdx. C.1 Fuel Induction, Page: 26 of 48
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                        APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                 CASE STUDY #0102
                                                                                                                                              Printed: 3/2 6/2010

Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
Study Case*: 0102 ( N0102 New Technology Configuration)
( B0102 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0111 Fuel Induction Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13



|01 Fuel Rails

|04 Fuel Injectors

|06 Pressure Regulators

|07 Fuel Injection Pumps

|65 Adaptors

|70 Pipes, Hoses: Low Pressure, High Pressure

|75 Brackets

|60 Bolting

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine Assembly

SUB-SUBSYSTEM ROLL-UP

































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
2.0L 14, DOHC, Turbo Dl
BASE TECHNOLOGY PACKAGE COST INFORMATION
3.0L V6, DOHC, NA, PFI
Manufacturing
Material



$ 9.32

$ 2.56

$

$ 1 6.99

$

$ 0.39

$

$

$

$

$

$

$ 0.09

$ 29.35
Labor



$ (0,43|

$ 0.16

$

$ 8.01

$

$ 0.34

$

$

$

$

$

$

$ 1.20

$ 9.28
Burden



$ 0.79

$ (0.22)

$

$ 24.95

$

$ 0.71

$

$

$

$

$

$

$ 1.08

$ 27.31
Total
Manufacturing
Cost
(Component/
Assembly)



$ 9.68

$ 2.50

$

$ 49.94

$

$ 1.44

$

$

$

$

$

$

$ 2.38

$ 65.94
Markup
End Item
Scrap



$ 0.03

$ 0.10

$

$ 0.68

$

$ 0.00

$

$

$

$

$

$

$

$ 0.81
SGSA



$ 0.58

$ 1.08

$

$ 5.88

$

$ 0.09

$

$

$

$

$

$

$

$ 7.62
Profit



$ 0.39

$ 1.12

$

$ 5.97

$

$ 0.06

$

$

$

$

$

$

$

$ 7.53
EDST-RSD



$ 0.10

$ 0.32

$

$ 2.32

$

$ 0.01

$

$

$

$

$

$

$

$ 2.75
Total Markup
Cost
(Component/
Assembly)



$ 1.09

$ 2.61

$

$ 14.84

$

$ 0.16

$

$

$

$

$

$

$

$ 18.71
Total
Packaging
Cost
(Component/
Assembly)



$ (o.oo!

$ (0.02)

$

$ 0.11

$

$ 0.01

$

$

$

$

$

$

$

$ 0.10
Net
Component/
Assembly Cosl
Impact to OEM



$ 10.77

$ 5.10

$

$ 64.90

$

$ 1.61

$

$

$

$

$

$

$ 2.38

$ 84.76
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                 Apdx. C.1 Fuel Induction, Page: 27 of 48
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0102
                                                                                                                                                                       Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case*: 0102  ( N0102 New Technology Configuration)
                     ( B0102 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0112 Exhaust Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15



|01 Exhaust Manifold

|04 Collector Pipes

|05 Catalysts

|06 Particle Filters

|07 Silencers (Mufflers)

|08 Oxygen Sensors

|65 Adapters

|70 Pipes, Hoses: Low Pressure, High Pressure

|75 Brackets

|60 Bolting

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine and Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP




































NEW TECHNOLOGY PACKAGE COST INFORMATION
2.0L 14, DOHC, Turbo Dl
Manufacturing
Material



$ 29.60

$ 24.63

$ 64.73

$

$

$ 11.62

$

$

$ 1.21

$

$

$

$

$

$ 12.80

$ 144.60
Labor



$ 3.30

$ 8.21

$ 12.95

$

$

$ 2.32

$

$

$ 0.24

$

$

$

$

$

$ 4.81

$ 31.84
Burden



$ 11.02

$ 21.89

$ 51.78

$

$

$ 9.30

$

$

$ 0.97

$

$

$

$

$

$ 3.18

$ 98.14
Total
Cost
(Component/
Assembly)



$ 43.92

$ 54.73

$ 129.45

$

$

$ 23.25

$

$

$ 2.42

$

$

$

$

$

$ 20.79

$ 274.57
Markup
End Item
Scrap



$ 3.70

$ 0.27

$ 6.91

$

$

$ 0.16

$

$

$ 0.01

$

$

$

$

$

$

$ 11.06
SGSA



$ 3.08

$ 3.56

$ 8.82

$

$

$ 1.63

$

$

$ 0.16

$

$

$

$

$

$

$ 17.24
Profit



$ 2.84

$ 3.28

$ 8.14

$

$

$ 1.86

$

$

$ 0.15

$

$

$

$

$

$

$ 16.27
EDST-RSD



$ 1.18

$ 1.37

$ 3.39

$

$

$ 0.93

$

$

$ 0.06

$

$

$

$

$

$

$ 6.94
Total Markup
Cost
(Component/
Assembly)



$ 10.81

$ 8.48

$ 27.26

$

$

$ 4.58

$

$

$ 0.38

$

$

$

$

$

$

$ 51.51
Total
Packaging
Cost
(Component/
Assembly)



$ 0.06

$ 0.20

$ 0.20

$

$

$ 0.10

$

$

$ 0.03

$

$

$

$

$

$

$ 0.59
Net
Component/
Assembly Cosl
Impact to OEM



$ 54.80

$ 63.41

$ 156.91

$

$

$ 27.93

$

$

$ 2.83

$

$

$

$

$

$ 20.79

$ 326.67
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                               Apdx. C.1 Exhaust, Page: 28 of 48
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0102
                                                                                                                                                                       Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case*: 0102  ( N0102 New Technology Configuration)
                     ( B0102 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0112 Exhaust Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15



|01 Exhaust Manifold

|04 Collector Pipes

|05 Catalysts

|06 Particle Filters

|07 Silencers (Mufflers)

|08 Oxygen Sensors

|65 Adapters

|70 Pipes, Hoses: Low Pressure, High Pressure

|75 Brackets

|60 Bolting

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine and Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP




































BASE TECHNOLOGY PACKAGE COST INFORMATION
3.0L V6, DOHC, NA, PR
Manufacturing
Material



$ 6.09

$ 30.78

$ 65.98

$

$

$ 23.25

$

$

$

$

$ 1.19

$

$

$

$ 8.08

$ 135.37
Labor



$ 6.09

$ 1 0.26

$ 13.20

$

$

$ 4.65

$

$

$

$

$ 0.24

$

$

$

$ 9.03

$ 43.46
Burden



$ 18.26

$ 27.36

$ 52.78

$

$

$ 1 8.60

$

$

$

$

$ 0.96

$

$

$

$ 3.85

$121.81
Total
Cost
(Component/
Assembly)



$ 30.43

$ 68.41

$ 131.95

$

$

$ 46.50

$

$

$

$

$ 2.39

$

$

$

$ 20.95

$ 300.63
Markup
End Item
Scrap



$ 0.15

$ 0.34

$ 6.80

$

$

$ 0.33

$

$

$

$

$ 0.01

$

$

$

$

$ 7.63
SGSA



$ 1.98

$ 4.45

$ 8.97

$

$

$ 3.25

$

$

$

$

$ 0.16

$

$

$

$

$ 18.81
Profit



$ 1.83

$ 4.10

$ 8.28

$

$

$ 3.72

$

$

$

$

$ 0.14

$

$

$

$

$ 18.08
EDST-RSD



$ 0.76

$ 1.71

$ 3.45

$

$

$ 1.86

$

$

$

$

$ 0.06

$

$

$

$

$ 7.84
Total Markup
Cost
(Component/
Assembly)



$ 4.72

$ 10.60

$ 27.51

$

$

$ 9.16

$

$

$

$

$ 0.37

$

$

$

$

$ 52.36
Total
Packaging
Cost
(Component/
Assembly)



$ 0.12

$ 0.20

$ 0.40

$

$

$ 0.20

$

$

$

$

$ 0.06

$

$

$

$

$ 0.98
Net
Component/
Assembly Cosl
Impact to OEM



$ 35.27

$ 79.21

$ 159.86

$

$

$ 55.86

$

$

$

$

$ 2.82

$

$

$

$ 20.95

$ 353.97
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                               Apdx. C.1 Exhaust, Page: 29 of 48
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                        APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                CASE STUDY #0102
                                                                                                                                            Printed: 3/2 6/2010

Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
Study Case*: 0102 ( N0102 New Technology Configuration)
( B0102 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0112 Exhaust Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15



|01 Exhaust Manifold

|04 Collector Pipes

|05 Catalysts

|06 Particle Filters

|07 Silencers (Mufflers)

|08 Oxygen Sensors

|65 Adapters

|70 Pipes, Hoses: Low Pressure, High Pressure

|75 Brackets

|60 Bolting

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine and Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP





































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
2.0L 14, DOHC, Turbo Dl
BASE TECHNOLOGY PACKAGE COST INFORMATION
3.0L V6, DOHC, NA, PFI
Manufacturing
Material



$ 23.52

t (6.16)

$ (1.25)

$

$

t (11.62)

$

$

$ 1.21

$

$ (1.19)

$

$

$

$ 4.72

$ 9.22
Labor



$ (2.79)

$ (2.05)

$ (0.25)

$

$

$ (2.32)

$

$

$ 0.24

$

$ (0.24!

$

$

$

$ (4.21)

t (11.62)
Burden



$ (7.24)

t (5.47)

$ (1.00J

$

$

$ 0.30)

$

$

$ 0.97

$

$ (OJ8J

$

$

$

$ (0.67J

$ (23,67)
Total
Manufacturing
Cost
(Component/
Assembly)



$ 13.49

$ (1 3.88)

$ (2.505

$

$

$ (23.25)

$

$

$ 2.42

$

$ (2,395

$

$

$

$ (0.16J

$ (26,06)
Markup
End Item
Scrap



$ 3.55

$ (0.07)

$ 0.11

$

$

$ (0.1 6)

$

$

$ 0.01

$

$ (0.015

$

$

$

$

$ 3.43
SGSA



$ 1.10

$ (0.89)

$ (0.15)

$

$

$ (1.63)

$

$

$ 0.16

$

$ (0.16J

$

$

$

$

t (1.57)
Profit



$ 1.02

$ (0.82)

$ (0.1 4)

$

$

$ (1.86)

$

$

$ 0.15

$

$ (0.1 4!

$

$

$

$

t (1,80)
EDST-RSD



$ 0.42

$ (0.34)

$ (0.06)

$

$

$ (0,93)

$

$

$ 0.06

$

$ (0.06)

$

$

$

$

t (0.91)
Total Markup
Cost
(Component/
Assembly)



$ 6.09

$ (2.12)

$ (0.25)

$

$

$ (4.5S)

$

$

$ 0.38

$

$ (0.3?)

$

$

$

$

t (0.85)
Total
Packaging
Cost
(Component/
Assembly)



$ (0.06J

$

$ (0.20!

$

$

$ (0.10)

$

$

$ 0.03

$

$ (0.06!

$

$

$

$

t (0.39)
Net
Component/
Assembly Cosl
Impact to OEM



$ 19.53

t (1 s.eo;

$ (2.95!

$

$

t (27.93)

$

$

$ 2.83

$

$ (2.82!

$

$

$

$ (0.16J

t (27,30)
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                  Apdx. C.1 Exhaust, Page: 30 of 48
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.1  - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0102
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case*: 0102  ( N0102 New Technology Configuration)
                     ( B0102 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0113 Lubrication Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13



|01 Oil Pans (Oil Sump)

|02 Oil Pumps

|05 Pressure Regulators

|06 Oil Filter

|65 Adapter for Oil Filters

I Pipes, Hoses: Suction Pipe for Oil Pump, Oil Return, High Pressure,
Low Pressure.

|75 Brackets

|80 Boltings & Clamps

|85 Sealing Elements: Oil Pan Gasket,...

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine & Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP
































NEW TECHNOLOGY PACKAGE COST INFORMATION
2.0L 14, DOHC, Turbo Dl
Manufacturing
Material



$ 2.31

$

$

$ 2.93

$

$ 1.69

$

$

$

$

$

$ 3.75

$ 1.23

$ 11.91
Labor



$ 1.13

$

$

$ 2.23

$

$ 1.61

$

$

$

$

$

$

$ 1.46

$ 6.43
Burden



$ 1.72

$

$

$ 4.61

$

$ 3.79

$

$

$

$

$

$

$ 2.63

$ 12.74
Total
Cost
(Component/
Assembly)



$ 5.15

$

$

$ 9.77

$

$ 7.09

$

$

$

$

$

$ 3.75

$ 5.32

$ 31.08
Markup
End Item
Scrap



$ 0.03

$

$

$ 0.09

$

$ 0.02

$

$

$

$

$

$

$

$ 0.14
SGSA



$ 0.33

$

$

$ 1.35

$

$ 0.47

$

$

$

$

$

$

$

$ 2.15
Profit



$ 0.31

$

$

$ 1.14

$

$ 0.31

$

$

$

$

$

$

$

$ 1.76
EDST-RSD



$ 0.13

$

$

$ 0.36

$

$

$

$

$

$

$

$

$

$ 0.49
Total Markup
Cost
(Component/
Assembly)



$ 0.80

$

$

$ 2.94

$

$ 0.81

$

$

$

$

$

$

$

$ 4.55
Total
Packaging
Cost
(Component/
Assembly)



$ 0.09

$

$

$ 0.16

$

$ 0.08

$

$

$

$

$

$

$

$ 0.33
Net
Component/
Assembly Cosl
Impact to OEM



$ 6.04

$

$

$ 1 2.87

$

$ 7.98

$

$

$

$

$

$ 3.75

$ 5.32

$ 35.96
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                              Apdx. C.1 Lubrication, Page: 31 of 48
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.1  - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0102
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case*: 0102  ( N0102 New Technology Configuration)
                     ( B0102 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0113 Lubrication Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13



|01 Oil Pans (Oil Sump)

|02 Oil Pumps

|05 Pressure Regulators

|06 Oil Filter

|65 Adapter for Oil Filters

I Pipes, Hoses: Suction Pipe for Oil Pump, Oil Return, High Pressure,
Low Pressure.

|75 Brackets

|80 Boltings & Clamps

|85 Sealing Elements: Oil Pan Gasket,...

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine & Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP
































BASE TECHNOLOGY PACKAGE COST INFORMATION
3.0L V6, DOHC, NA, PR
Manufacturing
Material



$ 13.53

$

$

$

$

$

$

$

$

$

$

$

$ 1.24

$ 14.77
Labor



$ 2.87

$

$

$

$

$

$

$

$

$

$

$

$

$ 2.87
Burden



$ 18.14

$

$

$

$

$

$

$

$

$

$

$

$

$ 18.14
Total
Cost
(Component/
Assembly)



$ 34.54

$

$

$

$

$

$

$

$

$

$

$

$ 1.24

$ 35.77
Markup
End Item
Scrap



$ 0.18

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.18
SGSA



$ 2.35

$

$

$

$

$

$

$

$

$

$

$

$

$ 2.35
Profit



$ 2.14

$

$

$

$

$

$

$

$

$

$

$

$

$ 2.14
EDST-RSD



$ 0.87

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.87
Total Markup
Cost
(Component/
Assembly)



$ 5.54

$

$

$

$

$

$

$

$

$

$

$

$

$ 5.54
Total
Packaging
Cost
(Component/
Assembly)



$ 0.32

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.32
Net
Component/
Assembly Cosl
Impact to OEM



$ 40.39

$

$

$

$

$

$

$

$

$

$

$

$ 1.24

$ 41.63
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                              Apdx. C.1 Lubrication, Page: 32 of 48
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                        APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                 CASE STUDY #0102
                                                                                                                                             Printed: 3/2 6/2010


Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
Study Case*: 0102 ( N0102 New Technology Configuration)
( B0102 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

Sub-Subsystem

Sub-Subsystem Description

0113 Lubrication Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13



(01 Oil Pans (Oil Sump)


J02 Oil Pumps


|05 Pressure Regulators


J06 Oil Filter


J65 Adapter for Oil Filters


I Pipes, Hoses: Suction Pipe for Oil Pump, Oil Return, High Pressure,
Low Pressure.

|75 Brackets


\80 Boltings & Clamps

(85 Sealing Elements: Oil Pan Gasket,...


|90 Bearing Elements


J95 Tools


|99 Miscellaneous

|00 Engine & Vehicle Assembly


SUB-SUBSYSTEM ROLL-UP

































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
2.0L 14, DOHC, Turbo Dl
BASE TECHNOLOGY PACKAGE COST INFORMATION
3.0L V6, DOHC, NA, PFI
Manufacturing
Material



$ (11. 23}

$

$

$ 2.93

$

$ 1.69

$

$

$

$

$

$ 3.75

$ (0.00)

$ (2,86)
Labor



$ (1.74)

$

$

$ 2.23

$

$ 1.61

$

$

$

$

$

$

$ 1.46

$ 3.56
Burden



$ (16.42)

$

$

$ 4.61

$

$ 3.79

$

$

$

$

$

$

$ 2.63

$ (5,40)
Total
Manufacturing
Cost
(Component/
Assembly)



$ (29.38)

$

$

$ 9.77

$

$ 7.09

$

$

$

$

$

$ 3.75

$ 4.08

$ (4,69)
Markup
End Item
Scrap



$ (0,15)

$

$

$ 0.09

$

$ 0.02

$

$

$

$

$

$

$

$ (0,04)
SGSA



$ (2.01)

$

$

$ 1.35

$

$ 0.47

$

$

$

$

$

$

$

$ (0,20)
Profit



$ (1 .83)

$

$

$ 1.14

$

$ 0.31

$

$

$

$

$

$

$

$ (0,38)
EDST-RSD



$ (0.74)

$

$

$ 0.36

$

$

$

$

$

$

$

$

$

$ (0,38)
Total Markup
Cost
(Component/
Assembly)



$ (4.74)

$

$

$ 2.94

$

$ 0.81

$

$

$

$

$

$

$

$ (0,99)
Total
Packaging
Cost
(Component/
Assembly)



S (0.23)

$

$

$ 0.16

$

$ 0.08

$

$

$

$

$

$

$

$ 0.02
Net
Component/
Assembly Cosl
Impact to OEM



$ {34,35}

$

$

$ 1 2.87

$

$ 7.98

$

$

$

$

$

$ 3.75

$ 4.08

$ (5,66)
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                  Apdx. C.1 Lubrication, Page: 33 of 48
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0102
                                                                                                                                                                       Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case*: 0102  ( N0102 New Technology Configuration)
                     ( B0102 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
o>
-g Sub-Subsystem Description
CO
.a
CO

0114 Cooling Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14



|01 Water Pumps

|02 Thermostat Housing

|04 Heat Exchangers

|05 Pressure Regulators

|06 Expansion Tanks

|65 Adapters

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings & Clamps

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine and Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP


































NEW TECHNOLOGY PACKAGE COST INFORMATION
2.0L 14, DOHC, Turbo Dl
Manufacturing
Material



$ 15.15

$

$

$

$

$

$ 2.60

$

$

$

$

$

$

$ 0.74

$ 18.49
Labor



$ 1.78

$

$

$

$

$

$ 2.57

$

$

$

$

$

$

$ 1.94

$ 6.29
Burden



$ 3.51

$

$

$

$

$

$ 3.54

$

$

$

$

$

$

$ 3.50

$ 10.55
Total
Cost
(Component/
Assembly)



$ 20.43

$

$

$

$

$

$ 8.71

$

$

$

$

$

$

$ 6.19

$ 35.33
Markup
End Item
Scrap



$ 0.19

$

$

$

$

$

$ 0.02

$

$

$

$

$

$

$

$ 0.20
SGSA



$ 1.88

$

$

$

$

$

$ 0.52

$

$

$

$

$

$

$

$ 2.40
Profit



$ 2.14

$

$

$

$

$

$ 0.35

$

$

$

$

$

$

$

$ 2.48
EDST-RSD



$ 1.06

$

$

$

$

$

$

$

$

$

$

$

$

$

$ 1.06
Total Markup
Cost
(Component/
Assembly)



$ 5.26

$

$

$

$

$

$ 0.89

$

$

$

$

$

$

$

$ 6.15
Total
Packaging
Cost
(Component/
Assembly)



$ 0.06

$

$

$

$

$

$ 0.04

$

$

$

$

$

$

$

$ 0.11
Net
Component/
Assembly Cosl
Impact to OEM



$ 25.76

$

$

$

$

$

$ 9.64

$

$

$

$

$

$

$ 6.19

$ 41.59
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                               Apdx. C.1 Cooling, Page: 34 of 48
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0102
                                                                                                                                                                       Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case*: 0102  ( N0102 New Technology Configuration)
                     ( B0102 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0114 Cooling Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14



|01 Water Pumps

|02 Thermostat Housing

|04 Heat Exchangers

|05 Pressure Regulators

|06 Expansion Tanks

|65 Adapters

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings & Clamps

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine and Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP


































BASE TECHNOLOGY PACKAGE COST INFORMATION
3.0L V6, DOHC, NA, PR
Manufacturing
Material



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
Labor



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
Burden



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
Total
Manufacturing
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Markup
End Item
Scrap



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
SGSA



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
Profit



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
EDST-RSD



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Net
Component/
Assembly Cosl
Impact to OEM



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                               Apdx. C.1 Cooling, Page: 35 of 48
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                        APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                CASE STUDY #0102
                                                                                                                                            Printed: 3/2 6/2010

Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
Study Case*: 0102 ( N0102 New Technology Configuration)
( B0102 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0114 Cooling Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14



|01 Water Pumps

|02 Thermostat Housing

|04 Heat Exchangers

|05 Pressure Regulators

|06 Expansion Tanks

|65 Adapters

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings & Clamps

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine and Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP



































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
2.0L 14, DOHC, Turbo Dl
BASE TECHNOLOGY PACKAGE COST INFORMATION
3.0L V6, DOHC, NA, PFI
Manufacturing
Material



$ 15.15

$

$

$

$

$

$ 2.60

$

$

$

$

$

$

$ 0.74

$ 18.49
Labor



$ 1.78

$

$

$

$

$

$ 2.57

$

$

$

$

$

$

$ 1.94

$ 6.29
Burden



$ 3.51

$

$

$

$

$

$ 3.54

$

$

$

$

$

$

$ 3.50

$ 10.55
Total
Manufacturing
Cost
(Component/
Assembly)



$ 20.43

$

$

$

$

$

$ 8.71

$

$

$

$

$

$

$ 6.19

$ 35.33
Markup
End Item
Scrap



$ 0.19

$

$

$

$

$

$ 0.02

$

$

$

$

$

$

$

$ 0.20
SGSA



$ 1.88

$

$

$

$

$

$ 0.52

$

$

$

$

$

$

$

$ 2.40
Profit



$ 2.14

$

$

$

$

$

$ 0.35

$

$

$

$

$

$

$

$ 2.48
EDST-RSD



$ 1.06

$

$

$

$

$

$

$

$

$

$

$

$

$

$ 1.06
Total Markup
Cost
(Component/
Assembly)



$ 5.26

$

$

$

$

$

$ 0.89

$

$

$

$

$

$

$

$ 6.15
Total
Packaging
Cost
(Component/
Assembly)



$ 0.06

$

$

$

$

$

$ 0.04

$

$

$

$

$

$

$

$ 0.11
Net
Component/
Assembly Cosl
Impact to OEM



$ 25.76

$

$

$

$

$

$ 9.64

$

$

$

$

$

$

$ 6.19

$ 41.59
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                  Apdx. C.1 Cooling, Page: 36 of 48
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0102
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case*: 0102  ( N0102 New Technology Configuration)
                     ( B0102 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0115 Induction Air Charging Subsystem

1

2

3

4

5

6

7



|01 Turbo Chargers (Assemblies)

|05 Heat Exchanger

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings, Clamps, Misc Fastening

|99 Miscellaneous

|00 Engine & Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP




















NEW TECHNOLOGY PACKAGE COST INFORMATION
2.0L 14, DOHC, Turbo Dl
Manufacturing
Material



$ 53.92

$ 8.16

$ 27.60

$ 1.07

$

$ 6.27

$ 1.14

$ 98.15
Labor



$ 29.21

$ 3.36

$ 9.09

$ 0.15

$

$ 0.34

$ 9.81

$ 51.97
Burden



$ 39.70

$ 6.65

$ 11.44

$ 0.39

$

$ 0.48

$ 14.72

$ 73.38
Total
Cost
(Component/
Assembly)



$ 122.82

$ 1 8.1 7

$ 48.14

$ 1.61

$

$ 7.09

$ 25.67

$ 223.50
Markup
End Item
Scrap



$ 7.08

$ 0.09

$ 0.14

$ 0.00

$

$ 0.04

$

$ 7.36
SGSA



$ 16.00

$ 1.09

$ 2.89

$ 0.10

$

$ 0.54

$

$ 20.61
Profit



$ 17.15

$ 1.09

$ 1.93

$ 0.06

$

$ 0.48

$

$ 20.71
EDST-RSD



$ 6.73

$ 0.36

$ 0.48

$

$

$ 0.18

$

$ 7.75
Total Markup
Cost
(Component/
Assembly)



$ 46.96

$ 2.63

$ 5.44

$ 0.17

$

$ 1.24

$

$ 56.44
Total
Packaging
Cost
(Component/
Assembly)



$ 0.12

$ 0.11

$ 0.35

$ 0.06

$

$ 0.13

$

$ 0.76
Net
Component/
Assembly Cosl
Impact to OEM



$ 169.89

$ 20.92

$ 53.93

$ 1.83

$

$ 8.45

$ 25.67

$ 280.70
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                            Apdx. C.1 Induct. Air Charging, Page: 37 of 48
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0102
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case*: 0102  ( N0102 New Technology Configuration)
                     ( B0102 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0115 Induction Air Charging Subsystem

1

2

3

4

5

6

7



|01 Turbo Chargers (Assemblies)

|05 Heat Exchanger

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings, Clamps, Misc Fastening

|99 Miscellaneous

|00 Engine & Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP




















BASE TECHNOLOGY PACKAGE COST INFORMATION
3.0L V6, DOHC, NA, PR
Manufacturing
Material



$

$

$

$

$

$

$

$ -
Labor



$

$

$

$

$

$

$

$
Burden



$

$

$

$

$

$

$

$
Total
Manufacturing
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$
Markup
End Item
Scrap



$

$

$

$

$

$

$

$ -
SGSA



$

$

$

$

$

$

$

$
Profit



$

$

$

$

$

$

$

$
EDST-RSD



$

$

$

$

$

$

$

$ -
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$
Net
Component/
Assembly Cosl
Impact to OEM



$

$

$

$

$

$

$

$
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                            Apdx. C.1 Induct. Air Charging, Page: 38 of 48
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                         APPENDIX C.1  - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                 CASE STUDY #0102
                                                                                                                                               Printed: 3/2 6/2010


Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
Study Case*: 0102 ( N0102 New Technology Configuration)
( B0102 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

Sub-Subsystem

Sub-Subsystem Description

0115 Induction Air Charging Subsystem

1

2

3

4

5

6

7



|01 Turbo Chargers (Assemblies)


|05 Heat Exchanger


|70 Pipes, Hoses, Ducting


J75 Brackets


|80 Boltings, Clamps, Misc Fastening

|99 Miscellaneous

|00 Engine & Vehicle Assembly


SUB-SUBSYSTEM ROLL-UP





















INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
2.0L 14, DOHC, Turbo Dl
BASE TECHNOLOGY PACKAGE COST INFORMATION
3.0L V6, DOHC, NA, PFI
Manufacturing
Material



$ 53.92

$ 8.16

$ 27.60

$ 1.07

$

$ 6.27

$ 1.14

$ 98.15
Labor



$ 29.21

$ 3.36

$ 9.09

$ 0.15

$

$ 0.34

$ 9.81

$ 51.97
Burden



$ 39.70

$ 6.65

$ 11.44

$ 0.39

$

$ 0.48

$ 14.72

$ 73.38
Total
Manufacturing
Cost
(Component/
Assembly)



$ 122.82

$ 1 8.1 7

$ 48.14

$ 1.61

$

$ 7.09

$ 25.67

$ 223.50
Markup
End Item
Scrap



$ 7.08

$ 0.09

$ 0.14

$ 0.00

$

$ 0.04

$

$ 7.36
SGSA



$ 16.00

$ 1.09

$ 2.89

$ 0.10

$

$ 0.54

$

$ 20.61
Profit



$ 17.15

$ 1.09

$ 1.93

$ 0.06

$

$ 0.48

$

$ 20.71
EDST-RSD



$ 6.73

$ 0.36

$ 0.48

$

$

$ 0.18

$

$ 7.75
Total Markup
Cost
(Component/
Assembly)



$ 46.96

$ 2.63

$ 5.44

$ 0.17

$

$ 1.24

$

$ 56.44
Total
Packaging
Cost
(Component/
Assembly)



$ 0.12

$ 0.11

$ 0.35

$ 0.06

$

$ 0.13

$

$ 0.76
Net
Component/
Assembly Cosl
Impact to OEM



$ 169.89

$ 20.92

$ 53.93

$ 1.83

$

$ 8.45

$ 25.67

$ 280.70
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                Apdx. C.1 Induct. Air Charging, Page: 39 of 48
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0102
                                                                                                                                                                       Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case*: 0102  ( N0102 New Technology Configuration)
                     ( B0102 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0117 Breather Subsystem

1

2

3

4

5

6

7

8

9

10

11



|02 Oil/Air Separator

|03 Valves

|65 Adapters

|70 Pipes, Hoses, Ducting

|75 Brackets

|60 Boltings

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine and Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP




























NEW TECHNOLOGY PACKAGE COST INFORMATION
2.0L 14, DOHC, Turbo Dl
Manufacturing
Material



$ 7.10

$

$

$ 2.00

$

$

$

$

$

$

$ 0.05

$ 9.14
Labor



$ 1.42

$

$

$ 0.40

$

$

$

$

$

$

$ 0.60

$ 2.42
Burden



$ 5.68

$

$

$ 1.60

$

$

$

$

$

$

$ 0.11

$ 7.38
Total
Cost
(Component/
Assembly)



$ 14.19

$

$

$ 3.99

$

$

$

$

$

$

$ 0.76

$ 18.94
Markup
End Item
Scrap



$ 0.05

$

$

$ 0.01

$

$

$

$

$

$

$

$ 0.06
SGSA



$ 0.96

$

$

$ 0.27

$

$

$

$

$

$

$

$ 1.23
Profit



$ 0.64

$

$

$ 0.18

$

$

$

$

$

$

$

$ 0.82
EDST-RSD



$ 0.16

$

$

$ 0.05

$

$

$

$

$

$

$

$ 0.21
Total Markup
Cost
(Component/
Assembly)



$ 1.81

$

$

$ 0.51

$

$

$

$

$

$

$

$ 2.32
Total
Packaging
Cost
(Component/
Assembly)



$ 0.05

$

$

$

$

$

$

$

$

$

$

$ 0.05
Net
Component/
Assembly Cosl
Impact to OEM



$ 16.05

$

$

$ 4.50

$

$

$

$

$

$

$ 0.76

$ 21.31
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                               Apdx. C.1 Breather, Page: 40 of 48
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0102
                                                                                                                                                                       Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case*: 0102  ( N0102 New Technology Configuration)
                     ( B0102 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0117 Breather Subsystem

1

2

3

4

5

6

7

8

9

10

11



|02 Oil/Air Separator

|03 Valves

|65 Adapters

|70 Pipes, Hoses, Ducting

|75 Brackets

|60 Boltings

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine and Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP




























BASE TECHNOLOGY PACKAGE COST INFORMATION
3.0L V6, DOHC, NA, PR
Manufacturing
Material



$ 0.67

$

$ 0.50

$

$

$

$

$

$

$

$ 0.05

$ 1.21
Labor



$ 0.13

$

$

$

$

$

$

$

$

$

$ 0.30

$ 0.43
Burden



$ 0.53

$

$

$

$

$

$

$

$

$

$ 0.05

$ 0.59
Total
Cost
(Component/
Assembly)



$ 1.33

$

$ 0.50

$

$

$

$

$

$

$

$ 0.40

$ 2.23
Markup
End Item
Scrap



$ 0.00

$

$

$

$

$

$

$

$

$

$

$ 0.00
SGSA



$ 0.09

$

$

$

$

$

$

$

$

$

$

$ 0.09
Profit



$ 0.06

$

$

$

$

$

$

$

$

$

$

$ 0.06
EDST-RSD



$ 0.02

$

$

$

$

$

$

$

$

$

$

$ 0.02
Total Markup
Cost
(Component/
Assembly)



$ 0.17

$

$

$

$

$

$

$

$

$

$

$ 0.17
Total
Packaging
Cost
(Component/
Assembly)



$ 0.02

$

$

$

$

$

$

$

$

$

$

$ 0.02
Net
Component/
Assembly Cosl
Impact to OEM



$ 1.52

$

$ 0.50

$

$

$

$

$

$

$

$ 0.40

$ 2.42
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                               Apdx. C.1 Breather, Page: 41 of 48
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                        APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                CASE STUDY #0102
                                                                                                                                             Printed: 3/2 6/2010


Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
Study Case*: 0102 ( N0102 New Technology Configuration)
( B0102 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

Sub-Subsystem

Sub-Subsystem Description

0117 Breather Subsystem

1

2

3

4

5

6

7

8

9

10

11



(02 Oil/Air Separator


J03 Valves


J65 Adapters


|70 Pipes, Hoses, Ducting


J75 Brackets


|so Boltings

(85 Sealing Elements


|90 Bearing Elements


J95 Tools


|99 Miscellaneous

|00 Engine and Vehicle Assembly


SUB-SUBSYSTEM ROLL-UP





























INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
2.0L 14, DOHC, Turbo Dl
BASE TECHNOLOGY PACKAGE COST INFORMATION
3.0L V6, DOHC, NA, PFI
Manufacturing
Material



$ 6.43

$

$ (0.50J

$ 2.00

$

$

$

$

$

$

$

$ 7.93
Labor



$ 1.29

$

$

$ 0.40

$

$

$

$

$

$

$ 0.30

$ 1.99
Burden



$ 5.14

$

$

$ 1.60

$

$

$

$

$

$

$ 0.05

$ 6.80
Total
Manufacturing
Cost
(Component/
Assembly)



$ 12.86

$

$ (0.50)

$ 3.99

$

$

$

$

$

$

$ 0.36

$ 16.71
Markup
End Item
Scrap



$ 0.04

$

$

$ 0.01

$

$

$

$

$

$

$

$ 0.06
SGSA



$ 0.87

$

$

$ 0.27

$

$

$

$

$

$

$

$ 1.14
Profit



$ 0.58

$

$

$ 0.18

$

$

$

$

$

$

$

$ 0.76
EDST-RSD



$ 0.15

$

$

$ 0.05

$

$

$

$

$

$

$

$ 0.19
Total Markup
Cost
(Component/
Assembly)



$ 1.64

$

$

$ 0.51

$

$

$

$

$

$

$

$ 2.15
Total
Packaging
Cost
(Component/
Assembly)



$ 0.03

$

$

$

$

$

$

$

$

$

$

$ 0.03
Net
Component/
Assembly Cosl
Impact to OEM



$ 14.53

$

f (0.50)

$ 4.50

$

$

$

$

$

$

$ 0.36

$ 18.89
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                  Apdx. C.1 Breather, Page: 42 of 48
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.1 - SUBSYSTEM  COST MODEL ANALYSIS TEMPLATE
                                                                             CASE  STUDY #0102
                                                                                                                                                                         Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case*: 0102 ( N0102 New Technology Configuration)
                      ( B0102 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO




NEW TECHNOLOGY PACKAGE COST INFORMATION
2.0L 14, DOHC, Turbo Dl
Manufacturing
Material

Labor

Burden

Total
Manufacturing
Cost
(Component/
Assembly)

0160 Engine Management, Engine Electronic, and Electrical Subsystems

1

2

3

4

5

6

7

8

9

10

11

12



|01 Spark Plugs, Glow Plugs

|02 Engine Management Systems, Engine Electronic Systems






|03 Engine Electrical Systems (including Wiring Harnesses, Earth Straps, I

|65 Adapters

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine and Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP





















$ 2.70

$ 1 6.06

$ 32.50

$

$

$

$

$

$

$

$

$ 0.10

$ 51.36

$ 0.54

$ 3.21

$ 17.04

$

$

$

$

$

$

$

$

$ 1.20

$ 22.00

$ 2.16

$ 1 2.85

$ 23.06

$

$

$

$

$

$

$

$

$ 0.83

$ 38.90

$ 5.41

$ 32.1 2

$ 72.60

$

$

$

$

$

$

$

$

$ 2.13

$ 112.26
Markup
End Item
Scrap



$ 0.03

$ 0.28

$ 0.31

$

$

$

$

$

$

$

$

$

$ 0.62
SGSA



$ 0.42

$ 2.80

$ 4.89

$

$

$

$

$

$

$

$

$

$ 8.11
Profit



$ 0.38

$ 3.20

$ 3.88

$

$

$

$

$

$

$

$

$

$ 7.47
EDST-RSD



$ 0.16

$ 1.60

$ 1.35

$

$

$

$

$

$

$

$

$

$ 3.11
Total Markup
Cost
(Component/
Assembly)



$ 0.99

$ 7.88

$ 10.43

$

$

$

$

$

$

$

$

$

$ 19.30
Total
Packaging
Cost
(Component/
Assembly)



$

$

$ 0.07

$

$

$

$

$

$

$

$

$

$ 0.07
Net
Component/
Assembly Cosl
Impact to OEM



$ 6.40

$ 40.00

$ 83.11

$

$

$

$

$

$

$

$

$ 2.13

$ 131.64
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                            Apdx. C.1 Electronic-Electrical, Page: 43 of 48
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.1 - SUBSYSTEM  COST MODEL ANALYSIS TEMPLATE
                                                                             CASE  STUDY #0102
                                                                                                                                                                         Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case*: 0102 ( N0102 New Technology Configuration)
                      ( B0102 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
o>
-g Sub-Subsystem Description
CO
.a
CO




0160 Engine Management, Engine Electronic, and E

1

2

3

4

5

6

7

8

9

10

11

12



|01 Spark Plugs, Glow Plugs

|02 Engine Management Systems, Engine Electronic Systems






|03 Engine Electrical Systems (including Wiring Harnesses, Earth Straps,

|65 Adapters

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine and Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP




















BASE TECHNOLOGY PACKAGE COST INFORMATION
3.0L V6, DOHC, NA, PR
Manufacturing
Material



$ 2.54

$

$ 37.57

$

$

$

$

$

$

$

$

$ 0.10

$ 40.21
Labor



$ 0.51

$

$ 19.84

$

$

$

$

$

$

$

$

$ 2.87

$ 23.22
Burden



$ 2.03

$

$ 29.87

$

$

$

$

$

$

$

$

$ 0.91

$ 32.81
Total
Cost
(Component/
Assembly)



$ 5.07

$

$ 87.28

$

$

$

$

$

$

$

$

$ 3.88

$ 96.24
Markup
End Item
Scrap



$ 0.03

$

$ 0.39

$

$

$

$

$

$

$

$

$

$ 0.42
SGSA



$ 0.39

$

$ 5.95

$

$

$

$

$

$

$

$

$

$ 6.34
Profit



$ 0.36

$

$ 4.80

$

$

$

$

$

$

$

$

$

$ 5.16
EDST-RSD



$ 0.15

$

$ 1.70

$

$

$

$

$

$

$

$

$

$ 1.85
Total Markup
Cost
(Component/
Assembly)



$ 0.93

$

$ 12.84

$

$

$

$

$

$

$

$

$

$ 13.77
Total
Packaging
Cost
(Component/
Assembly)



$

$

$ 0.07

$

$

$

$

$

$

$

$

$

$ 0.07
Net
Component/
Assembly Cosl
Impact to OEM



$ 6.00

$

$ 100.19

$

$

$

$

$

$

$

$

$ 3.88

$ 110.07
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                            Apdx. C.1 Electronic-Electrical, Page: 44 of 48
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                         APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                  CASE STUDY #0102
                                                                                                                                                Printed: 3/2 6/2010

Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
Study Case*: 0102 ( N0102 New Technology Configuration)
( B0102 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO





0160 Engine Management, Engine Electronic, and E

1

2

3

4

5

6

7

8

9

10

11

12



|01 Spark Plugs, Glow Plugs

|02 Engine Management Systems, Engine Electronic Systems


0

0

|03 Engine Electrical Systems (including Wiring Harnesses, Earth Straps, o

|65 Adapters

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine and Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP

0

0

0

0

0

0

0

0

0


INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
2.0L 14, DOHC, Turbo Dl
BASE TECHNOLOGY PACKAGE COST INFORMATION
3.0L V6, DOHC, NA, PFI
Manufacturing
Material



$

$

$

$

$

$

$

$

$

$

$

$

$ -
Labor



$

$

$

$

$

$

$

$

$

$

$

$

$ -
Burden



$ 0.14

$ 1 2.85

$ (6.S1J

$

$

$

$

$

$

$

$

$ (0.08)

$ 6.09
Total
Manufacturing
Cost
(Component/
Assembly)



$ 0.34

$ 32.1 2

? (1 4.6SJ

$

$

$

$

$

$

$

$

$ (1.75)

$ 16.03
Markup
End Item
Scrap



$ 0.00

$ 0.28

f (0.08!

$

$

$

$

$

$

$

$

$

$ 0.21
SGSA



$ 0.03

$ 2.80

$ (1,06!

$

$

$

$

$

$

$

$

$

$ 1.76
Profit



$ 0.02

$ 3.20

$ (0.92)

$

$

$

$

$

$

$

$

$

$ 2.31
EDST-RSD



$ 0.01

$ 1.60

$ (0.36)

$

$

$

$

$

$

$

$

$

$ 1.25
Total Markup
Cost
(Component/
Assembly)



$ 0.06

$ 7.88

$ (2.41)

$

$

$

$

$

$

$

$

$

$ 5.53
Total
Packaging
Cost
(Component/
Assembly)



$

$

$ 0.01

$

$

$

$

$

$

$

$

$

$ 0.01
Net
Component/
Assembly Cosl
Impact to OEM



$ 0.40

$ 40.00

f (17.08!

$

$

$

$

$

$

$

$

$ (1.75)

$ 21.57
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                 Apdx. C.1 Electronic-Electrical, Page: 45 of 48
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0102
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case*: 0102  ( N0102 New Technology Configuration)
                     ( B0102 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO




NEW TECHNOLOGY PACKAGE COST INFORMATION
2.0L 14, DOHC, Turbo Dl
Manufacturing
Material

Labor

Burden

Total
Manufacturing
Cost
(Component/
Assembly)

Markup
End Item
Scrap

0170 Accessory Subsystem (Starter Motor, Alternators, Power Steering Pumps, etc)

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17



|01 Starter Motors

|02 Alternators

|03 Power Steering Pumps

|04 Vacuum Pumps

|05 Air Conditioning Compressors

|06 Hydraulic Pumps

|07 Ventilator

|10 Other Accessories

|65 Adapters

|70 Pipes, Hoses, Ducting

|75 Brackets

|60 Boltings

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine & Vehicle Assembly of Accessory Components

SUB-SUBSYSTEM ROLL-UP





































$

$

$

$ 3.31

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.13

$ 3.44

$

$

$

$ 1.81

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.74

$ 2.55

$

$

$

$ 6.11

$

$

$

$

$

$

$

$

$

$

$

$

$ 1.34

$ 7.45

$

$

$

$ 1 1 .24

$

$

$

$

$

$

$

$

$

$

$

$

$ 2.20

$ 13.45

$

$

$

$ 0.09

$

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.09
SGSA



$

$

$

$ 1.35

$

$

$

$

$

$

$

$

$

$

$

$

$

$ 1.35
Profit



$

$

$

$ 1.10

$

$

$

$

$

$

$

$

$

$

$

$

$

$ 1.10
EDST-RSD



$

$

$

$ 0.30

$

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.30
Total Markup
Cost
(Component/
Assembly)



$

$

$

$ 2.84

$

$

$

$

$

$

$

$

$

$

$

$

$

$ 2.84
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$ 0.09

$

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.09
Net
Component/
Assembly Cosl
Impact to OEM



$

$

$

$ 14.18

$

$

$

$

$

$

$

$

$

$

$

$

$ 2.20

$ 16.38
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                              Apdx. C.1 Accessory, Page: 46 of 48
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0102
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case*: 0102  ( N0102 New Technology Configuration)
                     ( B0102 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

01 70 Accessory Subsystem (Starter Motor, Alternat

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17



|01 Starter Motors

|02 Alternators

|03 Power Steering Pumps

|04 Vacuum Pumps

|05 Air Conditioning Compressors

|06 Hydraulic Pumps

|07 Ventilator

|10 Other Accessories

|65 Adapters

|70 Pipes, Hoses, Ducting

|75 Brackets

|60 Boltings

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine & Vehicle Assembly of Accessory Components

SUB-SUBSYSTEM ROLL-UP








































BASE TECHNOLOGY PACKAGE COST INFORMATION
3.0L V6, DOHC, NA, PR
Manufacturing
Material



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
Labor



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Burden



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Total
Manufacturing
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Markup
End Item
Scrap



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
SGSA



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Profit



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
EDST-RSD



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Net
Component/
Assembly Cosl
Impact to OEM



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                              Apdx. C.1 Accessory, Page: 47 of 48
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                        APPENDIX C.1 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                 CASE STUDY #0102
                                                                                                                                             Printed: 3/2 6/2010

Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
Vehicle Class: 02-Mid to Large Size Passenger Vehicle, 4-6 Passengers
Study Case*: 0102 ( N0102 New Technology Configuration)
( B0102 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

01 70 Accessory Subsystem (Starter Motor, Alternat

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17



|01 Starter Motors

|02 Alternators

|03 Power Steering Pumps

|04 Vacuum Pumps

|05 Air Conditioning Compressors

|06 Hydraulic Pumps

|07 Ventilator

|10 Other Accessories

|65 Adapters

|70 Pipes, Hoses, Ducting

|75 Brackets

|60 Boltings

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine & Vehicle Assembly of Accessory Components

SUB-SUBSYSTEM ROLL-UP









































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
2.0L 14, DOHC, Turbo Dl
BASE TECHNOLOGY PACKAGE COST INFORMATION
3.0L V6, DOHC, NA, PFI
Manufacturing
Material



$

$

$

$ 3.31

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.13

$ 3.44
Labor



$

$

$

$ 1.81

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.74

$ 2.55
Burden



$

$

$

$ 6.11

$

$

$

$

$

$

$

$

$

$

$

$

$ 1.34

$ 7.45
Total
Manufacturing
Cost
(Component/
Assembly)



$

$

$

$ 1 1 .24

$

$

$

$

$

$

$

$

$

$

$

$

$ 2.20

$ 13.45
Markup
End Item
Scrap



$

$

$

$ 0.09

$

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.09
SGSA



$

$

$

$ 1.35

$

$

$

$

$

$

$

$

$

$

$

$

$

$ 1.35
Profit



$

$

$

$ 1.10

$

$

$

$

$

$

$

$

$

$

$

$

$

$ 1.10
EDST-RSD



$

$

$

$ 0.30

$

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.30
Total Markup
Cost
(Component/
Assembly)



$

$

$

$ 2.84

$

$

$

$

$

$

$

$

$

$

$

$

$

$ 2.84
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$ 0.09

$

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.09
Net
Component/
Assembly Cosl
Impact to OEM



$

$

$

$ 14.18

$

$

$

$

$

$

$

$

$

$

$

$

$ 2.20

$ 16.38
File: Subsystem CMAT, CS0102, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                  Apdx. C.1 Accessory, Page: 48 of 48
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0104
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
        Study Case*: 0104  ( N0104 New Technology Configuration)
                     ( B0104 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0103 Crank Drive Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15




|01 Crank Shaft

|02 Flywheels

|03 Connect Rods (Assemblies: Connecting Rod, Connecting Rod Cap)

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

|05 Drive for Accessory Drives (Downforce, Flywheel side)

|06 Drive for Timing Drive (Downforce, Flywheel side)

1 65 Adaptors

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings: Connecting-Rod Bolts

|85 Sealing Elements

h Bearing Elements: Connecting Rod Bearing Shells, Connecting Rod
Bush

|95 Tools

|99 Miscellaneous

|00 Engine & Vehicle Assembly


SUB-SUBSYSTEM ROLL-UP





































NEW TECHNOLOGY PACKAGE COST INFORMATION
3.5L.V6 DOHC, Turbo Dl
Manufacturing
Material



$ 36.62

$

$ 8.24

$ 8.53

$

$

$

$

$

$

$

$

$

$

$ 17.28


$ 70.67
Labor



$ 11.49

$

$ 9.60

$ 8.48

$

$

$

$

$

$

$

$

$

$

$ 3.61


$ 33.19
Burden



$ 38.17

$

$ 24.14

$ 28.47

$

$

$

$

$

$

$

$

$

$

$ 5.96


$ 96.75
Total
Cost
(Component/
Assembly)



$ 86.29

$

$ 41.99

$ 45.48

$

$

$

$

$

$

$

$

$

$

$ 26.85


$ 200.61
Markup
End Item
Scrap



$ 0.31

$

$ 0.21

$ 1.70

$

$

$

$

$

$

$

$

$

$

$


$ 2.22
SGSA



$ 3.11

$

$ 2.73

$ 3.02

$

$

$

$

$

$

$

$

$

$

$


$ 8.86
Profit



$ 3.56

$

$ 2.52

$ 2.70

$

$

$

$

$

$

$

$

$

$

$


$ 8.78
EDST-RSD



$ 0.89

$

$ 1.05

$ 1.09

$

$

$

$

$

$

$

$

$

$

$


$ 3.02
Total Markup
Cost
(Component/
Assembly)



$ 7.87

$

$ 6.51

$ 8.50

$

$

$

$

$

$

$

$

$

$

$


$ 22.88
Total
Packaging
Cost
(Component/
Assembly)



$ 0.14

$

$ 0.11

$ 0.58

$

$

$

$

$

$

$

$

$

$

$


$ 0.83
Net
Component/
Assembly Cosl
Impact to OEM



$ 94.30

$

$ 48.60

$ 54.56

$

$

$

$

$

$

$

$

$

$

$ 26.85


$ 224.31
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                              Apdx. C.2 Crank Drive, Page: 1 of 45
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0104
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
        Study Case*: 0104  ( N0104 New Technology Configuration)
                     ( B0104 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0103 Crank Drive Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15




|01 Crank Shaft

|02 Flywheels

|03 Connect Rods (Assemblies: Connecting Rod, Connecting Rod Cap)

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

|05 Drive for Accessory Drives (Downforce, Flywheel side)

|06 Drive for Timing Drive (Downforce, Flywheel side)

1 65 Adaptors

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings: Connecting-Rod Bolts

|85 Sealing Elements

h Bearing Elements: Connecting Rod Bearing Shells, Connecting Rod
Bush

|95 Tools

|99 Miscellaneous

|00 Engine & Vehicle Assembly


SUB-SUBSYSTEM ROLL-UP





































BASE TECHNOLOGY PACKAGE COST INFORMATION
5.4L V8, SOHC, NA, PR
Manufacturing
Material



$ 42.06

$

$ 10.79

$ 9.55

$

$

$

$

$

$

$

$

$

$

$ 13.36


$ 75.77
Labor



$ 11.69

$

$ 12.80

$ 10.38

$

$

$

$

$

$

$

$

$

$

$ 3.61


$ 38.48
Burden



$ 43.58

$

$ 32.19

$ 27.53

$

$

$

$

$

$

$

$

$

$

$ 5.96


$ 109.25
Total
Cost
(Component/
Assembly)



$ 97.32

$

$ 55.78

$ 47.46

$

$

$

$

$

$

$

$

$

$

$ 22.93


$ 223.50
Markup
End Item
Scrap



$ 0.36

$

$ 0.28

$ 0.79

$

$

$

$

$

$

$

$

$

$

$


$ 1.43
SGSA



$ 3.61

$

$ 3.63

$ 3.08

$

$

$

$

$

$

$

$

$

$

$


$ 10.32
Profit



$ 4.12

$

$ 3.35

$ 2.73

$

$

$

$

$

$

$

$

$

$

$


$ 10.20
EDST-RSD



$ 1.03

$

$ 1.39

$ 1.09

$

$

$

$

$

$

$

$

$

$

$


$ 3.51
Total Markup
Cost
(Component/
Assembly)



$ 9.12

$

$ 8.65

$ 7.69

$

$

$

$

$

$

$

$

$

$

$


$ 25.46
Total
Packaging
Cost
(Component/
Assembly)



$ 0.14

$

$ 0.14

$ 0.77

$

$

$

$

$

$

$

$

$

$

$


$ 1.06
Net
Component/
Assembly Cosl
Impact to OEM



$ 106.59

$

$ 64.57

$ 55.92

$

$

$

$

$

$

$

$

$

$

$ 22.93


$ 250.01
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                              Apdx. C.2 Crank Drive, Page: 2 of 45
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                        APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                CASE STUDY #0104
                                                                                                                                             Printed: 3/2 6/2010

Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
Study Case*: 0104 ( N0104 New Technology Configuration)
( B0104 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0103 Crank Drive Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15




|01 Crank Shaft

|02 Flywheels

|03 Connect Rods (Assemblies: Connecting Rod, Connecting Rod Cap)

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

|05 Drive for Accessory Drives (Downforce, Flywheel side)

|06 Drive for Timing Drive (Downforce, Flywheel side)

1 65 Adaptors

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings: Connecting-Rod Bolts

|85 Sealing Elements

h Bearing Elements: Connecting Rod Bearing Shells, Connecting Rod
Bush

|95 Tools

|99 Miscellaneous

|00 Engine & Vehicle Assembly


SUB-SUBSYSTEM ROLL-UP






































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
3.5L.V6 DOHC, Turbo Dl
BASE TECHNOLOGY PACKAGE COST INFORMATION
5.4L V8, SOHC, NA, PFI
Manufacturing
Material



$ (5.44)

$

$ {2,55}

$ {1.03)

$

$

$

$

$

$

$

$

$

$

$ 3.92


$ (5,10)
Labor



$ J0.20S

$

$ J3.20J

$ (1.90)

$

$

$

$

$

$

$

$

$

$

$


$ (5,29)
Burden



$ (5.40)

$

$ (8.05)

$ 0.95

$

$

$

$

$

$

$

$

$

$

$


$ (12,50)
Total
Manufacturing
Cost
(Component/
Assembly)



$ (11.04)

$

f (1 3.SOJ

$ (1.^8)

$

$

$

$

$

$

$

$

$

$

$ 3.92


$ (22,89)
Markup
End Item
Scrap



f, (0.05)

$

$ (0.07)

$ 0.91

$

$

$

$

$

$

$

$

$

$

$


$ 0.79
SGSA



$ J0.49)

$

$ (0.90)

$ (0.06)

$

$

$

$

$

$

$

$

$

$

$


$ (1,45)
Profit



$ (0.57)

$

$ (0.83)

$ J0.03)

$

$

$

$

$

$

$

$

$

$

$


$ (1,43)
EDST-RSD



$ (0.14)

$

$ (0.34)

$ JO.OO)

$

$

$

$

$

$

$

$

$

$

$


$ (0,49)
Total Markup
Cost
(Component/
Assembly)



$ 1*1.25)

$

$ (2.14)

$ 0.81

$

$

$

$

$

$

$

$

$

$

$


$ (2,58)
Total
Packaging
Cost
(Component/
Assembly)



$

$

$ J0.04J

$ 1*0.1 V,

$

$

$

$

$

$

$

$

$

$

$


$ (0,23)
Net
Component/
Assembly Cosl
Impact to OEM



$ (12.29)

$

$ (15.97)

$ (1.36)

$

$

$

$

$

$

$

$

$

$

$ 3.92


$ (25,70)
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                  Apdx. C.2 Crank Drive, Page: 3 of 45
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0104
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
        Study Case*: 0104  ( N0104 New Technology Configuration)
                     ( B0104 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0105 Cylinder Block Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15



I 01 Cylinder Block

I 02 Crankshaft Bearing Caps

I 03 Bedplates

I 04 Piston Cooling

I 65 Crankcase Adaptor

I 66 Water Jacket

I 67 Cylinder Barrel

I 70 Pipes, Hoses, Ducting

I 75 Brackets

I 80 Boltings/Dowel Pins/Plugs/Studs Etc

I 85 Sealing Elements

I 90 Bearing Elements: Crankshaft bearing shells

I 95 Tools

I 99 Miscellaneous

| 00 Engine & Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP




































NEW TECHNOLOGY PACKAGE COST INFORMATION
3.5L.V6 DOHC, Turbo Dl
Manufacturing
Material



$ 79.42

$ 4.21

$

$ 3.90

$

$

$

$

$

$

$

$

$

$ 4.11

$ 13.94

$ 105.58
Labor



$ 13.23

$ 1.81

$

$ 0.96

$

$

$

$

$

$

$

$

$

$ 2.16

$ 3.61

$ 21.77
Burden



$ 109.26

$ 6.02

$

$ 5.42

$

$

$

$

$

$

$

$

$

$ 5.48

$ 2.20

$128.38
Total
Cost
(Component/
Assembly)



$ 201.91

$ 1 2.04

$

$ 1 0.28

$

$

$

$

$

$

$

$

$

$ 1 1 .74

$ 19.75

$ 255.72
Markup
End Item
Scrap



$ 6.98

$ 0.01

$

$ 0.06

$

$

$

$

$

$

$

$

$

$ 0.06

$

$ 7.11
SGSA



$ 9.68

$ 0.91

$

$ 1.30

$

$

$

$

$

$

$

$

$

$ 0.76

$

$ 12.65
Profit



$ 10.81

$ 0.84

$

$ 0.86

$

$

$

$

$

$

$

$

$

$ 0.70

$

$ 13.21
EDST-RSD



$ 2.61

$ 0.14

$

$

$

$

$

$

$

$

$

$

$

$ 0.29

$

$ 3.04
Total Markup
Cost
(Component/
Assembly)



$ 30.08

$ 1.90

$

$ 2.23

$

$

$

$

$

$

$

$

$

$ 1.82

$

$ 36.02
Total
Packaging
Cost
(Component/
Assembly)



$ 0.57

$ 0.12

$

$ 0.06

$

$

$

$

$

$

$

$

$

$ 0.05

$

$ 0.80
Net
Component/
Assembly Cosl
Impact to OEM



$ 232.56

$ 1 4.06

$

$ 1 2.56

$

$

$

$

$

$

$

$

$

$ 1 3.61

$ 19.75

$ 292.55
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                              Apdx. C.2 Cylinder Block, Page: 4 of 45
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0104
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
        Study Case*: 0104  ( N0104 New Technology Configuration)
                     ( B0104 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0105 Cylinder Block Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15



I 01 Cylinder Block

I 02 Crankshaft Bearing Caps

I 03 Bedplates

I 04 Piston Cooling

I 65 Crankcase Adaptor

I 66 Water Jacket

I 67 Cylinder Barrel

I 70 Pipes, Hoses, Ducting

I 75 Brackets

I 80 Boltings/Dowel Pins/Plugs/Studs Etc

I 85 Sealing Elements

I 90 Bearing Elements: Crankshaft bearing shells

I 95 Tools

I 99 Miscellaneous

| 00 Engine & Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP




































BASE TECHNOLOGY PACKAGE COST INFORMATION
5.4L V8, SOHC, NA, PR
Manufacturing
Material



$ 71.51

$ 4.21

$

$

$

$

$

$

$

$

$

$

$

$ 5.41

$ 14.89

$ 96.03
Labor



$ 13.88

$ 1.81

$

$

$

$

$

$

$

$

$

$

$

$ 2.37

$ 1.81

$ 19.85
Burden



$ 150.31

$ 6.02

$

$

$

$

$

$

$

$

$

$

$

$ 5.80

$ 2.38

$164.51
Total
Cost
(Component/
Assembly)



$ 235.70

$ 1 2.04

$

$

$

$

$

$

$

$

$

$

$

$ 1 3.58

$ 19.08

$ 280.40
Markup
End Item
Scrap



$ 7.03

$ 0.01

$

$

$

$

$

$

$

$

$

$

$

$ 0.07

$

$ 7.10
SGSA



$ 9.84

$ 0.91

$

$

$

$

$

$

$

$

$

$

$

$ 0.88

$

$ 11.63
Profit



$ 11.25

$ 0.84

$

$

$

$

$

$

$

$

$

$

$

$ 0.81

$

$ 12.90
EDST-RSD



$ 2.81

$ 0.14

$

$

$

$

$

$

$

$

$

$

$

$ 0.34

$

$ 3.29
Total Markup
Cost
(Component/
Assembly)



$ 30.93

$ 1.90

$

$

$

$

$

$

$

$

$

$

$

$ 2.10

$

$ 34.93
Total
Packaging
Cost
(Component/
Assembly)



$ 1.29

$ 0.12

$

$

$

$

$

$

$

$

$

$

$

$ 0.05

$

$ 1.46
Net
Component/
Assembly Cosl
Impact to OEM



$ 267.92

$ 1 4.06

$

$

$

$

$

$

$

$

$

$

$

$ 1 5.73

$ 19.08

$ 316.79
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                              Apdx. C.2 Cylinder Block, Page: 5 of 45
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                        APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                 CASE STUDY #0104
                                                                                                                                             Printed: 3/2 6/2010

Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
Study Case*: 0104 ( N0104 New Technology Configuration)
( B0104 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0105 Cylinder Block Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15



I 01 Cylinder Block

I 02 Crankshaft Bearing Caps

I 03 Bedplates

I 04 Piston Cooling

I 65 Crankcase Adaptor

I 66 Water Jacket

I 67 Cylinder Barrel

I 70 Pipes, Hoses, Ducting

I 75 Brackets

I 80 Boltings/Dowel Pins/Plugs/Studs Etc

I 85 Sealing Elements

I 90 Bearing Elements: Crankshaft bearing shells

I 95 Tools

I 99 Miscellaneous

| 00 Engine & Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP





































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
3.5L.V6 DOHC, Turbo Dl
BASE TECHNOLOGY PACKAGE COST INFORMATION
5.4L V8, SOHC, NA, PFI
Manufacturing
Material



$ 7.91

$

$

$ 3.90

$

$

$

$

$

$

$

$

$

1 (1.31)

$ (0.95!

$ 9.55
Labor



$ (0.65J

$

$

$ 0.96

$

$

$

$

$

$

$

$

$

$ (0,21)

$ 1.81

$ 1.91
Burden



$ (41.05)

$

$

$ 5.42

$

$

$

$

$

$

$

$

$

t (0.32)

$ (0.1 8)

$ (36,13)
Total
Manufacturing
Cost
(Component/
Assembly)



$ (33.79)

$

$

$ 1 0.28

$

$

$

$

$

$

$

$

$

$ (1,83)

$ 0.67

$ (24,6?)
Markup
End Item
Scrap



$ (0.05)

$

$

$ 0.06

$

$

$

$

$

$

$

$

$

$ (0,01)

$

$ 0.01
SGSA



$ (0.16)

$

$

$ 1.30

$

$

$

$

$

$

$

$

$

$ (0.12)

$

$ 1.02
Profit



$ (0.44)

$

$

$ 0.86

$

$

$

$

$

$

$

$

$

$ (0.11)

$

$ 0.31
EDST-RSD



$ (0.20)

$

$

$

$

$

$

$

$

$

$

$

$

t (0.05)

$

$ (0,25)
Total Markup
Cost
(Component/
Assembly)



$ (0.85)

$

$

$ 2.23

$

$

$

$

$

$

$

$

$

t (0,28)

$

$ 1.09
Total
Packaging
Cost
(Component/
Assembly)



$ (0.72)

$

$

$ 0.06

$

$

$

$

$

$

$

$

$

$ 0.00

$

$ (0,66)
Net
Component/
Assembly Cosl
Impact to OEM



$ (35.36!

$

$

$ 1 2.56

$

$

$

$

$

$

$

$

$

t (2,12)

$ 0.67

$ (24,24)
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                 Apdx. C.2 Cylinder Block, Page: 6 of 45
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0104
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
        Study Case*: 0104  ( N0104 New Technology Configuration)
                     ( B0104 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0106 Cylinder Head Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17



|01 Cylinder Head

|02 Valve Guides. Valve Seats

|03 Guides for Valve Train

|06 Camshaft Bearing Housing

|07 Cam Shaft Speed Sensor

|08 Camshaft Carrier

|09 Other Parts for Cylinder Head

|20 Cylinder Head Covers

|65 Adapter

|70 Pipes

|75 Brackets

|60 Boltings: Cylinder Head, Cylinder Head Cover, Manifold

|85 Sealing Elements: Cylinder Head, Cylinder Head Cover, ....

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Vehicle and Engine Assembly

SUB-SUBSYSTEM ROLL-UP








































NEW TECHNOLOGY PACKAGE COST INFORMATION
3.5L.V6 DOHC, Turbo Dl
Manufacturing
Material



$ 96.49

$

$

$

$

$

$

$ 23.17

$

$

$

$

$

$

$

$

$ 48.16

$ 167.82
Labor



$ 23.78

$

$

$

$

$

$

$ 4.08

$

$

$

$

$

$

$

$

$ 4.21

$ 32.07
Burden



$ 170.58

$

$

$

$

$

$

$ 1 4.48

$

$

$

$

$

$

$

$

$ 19.36

$ 204.42
Total
Cost
(Component/
Assembly)



$ 290.85

$

$

$

$

$

$

$ 41 .73

$

$

$

$

$

$

$

$

$ 71.73

$ 404.31
Markup
End Item
Scrap



$ 7.16

$

$

$

$

$

$

$ 0.21

$

$

$

$

$

$

$

$

$

$ 7.37
SGSA



$ 10.02

$

$

$

$

$

$

$ 2.71

$

$

$

$

$

$

$

$

$

$ 12.73
Profit



$ 11.45

$

$

$

$

$

$

$ 2.50

$

$

$

$

$

$

$

$

$

$ 13.96
EDST-RSD



$ 2.86

$

$

$

$

$

$

$ 1.04

$

$

$

$

$

$

$

$

$

$ 3.91
Total Markup
Cost
(Component/
Assembly)



$ 31.50

$

$

$

$

$

$

$ 6.47

$

$

$

$

$

$

$

$

$

$ 37.96
Total
Packaging
Cost
(Component/
Assembly)



$ 0.54

$

$

$

$

$

$

$ 0.32

$

$

$

$

$

$

$

$

$

$ 0.86
Net
Component/
Assembly Cosl
Impact to OEM



$ 322.89

$

$

$

$

$

$

$ 48.51

$

$

$

$

$

$

$

$

$ 71.73

$ 443.13
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                              Apdx. C.2 Cylinder Head, Page: 7 of 45
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0104
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
        Study Case*: 0104  ( N0104 New Technology Configuration)
                     ( B0104 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0106 Cylinder Head Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17



|01 Cylinder Head

|02 Valve Guides. Valve Seats

|03 Guides for Valve Train

|06 Camshaft Bearing Housing

|07 Cam Shaft Speed Sensor

|08 Camshaft Carrier

|09 Other Parts for Cylinder Head

|20 Cylinder Head Covers

|65 Adapter

|70 Pipes

|75 Brackets

|60 Boltings: Cylinder Head, Cylinder Head Cover, Manifold

|85 Sealing Elements: Cylinder Head, Cylinder Head Cover, ....

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Vehicle and Engine Assembly

SUB-SUBSYSTEM ROLL-UP








































BASE TECHNOLOGY PACKAGE COST INFORMATION
5.4L V8, SOHC, NA, PR
Manufacturing
Material



$ 105.91

$

$

$

$

$

$

$ 25.94

$

$

$

$

$

$

$

$

$ 38.46

$ 170.31
Labor



$ 23.24

$

$

$

$

$

$

$ 3.47

$

$

$

$

$

$

$

$

$ 3.61

$ 30.32
Burden



$ 160.50

$

$

$

$

$

$

$ 1 4.22

$

$

$

$

$

$

$

$

$ 19.25

$ 193.96
Total
Cost
(Component/
Assembly)



$ 289.66

$

$

$

$

$

$

$ 43.62

$

$

$

$

$

$

$

$

$ 61.32

$ 394.60
Markup
End Item
Scrap



$ 7.81

$

$

$

$

$

$

$ 0.23

$

$

$

$

$

$

$

$

$

$ 8.04
SGSA



$ 10.93

$

$

$

$

$

$

$ 2.98

$

$

$

$

$

$

$

$

$

$ 13.91
Profit



$ 12.49

$

$

$

$

$

$

$ 2.75

$

$

$

$

$

$

$

$

$

$ 15.24
EDST-RSD



$ 3.12

$

$

$

$

$

$

$ 1.15

$

$

$

$

$

$

$

$

$

$ 4.27
Total Markup
Cost
(Component/
Assembly)



$ 34.35

$

$

$

$

$

$

$ 7.11

$

$

$

$

$

$

$

$

$

$ 41.46
Total
Packaging
Cost
(Component/
Assembly)



$ 0.54

$

$

$

$

$

$

$ 0.33

$

$

$

$

$

$

$

$

$

$ 0.86
Net
Component/
Assembly Cosl
Impact to OEM



$ 324.54

$

$

$

$

$

$

$ 51.06

$

$

$

$

$

$

$

$

$ 61.32

$ 436.92
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                              Apdx. C.2 Cylinder Head, Page: 8 of 45
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                        APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                 CASE STUDY #0104
                                                                                                                                             Printed: 3/2 6/2010

Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
Study Case*: 0104 ( N0104 New Technology Configuration)
( B0104 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0106 Cylinder Head Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17



|01 Cylinder Head

|02 Valve Guides. Valve Seats

|03 Guides for Valve Train

|06 Camshaft Bearing Housing

|07 Cam Shaft Speed Sensor

|08 Camshaft Carrier

|09 Other Parts for Cylinder Head

|20 Cylinder Head Covers

|65 Adapter

|70 Pipes

|75 Brackets

|60 Boltings: Cylinder Head, Cylinder Head Cover, Manifold

|85 Sealing Elements: Cylinder Head, Cylinder Head Cover, ....

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Vehicle and Engine Assembly

SUB-SUBSYSTEM ROLL-UP









































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
3.5L.V6 DOHC, Turbo Dl
BASE TECHNOLOGY PACKAGE COST INFORMATION
5.4L V8, SOHC, NA, PFI
Manufacturing
Material



$ (9.42)

$

$

$

$

$

$

$ (2,77)

$

$

$

$

$

$

$

$

$ 9.70

$ (2,50)
Labor



$ 0.53

$

$

$

$

$

$

$ 0.61

$

$

$

$

$

$

$

$

$ 0.60

$ 1.75
Burden



$ 10.08

$

$

$

$

$

$

$ 0.26

$

$

$

$

$

$

$

$

$ 0.11

$ 10.46
Total
Manufacturing
Cost
(Component/
Assembly)



$ 1.19

$

$

$

$

$

$

$ (1.90)

$

$

$

$

$

$

$

$

$ 10.41

$ 9.71
Markup
End Item
Scrap



$ (0,85)

$

$

$

$

$

$

$ (0,02)

$

$

$

$

$

$

$

$

$

$ (0,67)
SGSA



$ (0.91)

$

$

$

$

$

$

$ (0,27)

$

$

$

$

$

$

$

$

$

$ (1,18)
Profit



$ (1 .04)

$

$

$

$

$

$

$ (0,25)

$

$

$

$

$

$

$

$

$

$ (1,29)
EDST-RSD



$ (0.26)

$

$

$

$

$

$

$ (0,10)

$

$

$

$

$

$

$

$

$

$ (0,36)
Total Markup
Cost
(Component/
Assembly)



$ (2.85)

$

$

$

$

$

$

$ (0,64)

$

$

$

$

$

$

$

$

$

$ (3,50)
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$ (0,01)

$

$

$

$

$

$

$

$

$

$ (0,01)
Net
Component/
Assembly Cosl
Impact to OEM



$ (1 .88)

$

$

$

$

$

$

$ (2.SS)

$

$

$

$

$

$

$

$

$ 10.41

$ 6.21
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                 Apdx. C.2 Cylinder Head, Page: 9 of 45
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0104
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
        Study Case*: 0104  ( N0104 New Technology Configuration)
                     ( B0104 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0107 Valvetrain Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16



|01 Intake Valves

|02 Exhaust Valves

|03 Valve Springs

|04 Spring Retainers & Keepers, Spring Seats

t Valve Actuation Elements: Rockers, Finger Followers, Hydraulic
Lash Adjusters,...

|06 Camshafts

|08 Camshaft Phaser and/or Cam Sprockets

|65 Adapters

1 70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings

|85 Sealings: e.g. Valve-stem, Seals

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

lOO Engine and Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP






































NEW TECHNOLOGY PACKAGE COST INFORMATION
3.5L.V6 DOHC, Turbo Dl
Manufacturing
Material



$ 13.80

$ 39.00

$ 7.20

$

$ 19.20

$ 9.18

$ 25.31

$

$

$

$ 0.60

$

$

$

$ 7.94

$

$ 122.22
Labor



$

$

$

$

$

$ 8.50

$ 10.85

$

$

$

$

$

$

$

$ 4.76

$ 7.22

$ 31.33
Burden



$

$

$

$

$

$ 31.52

$ 36.15

$

$

$

$

$

$

$

$ 19.05

$ 25.73

$112.44
Total
Cost
(Component/
Assembly)



$ 13.80

$ 39.00

$ 7.20

$

$ 19.20

$ 49.20

$ 72.30

$

$

$

$ 0.60

$

$

$

$ 31.75

$ 32.95

$ 265.99
Markup
End Item
Scrap



$

$

$

$

$

$ 2.51

$ 0.36

$

$

$

$

$

$

$

$ 0.22

$

$ 3.09
SGSA



$

$

$

$

$

$ 5.15

$ 4.70

$

$

$

$

$

$

$

$ 2.22

$

$ 12.07
Profit



$

$

$

$

$

$ 4.75

$ 4.34

$

$

$

$

$

$

$

$ 2.54

$

$ 11.63
EDST-RSD



$

$

$

$

$

$ 1.61

$ 1.81

$

$

$

$

$

$

$

$ 1.27

$

$ 4.69
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$ 14.02

$ 11.21

$

$

$

$

$

$

$

$ 6.25

$

$ 31.48
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$ 0.16

$ 0.20

$

$

$

$

$

$

$

$ 0.16

$

$ 0.52
Net
Component/
Assembly Cosl
Impact to OEM



$ 13.80

$ 39.00

$ 7.20

$

$ 19.20

$ 63.38

$ 83.71

$

$

$

$ 0.60

$

$

$

$ 38.16

$ 32.95

$ 297.99
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                               Apdx. C.2 Valvetrain, Page: 10 of 45
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0104
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
        Study Case*: 0104  ( N0104 New Technology Configuration)
                     ( B0104 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0107 Valvetrain Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16



|01 Intake Valves

|02 Exhaust Valves

|03 Valve Springs

|04 Spring Retainers & Keepers, Spring Seats

t Valve Actuation Elements: Rockers, Finger Followers, Hydraulic
Lash Adjusters,...

|06 Camshafts

|08 Camshaft Phaser and/or Cam Sprockets

|65 Adapters

1 70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings

|85 Sealings: e.g. Valve-stem, Seals

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

lOO Engine and Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP






































BASE TECHNOLOGY PACKAGE COST INFORMATION
5.4L V8, SOHC, NA, PR
Manufacturing
Material



$ 17.14

$ 25.64

$ 9.94

$

$ 108.00

$ 6.10

$ 12.58

$

$

$

$ 0.30

$

$

$

$ 3.97

$

$ 183.67
Labor



$

$

$

$

$

$ 6.16

$ 5.39

$

$

$

$

$

$

$

$ 2.38

$ 4.81

$ 18.74
Burden



$

$

$

$

$

$ 28.74

$ 17.97

$

$

$

$

$

$

$

$ 9.52

$ 1 4.08

$ 70.32
Total
Cost
(Component/
Assembly)



$ 17.14

$ 25.64

$ 9.94

$

$ 108.00

$ 41 .00

$ 35.94

$

$

$

$ 0.30

$

$

$

$ 15.87

$ 18.90

$ 272.73
Markup
End Item
Scrap



$

$

$

$

$

$ 0.34

$ 0.18

$

$

$

$

$

$

$

$ 0.11

$

$ 0.63
SGSA



$

$

$

$

$

$ 4.42

$ 2.34

$

$

$

$

$

$

$

$ 1.11

$

$ 7.87
Profit



$

$

$

$

$

$ 4.08

$ 2.16

$

$

$

$

$

$

$

$ 1.27

$

$ 7.50
EDST-RSD



$

$

$

$

$

$ 1.34

$ 0.90

$

$

$

$

$

$

$

$ 0.63

$

$ 2.88
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$ 10.18

$ 5.57

$

$

$

$

$

$

$

$ 3.13

$

$ 18.88
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$ 0.09

$ 0.10

$

$

$

$

$

$

$

$ 0.08

$

$ 0.27
Net
Component/
Assembly Cosl
Impact to OEM



$ 17.14

$ 25.64

$ 9.94

$

$ 108.00

$ 51.27

$ 41.61

$

$

$

$ 0.30

$

$

$

$ 19.08

$ 1 8.90

$ 291.87
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                               Apdx. C.2 Valvetrain, Page: 11 of 45
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                        APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                CASE STUDY #0104
                                                                                                                                             Printed: 3/2 6/2010

Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
Study Case*: 0104 ( N0104 New Technology Configuration)
( B0104 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0107 Valvetrain Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16



|01 Intake Valves

|02 Exhaust Valves

|03 Valve Springs

|04 Spring Retainers & Keepers, Spring Seats

t Valve Actuation Elements: Rockers, Finger Followers, Hydraulic
Lash Adjusters,...

|06 Camshafts

|08 Camshaft Phaser and/or Cam Sprockets

|65 Adapters

1 70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings

|85 Sealings: e.g. Valve-stem, Seals

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

lOO Engine and Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP







































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
3.5L.V6 DOHC, Turbo Dl
BASE TECHNOLOGY PACKAGE COST INFORMATION
5.4L V8, SOHC, NA, PFI
Manufacturing
Material



$ (3,34|

$ 1 3.36

$ (2.74)

$

$ (88.80!

$ 3.08

$ 12.73

$

$

$

$ 0.30

$

$

$

$ 3.97

$

$ (81,45)
Labor



$

$

$

$

$

$ 2.34

$ 5.45

$

$

$

$

$

$

$

$ 2.38

$ 2.41

$ 12.59
Burden



$

$

$

$

$

$ 2.78

$ 18.18

$

$

$

$

$

$

$

$ 9.52

$ 11.65

$ 42.13
Total
Manufacturing
Cost
(Component/
Assembly)



$ (3.34)

$ 1 3.36

? (2.74J

$

$ (88.80)

$ 8.20

$ 36.36

$

$

$

$ 0.30

$

$

$

$ 15.87

$ 1 4.05

$ (8,74)
Markup
End Item
Scrap



$

$

$

$

$

$ 2.17

$ 0.18

$

$

$

$

$

$

$

$ 0.11

$

$ 2.46
SGSA



$

$

$

$

$

$ 0.73

$ 2.36

$

$

$

$

$

$

$

$ 1.11

$

$ 4.20
Profit



$

$

$

$

$

$ 0.67

$ 2.18

$

$

$

$

$

$

$

$ 1.27

$

$ 4.12
EDST-RSD



$

$

$

$

$

$ 0.27

$ 0.91

$

$

$

$

$

$

$

$ 0.63

$

$ 1.81
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$ 3.83

$ 5.64

$

$

$

$

$

$

$

$ 3.13

$

$ 12.60
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$ 0.08

$ 0.10

$

$

$

$

$

$

$

$ 0.08

$

$ 0.26
Net
Component/
Assembly Cosl
Impact to OEM



$ (3.34)

$ 1 3.36

? (2.74!

$

$ (88.80)

$ 12.11

$ 42.10

$

$

$

$ 0.30

$

$

$

$ 19.08

$ 1 4.05

$ 6.12
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                  Apdx. C.2 Valvetrain, Page: 12 of 45
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0104
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
        Study Case*: 0104  ( N0104 New Technology Configuration)
                     ( B0104 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0108 Timing Drive Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14



|01 Timing Wheels (Sprockets)

|02 Tensioners

|03 Guides

|05 Belts, Chains

|06 Covers

|65 Adaptors

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings

|85 Sealings

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine Assembly

SUB-SUBSYSTEM ROLL-UP


































NEW TECHNOLOGY PACKAGE COST INFORMATION
3.5L.V6 DOHC, Turbo Dl
Manufacturing
Material



$ 3.50

$

$

$ 1 4.00

$ 8.59

$

$

$

$

$

$

$

$

$ 3.41

$ 29.50
Labor



$

$

$

$

$ 3.91

$

$

$

$

$

$

$

$

$ 1.81

$ 5.72
Burden



$

$

$

$

$ 9.59

$

$

$

$

$

$

$

$

$ 1.81

$ 11.39
Total
Cost
(Component/
Assembly)



$ 3.50

$

$

$ 1 4.00

$ 22.09

$

$

$

$

$

$

$

$

$ 7.02

$ 46.61
Markup
End Item
Scrap



$

$

$

$

$ 0.58

$

$

$

$

$

$

$

$

$

$ 0.58
SGSA



$

$

$

$

$ 1.36

$

$

$

$

$

$

$

$

$

$ 1.36
Profit



$

$

$

$

$ 0.90

$

$

$

$

$

$

$

$

$

$ 0.90
EDST-RSD



$

$

$

$

$ 0.23

$

$

$

$

$

$

$

$

$

$ 0.23
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$ 3.07

$

$

$

$

$

$

$

$

$

$ 3.07
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$ 0.38

$

$

$

$

$

$

$

$

$

$ 0.38
Net
Component/
Assembly Cosl
Impact to OEM



$ 3.50

$

$

$ 1 4.00

$ 25.54

$

$

$

$

$

$

$

$

$ 7.02

$ 50.06
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                              Apdx. C.2 Timing Drives, Page: 13 of 45
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0104
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
        Study Case*: 0104  ( N0104 New Technology Configuration)
                     ( B0104 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0108 Timing Drive Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14



|01 Timing Wheels (Sprockets)

|02 Tensioners

|03 Guides

|05 Belts, Chains

|06 Covers

|65 Adaptors

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings

|85 Sealings

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine Assembly

SUB-SUBSYSTEM ROLL-UP


































BASE TECHNOLOGY PACKAGE COST INFORMATION
5.4L V8, SOHC, NA, PR
Manufacturing
Material



$ 5.00

$

$

$ 24.00

$ 10.61

$

$

$

$

$

$

$

$

$ 0.99

$ 40.60
Labor



$

$

$

$

$ 3.91

$

$

$

$

$

$

$

$

$ 1.81

$ 5.72
Burden



$

$

$

$

$ 9.59

$

$

$

$

$

$

$

$

$ 1.81

$ 11.39
Total
Cost
(Component/
Assembly)



$ 5.00

$

$

$ 24.00

$ 24.11

$

$

$

$

$

$

$

$

$ 4.60

$ 57.71
Markup
End Item
Scrap



$

$

$

$

$ 0.69

$

$

$

$

$

$

$

$

$

$ 0.69
SGSA



$

$

$

$

$ 1.48

$

$

$

$

$

$

$

$

$

$ 1.48
Profit



$

$

$

$

$ 0.99

$

$

$

$

$

$

$

$

$

$ 0.99
EDST-RSD



$

$

$

$

$ 0.25

$

$

$

$

$

$

$

$

$

$ 0.25
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$ 3.41

$

$

$

$

$

$

$

$

$

$ 3.41
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$ 0.38

$

$

$

$

$

$

$

$

$

$ 0.38
Net
Component/
Assembly Cosl
Impact to OEM



$ 5.00

$

$

$ 24.00

$ 27.90

$

$

$

$

$

$

$

$

$ 4.60

$ 61.50
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                              Apdx. C.2 Timing Drives, Page: 14 of 45
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                        APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                 CASE STUDY #0104
                                                                                                                                             Printed: 3/2 6/2010

Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
Study Case*: 0104 ( N0104 New Technology Configuration)
( B0104 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0108 Timing Drive Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14



|01 Timing Wheels (Sprockets)

|02 Tensioners

|03 Guides

|05 Belts, Chains

|06 Covers

|65 Adaptors

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings

|85 Sealings

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine Assembly

SUB-SUBSYSTEM ROLL-UP



































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
3.5L.V6 DOHC, Turbo Dl
BASE TECHNOLOGY PACKAGE COST INFORMATION
5.4L V8, SOHC, NA, PFI
Manufacturing
Material



$ (1.50)

$

$

$ (1 0,00)

$ (2.02)

$

$

$

$

$

$

$

$

$ 2.42

$ (11,10)
Labor



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
Burden



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
Total
Manufacturing
Cost
(Component/
Assembly)



$ (1.50)

$

$

$ (1 0,00)

$ (2,02)

$

$

$

$

$

$

$

$

$ 2.42

$ (11,10)
Markup
End Item
Scrap



$

$

$

$

$ (0.11)

$

$

$

$

$

$

$

$

$

$ (0,11)
SGSA



$

$

$

$

$ (0.13)

$

$

$

$

$

$

$

$

$

$ (0,13)
Profit



$

$

$

$

$ (0.08)

$

$

$

$

$

$

$

$

$

$ (0,08)
EDST-RSD



$

$

$

$

$ (0.02)

$

$

$

$

$

$

$

$

$

$ (0,02)
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$ (0.34)

$

$

$

$

$

$

$

$

$

$ (0,34)
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Net
Component/
Assembly Cosl
Impact to OEM



$ (1 ,50)

$

$

$ (10,00)

$ (2.38)

$

$

$

$

$

$

$

$

$ 2.42

$ (11,44)
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                 Apdx. C.2 Timing Drives, Page: 15 of 45
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0104
                                                                                                                                                                         Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
        Study Case*: 0104  ( N0104 New Technology Configuration)
                     ( B0104 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0109 Accessory Drive Subsystem

1

2

3

4

5

6

7

8

9

10

11



I 01 Pulleys

I 02 Tensioners

I 03 Guides

I 05 Belts

| 65 Adaptors

I 70 Pipes, Hoses, Ducting

I 85 Sealing Elements

I 90 Bearing Elements

I 95 Tools

I 99 Miscellaneous

| 00 Engine & Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP




























NEW TECHNOLOGY PACKAGE COST INFORMATION
3.5L.V6 DOHC, Turbo Dl
Manufacturing
Material



$ 33.00

$

$

$

$

$

$

$

$

$

$

$ 33.00
Labor



$

$

$

$

$

$

$

$

$

$

$

$
Burden



$

$

$

$

$

$

$

$

$

$

$

$
Total
Manufacturing
Cost
(Component/
Assembly)



$ 33.00

$

$

$

$

$

$

$

$

$

$

$ 33.00
Markup
End Item
Scrap



$

$

$

$

$

$

$

$

$

$

$

$ -
SGSA



$

$

$

$

$

$

$

$

$

$

$

$
Profit



$

$

$

$

$

$

$

$

$

$

$

$
EDST-RSD



$

$

$

$

$

$

$

$

$

$

$

$ -
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$
Net
Component/
Assembly Cosl
Impact to OEM



$ 33.00

$

$

$

$

$

$

$

$

$

$

$ 33.00
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                             Apdx. C.2 Accessory Drives, Page: 16 of 45
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0104
                                                                                                                                                                         Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
        Study Case*: 0104  ( N0104 New Technology Configuration)
                     ( B0104 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
o>
-g Sub-Subsystem Description
CO
.a
CO

0109 Accessory Drive Subsystem

1

2

3

4

5

6

7

8

9

10

11



I 01 Pulleys

I 02 Tensioners

I 03 Guides

I 05 Belts

| 65 Adaptors

I 70 Pipes, Hoses, Ducting

I 85 Sealing Elements

I 90 Bearing Elements

I 95 Tools

I 99 Miscellaneous

| 00 Engine & Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP




























BASE TECHNOLOGY PACKAGE COST INFORMATION
5.4L V8, SOHC, NA, PR
Manufacturing
Material



$ 22.00

$

$

$

$

$

$

$

$

$

$

$ 22.00
Labor



$

$

$

$

$

$

$

$

$

$

$

$
Burden



$

$

$

$

$

$

$

$

$

$

$

$
Total
Cost
(Component/
Assembly)



$ 22.00

$

$

$

$

$

$

$

$

$

$

$ 22.00
Markup
End Item
Scrap



$

$

$

$

$

$

$

$

$

$

$

$ -
SGSA



$

$

$

$

$

$

$

$

$

$

$

$
Profit



$

$

$

$

$

$

$

$

$

$

$

$
EDST-RSD



$

$

$

$

$

$

$

$

$

$

$

$ -
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$
Net
Component/
Assembly Cosl
Impact to OEM



$ 22.00

$

$

$

$

$

$

$

$

$

$

$ 22.00
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                             Apdx. C.2 Accessory Drives, Page: 17 of 45
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                         APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                 CASE STUDY #0104
                                                                                                                                              Printed: 3/2 6/2010

Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
Study Case*: 0104 ( N0104 New Technology Configuration)
( B0104 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0109 Accessory Drive Subsystem

1

2

3

4

5

6

7

8

9

10

11



I 01 Pulleys

I 02 Tensioners

I 03 Guides

I 05 Belts

| 65 Adaptors

I 70 Pipes, Hoses, Ducting

I 85 Sealing Elements

I 90 Bearing Elements

I 95 Tools

I 99 Miscellaneous

| 00 Engine & Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP





























INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
3.5L.V6 DOHC, Turbo Dl
BASE TECHNOLOGY PACKAGE COST INFORMATION
5.4L V8, SOHC, NA, PFI
Manufacturing
Material



$ 11.00

$

$

$

$

$

$

$

$

$

$

$ 11.00
Labor



$

$

$

$

$

$

$

$

$

$

$

$
Burden



$

$

$

$

$

$

$

$

$

$

$

$
Total
Manufacturing
Cost
(Component/
Assembly)



$ 11.00

$

$

$

$

$

$

$

$

$

$

$ 11.00
Markup
End Item
Scrap



$

$

$

$

$

$

$

$

$

$

$

$ -
SGSA



$

$

$

$

$

$

$

$

$

$

$

$
Profit



$

$

$

$

$

$

$

$

$

$

$

$
EDST-RSD



$

$

$

$

$

$

$

$

$

$

$

$ -
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$
Net
Component/
Assembly Cosl
Impact to OEM



$ 11.00

$

$

$

$

$

$

$

$

$

$

$ 11.00
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                Apdx. C.2 Accessory Drives, Page: 18 of 45
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0104
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
        Study Case*: 0104  ( N0104 New Technology Configuration)
                     ( B0104 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0110 Intake Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13



|01 Intake Manifolds

|02 Air Filter Box

|03 Air Filters

|05 Throttle Housing Assembly; including Supplies

|65 Adapters: Flanges for Port Shut-off

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Bolting & Clamps

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine and Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP
































NEW TECHNOLOGY PACKAGE COST INFORMATION
3.5L.V6 DOHC, Turbo Dl
Manufacturing
Material



$ 16.69

$

$

$ 39.00

$

$

$

$

$

$

$

$

$ 0.80

$ 56.49
Labor



$ 2.23

$

$

$

$

$

$

$

$

$

$

$

$ 1.55

$ 3.78
Burden



$ 4.56

$

$

$

$

$

$

$

$

$

$

$

$ 1.10

$ 5.66
Total
Cost
(Component/
Assembly)



$ 23.47

$

$

$ 39.00

$

$

$

$

$

$

$

$

$ 3.45

$ 65.93
Markup
End Item
Scrap



$ 0.16

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.16
SGSA



$ 1.64

$

$

$

$

$

$

$

$

$

$

$

$

$ 1.64
Profit



$ 1.88

$

$

$

$

$

$

$

$

$

$

$

$

$ 1.88
EDST-RSD



$ 0.47

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.47
Total Markup
Cost
(Component/
Assembly)



$ 4.15

$

$

$

$

$

$

$

$

$

$

$

$

$ 4.15
Total
Packaging
Cost
(Component/
Assembly)



$ 1.10

$

$

$ 0.02

$

$

$

$

$

$

$

$

$

$ 1.11
Net
Component/
Assembly Cosl
Impact to OEM



$ 28.72

$

$

$ 39.02

$

$

$

$

$

$

$

$

$ 3.45

$ 71.20
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                                Apdx. C.2 Intake, Page: 19 of 45
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0104
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
        Study Case*: 0104  ( N0104 New Technology Configuration)
                     ( B0104 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0110 Intake Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13



|01 Intake Manifolds

|02 Air Filter Box

|03 Air Filters

|05 Throttle Housing Assembly; including Supplies

|65 Adapters: Flanges for Port Shut-off

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Bolting & Clamps

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine and Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP
































BASE TECHNOLOGY PACKAGE COST INFORMATION
5.4L V8, SOHC, NA, PR
Manufacturing
Material



$ 32.46

$

$

$ 39.00

$

$ 3.59

$

$

$

$

$

$

$ 1.00

$ 76.05
Labor



$ 3.02

$

$

$

$

$ 1.56

$

$

$

$

$

$

$ 1.90

$ 6.48
Burden



$ 6.38

$

$

$

$

$ 2.86

$

$

$

$

$

$

$ 1.38

$ 10.63
Total
Cost
(Component/
Assembly)



$ 41.86

$

$

$ 39.00

$

$ 8.02

$

$

$

$

$

$

$ 4.28

$ 93.16
Markup
End Item
Scrap



$ 0.29

$

$

$

$

$ 0.06

$

$

$

$

$

$

$

$ 0.35
SGSA



$ 2.93

$

$

$

$

$ 0.56

$

$

$

$

$

$

$

$ 3.49
Profit



$ 3.35

$

$

$

$

$ 0.64

$

$

$

$

$

$

$

$ 3.99
EDST-RSD



$ 0.84

$

$

$

$

$ 0.16

$

$

$

$

$

$

$

$ 1.00
Total Markup
Cost
(Component/
Assembly)



$ 7.41

$

$

$

$

$ 1.42

$

$

$

$

$

$

$

$ 8.83
Total
Packaging
Cost
(Component/
Assembly)



$ 1.10

$

$

$ 0.02

$

$ 0.03

$

$

$

$

$

$

$

$ 1.15
Net
Component/
Assembly Cosl
Impact to OEM



$ 50.37

$

$

$ 39.02

$

$ 9.47

$

$

$

$

$

$

$ 4.28

$ 103.13
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                                Apdx. C.2 Intake, Page: 20 of 45
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                        APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                CASE STUDY #0104
                                                                                                                                            Printed: 3/2 6/2010

Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
Study Case*: 0104 ( N0104 New Technology Configuration)
( B0104 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0110 Intake Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13



|01 Intake Manifolds

|02 Air Filter Box

|03 Air Filters

|05 Throttle Housing Assembly; including Supplies

|65 Adapters: Flanges for Port Shut-off

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Bolting & Clamps

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine and Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP

































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
3.5L.V6 DOHC, Turbo Dl
BASE TECHNOLOGY PACKAGE COST INFORMATION
5.4L V8, SOHC, NA, PFI
Manufacturing
Material



$ (15.78)

$

$

$

$

$ (3.59)

$

$

$

$

$

$

$ (0.20S

$ (19,57)
Labor



$ (0.7SS

$

$

$

$

$ (1.56)

$

$

$

$

$

$

$ (0.35)

$ (2,70)
Burden



$ (1 ,82)

$

$

$

$

$ (2*6)

$

$

$

$

$

$

$ (0.28)

$ (4,96)
Total
Manufacturing
Cost
(Component/
Assembly)



$ (1 8.39)

$

$

$

$

$ (8-02)

$

$

$

$

$

$

$ (0.82)

$ (27,23)
Markup
End Item
Scrap



f, (0.13)

$

$

$

$

$ (0.06)

$

$

$

$

$

$

$

$ (0,18)
SGSA



$ (1.29)

$

$

$

$

$ (a 56)

$

$

$

$

$

$

$

$ (1 ,85)
Profit



$ (1.47)

$

$

$

$

$ (0,64)

$

$

$

$

$

$

$

$ (2,11)
EDST-RSD



$ (0.3?)

$

$

$

$

I (0,16)

$

$

$

$

$

$

$

$ (0,53)
Total Markup
Cost
(Component/
Assembly)



f (3.26)

$

$

$

$

$ (1.42)

$

$

$

$

$

$

$

$ (4,87)
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$ (0.03)

$

$

$

$

$

$

$

$ (0,03)
Net
Component/
Assembly Cosl
Impact to OEM



$ (21 .§5)

$

$

$

$

$ (9.47)

$

$

$

$

$

$

$ (0.82)

$ (31 ,94)
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                  Apdx. C.2 Intake, Page: 21 of 45
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0104
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
        Study Case*: 0104  ( N0104 New Technology Configuration)
                     ( B0104 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0111 Fuel Induction Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13



|01 Fuel Rails

|04 Fuel Injectors

|06 Pressure Regulators

|07 Fuel Injection Pumps

|65 Adaptors

|70 Pipes, Hoses: Low Pressure, High Pressure

|75 Brackets

|60 Bolting

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine Assembly

SUB-SUBSYSTEM ROLL-UP
































NEW TECHNOLOGY PACKAGE COST INFORMATION
3.5L.V6 DOHC, Turbo Dl
Manufacturing
Material



$ 16.03

$ 13.13

$

$ 21.23

$

$ 0.94

$

$

$

$

$

$

$ 0.75

$ 52.08
Labor



$ 3.07

$ 8.83

$

$ 1 0.01

$

$ 0.69

$

$

$

$

$

$

$ 3.22

$ 25.81
Burden



$ 7.01

$ 35.83

$

$ 31.19

$

$ 1.69

$

$

$

$

$

$

$ 3.37

$ 79.08
Total
Cost
(Component/
Assembly)



$ 26.11

$ 57.79

$

$ 62.43

$

$ 3.32

$

$

$

$

$

$

$ 7.34

$ 156.98
Markup
End Item
Scrap



$ 0.08

$ 0.62

$

$ 0.85

$

$ 0.01

$

$

$

$

$

$

$

$ 1.55
SGSA



$ 1.57

$ 6.70

$

$ 7.34

$

$ 0.20

$

$

$

$

$

$

$

$ 15.81
Profit



$ 1.04

$ 7.15

$

$ 7.47

$

$ 0.13

$

$

$

$

$

$

$

$ 15.79
EDST-RSD



$ 0.26

$ 2.86

$

$ 2.89

$

$ 0.03

$

$

$

$

$

$

$

$ 6.05
Total Markup
Cost
(Component/
Assembly)



$ 2.95

$ 17.33

$

$ 18.55

$

$ 0.36

$

$

$

$

$

$

$

$ 39.19
Total
Packaging
Cost
(Component/
Assembly)



$ 0.16

$ 0.08

$

$ 0.14

$

$ 0.02

$

$

$

$

$

$

$

$ 0.39
Net
Component/
Assembly Cosl
Impact to OEM



$ 29.21

$ 75.20

$

$ 81.12

$

$ 3.69

$

$

$

$

$

$

$ 7.34

$ 196.56
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                             Apdx. C.2 Fuel Induction, Page: 22 of 45
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0104
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
        Study Case*: 0104  ( N0104 New Technology Configuration)
                     ( B0104 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0111 Fuel Induction Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13



|01 Fuel Rails

|04 Fuel Injectors

|06 Pressure Regulators

|07 Fuel Injection Pumps

|65 Adaptors

|70 Pipes, Hoses: Low Pressure, High Pressure

|75 Brackets

|60 Bolting

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine Assembly

SUB-SUBSYSTEM ROLL-UP
































BASE TECHNOLOGY PACKAGE COST INFORMATION
5.4L V8, SOHC, NA, PR
Manufacturing
Material



$ 2.54

$ 8.26

$

$

$

$

$

$

$

$

$

$

$ 0.24

$ 11.04
Labor



$ 2.45

$ 7.63

$

$

$

$

$

$

$

$

$

$

$ 1.20

$ 11.29
Burden



$ 3.61

$ 32.14

$

$

$

$

$

$

$

$

$

$

$ 0.83

$ 36.58
Total
Cost
(Component/
Assembly)



$ 8.61

$ 48.03

$

$

$

$

$

$

$

$

$

$

$ 2.27

$ 58.92
Markup
End Item
Scrap



$ 0.03

$ 0.42

$

$

$

$

$

$

$

$

$

$

$

$ 0.45
SGSA



$ 0.52

$ 4.51

$

$

$

$

$

$

$

$

$

$

$

$ 5.03
Profit



$ 0.34

$ 4.87

$

$

$

$

$

$

$

$

$

$

$

$ 5.21
EDST-RSD



$ 0.09

$ 2.12

$

$

$

$

$

$

$

$

$

$

$

$ 2.20
Total Markup
Cost
(Component/
Assembly)



$ 0.97

$ 11.92

$

$

$

$

$

$

$

$

$

$

$

$ 12.89
Total
Packaging
Cost
(Component/
Assembly)



$ 0.08

$ 0.10

$

$

$

$

$

$

$

$

$

$

$

$ 0.18
Net
Component/
Assembly Cosl
Impact to OEM



$ 9.66

$ 60.05

$

$

$

$

$

$

$

$

$

$

$ 2.27

$ 71.99
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                             Apdx. C.2 Fuel Induction, Page: 23 of 45
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                        APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                 CASE STUDY #0104
                                                                                                                                             Printed: 3/2 6/2010

Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
Study Case*: 0104 ( N0104 New Technology Configuration)
( B0104 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0111 Fuel Induction Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13



|01 Fuel Rails

|04 Fuel Injectors

|06 Pressure Regulators

|07 Fuel Injection Pumps

|65 Adaptors

|70 Pipes, Hoses: Low Pressure, High Pressure

|75 Brackets

|60 Bolting

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine Assembly

SUB-SUBSYSTEM ROLL-UP

































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
3.5L.V6 DOHC, Turbo Dl
BASE TECHNOLOGY PACKAGE COST INFORMATION
5.4L V8, SOHC, NA, PFI
Manufacturing
Material



$ 13.49

$ 4.87

$

$ 21.23

$

$ 0.94

$

$

$

$

$

$

$ 0.51

$ 41.04
Labor



$ 0.62

$ 1.19

$

$ 1 0.01

$

$ 0.69

$

$

$

$

$

$

$ 2.01

$ 14.52
Burden



$ 3.39

$ 3.69

$

$ 31.19

$

$ 1.69

$

$

$

$

$

$

$ 2.54

$ 42.50
Total
Manufacturing
Cost
(Component/
Assembly)



$ 17.50

$ 9.76

$

$ 62.43

$

$ 3.32

$

$

$

$

$

$

$ 5.06

$ 98.06
Markup
End Item
Scrap



$ 0.05

$ 0.20

$

$ 0.85

$

$ 0.01

$

$

$

$

$

$

$

$ 1.11
SGSA



$ 1.05

$ 2.19

$

$ 7.34

$

$ 0.20

$

$

$

$

$

$

$

$ 10.78
Profit



$ 0.70

$ 2.28

$

$ 7.47

$

$ 0.13

$

$

$

$

$

$

$

$ 10.58
EDST-RSD



$ 0.17

$ 0.75

$

$ 2.89

$

$ 0.03

$

$

$

$

$

$

$

$ 3.85
Total Markup
Cost
(Component/
Assembly)



$ 1.98

$ 5.41

$

$ 18.55

$

$ 0.36

$

$

$

$

$

$

$

$ 26.30
Total
Packaging
Cost
(Component/
Assembly)



$ 0.07

$ (0.02)

$

$ 0.14

$

$ 0.02

$

$

$

$

$

$

$

$ 0.21
Net
Component/
Assembly Cosl
Impact to OEM



$ 19.55

$ 15.15

$

$ 81.12

$

$ 3.69

$

$

$

$

$

$

$ 5.06

$ 124.57
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                 Apdx. C.2 Fuel Induction, Page: 24 of 45
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0104
                                                                                                                                                                        Printed: 3/2 6/2010
         Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
           Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
            Study Case*: 0104  ( N0104 New Technology Configuration)
                         ( B0104 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0112 Exhaust Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15



|01 Exhaust Manifold

|04 Collector Pipes

|05 Catalysts

|06 Particle Filters

|07 Silencers (Mufflers)

|08 Oxygen Sensors

|65 Adapters

|70 Pipes, Hoses: Low Pressure, High Pressure

|75 Brackets

|60 Bolting

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine and Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP




































NEW TECHNOLOGY PACKAGE COST INFORMATION
3.5L.V6 DOHC, Turbo Dl
Manufacturing
Material



$ 64.58





$

$



$

$



$

$ 2.45

$

$

$

$ 9.92

$ 76.95
Labor



$ 2.98





$

$



$

$



$

$ 0.49

$

$

$

$

$ 3.47
Burden



$ 12.45





$

$



$

$



$

$ 1.96

$

$

$

$

$ 14.41
Total
Cost
(Component/
Assembly)



$ 80.01





$

$



$

$



$

$ 4.90

$

$

$

$ 9.92

$ 94.83
Markup
End Item
Scrap



$ 3.95





$

$



$

$



$

$ 0.02

$

$

$

$

$ 3.98
SGSA



$ 5.84





$

$



$

$



$

$ 0.32

$

$

$

$

$ 6.16
Profit



$ 6.67





$

$



$

$



$

$ 0.29

$

$

$

$

$ 6.96
EDST-RSD



$ 3.34





$

$



$

$



$

$ 0.05

$

$

$

$

$ 3.38
Total Markup
Cost
(Component/
Assembly)



$ 19.79





$

$



$

$



$

$ 0.69

$

$

$

$

$ 20.48
Total
Packaging
Cost
(Component/
Assembly)



$ 0.23





$

$



$

$



$

$ 0.06

$

$

$

$

$ 0.29
Net
Component/
Assembly Cosl
Impact to OEM



$ 100.04





$

$



$

$



$

$ 5.65

$

$

$

$ 9.92

$ 115.60
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                               Apdx. C.2 Exhaust, Page: 25 of 45
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0104
                                                                                                                                                                        Printed: 3/2 6/2010
         Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
           Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
            Study Case*: 0104  ( N0104 New Technology Configuration)
                         ( B0104 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0112 Exhaust Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15



|01 Exhaust Manifold

|04 Collector Pipes

|05 Catalysts

|06 Particle Filters

|07 Silencers (Mufflers)

|08 Oxygen Sensors

|65 Adapters

|70 Pipes, Hoses: Low Pressure, High Pressure

|75 Brackets

|60 Bolting

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine and Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP




































BASE TECHNOLOGY PACKAGE COST INFORMATION
5.4L V8, SOHC, NA, PR
Manufacturing
Material



$ 16.77

$

$

$

$

$

$

$

$

$

$ 1.19

$

$

$

$ 4.00

$ 21.97
Labor



$ 2.53

$

$

$

$

$

$

$

$

$

$ 0.24

$

$

$

$

$ 2.77
Burden



$ 12.66

$

$

$

$

$

$

$

$

$

$ 0.96

$

$

$

$

$ 13.61
Total
Cost
(Component/
Assembly)



$ 31.96

$

$

$

$

$

$

$

$

$

$ 2.39

$

$

$

$ 4.00

$ 38.35
Markup
End Item
Scrap



$ 1.17

$

$

$

$

$

$

$

$

$

$ 0.01

$

$

$

$

$ 1.18
SGSA



$ 2.14

$

$

$

$

$

$

$

$

$

$ 0.16

$

$

$

$

$ 2.30
Profit



$ 1.98

$

$

$

$

$

$

$

$

$

$ 0.14

$

$

$

$

$ 2.12
EDST-RSD



$ 0.82

$

$

$

$

$

$

$

$

$

$ 0.06

$

$

$

$

$ 0.88
Total Markup
Cost
(Component/
Assembly)



$ 6.11

$

$

$

$

$

$

$

$

$

$ 0.37

$

$

$

$

$ 6.48
Total
Packaging
Cost
(Component/
Assembly)



$ 0.29

$

$

$

$

$

$

$

$

$

$ 0.06

$

$

$

$

$ 0.35
Net
Component/
Assembly Cosl
Impact to OEM



$ 38.36

$

$

$

$

$

$

$

$

$

$ 2.82

$

$

$

$ 4.00

$ 45.18
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                               Apdx. C.2 Exhaust, Page: 26 of 45
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                        APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                CASE STUDY #0104
                                                                                                                                            Printed: 3/2 6/2010


Technology Level: 01 -Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capabilit
Study Case*: 01 04 ( N01 04 New Technology Configuration)
( B0104 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0112 Exhaust Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15



|01 Exhaust Manifold

|04 Collector Pipes

|05 Catalysts

|06 Particle Filters

|07 Silencers (Mufflers)

|08 Oxygen Sensors

|65 Adapters

|70 Pipes, Hoses: Low Pressure, High Pressure

|75 Brackets

|60 Bolting

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine and Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP





































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
3.5L.V6 DOHC, Turbo Dl
BASE TECHNOLOGY PACKAGE COST INFORMATION
5.4L V8, SOHC, NA, PFI
Manufacturing
Material



$ 47.81

$

$

$

$

$

$

$

$

$

$ 1.26

$

$

$

$ 5.92

$ 54.98
Labor



$ 0.45

$

$

$

$

$

$

$

$

$

$ 0.25

$

$

$

$

$ 0.70
Burden



$ (0.20)

$

$

$

$

$

$

$

$

$

$ 1.00

$

$

$

$

$ 0.80
Total
Manufacturing
Cost
(Component/
Assembly)



$ 48.06

$

$

$

$

$

$

$

$

$

$ 2.51

$

$

$

$ 5.92

$ 56.49
Markup
End Item
Scrap



$ 2.78

$

$

$

$

$

$

$

$

$

$ 0.01

$

$

$

$

$ 2.80
SGSA



$ 3.69

$

$

$

$

$

$

$

$

$

$ 0.16

$

$

$

$

$ 3.86
Profit



$ 4.69

$

$

$

$

$

$

$

$

$

$ 0.15

$

$

$

$

$ 4.84
EDST-RSD



$ 2.51

$

$

$

$

$

$

$

$

$

$ (0.01)

$

$

$

$

$ 2.50
Total Markup
Cost
(Component/
Assembly)



$ 13.68

$

$

$

$

$

$

$

$

$

$ 0.32

$

$

$

$

$ 14.00
Total
Packaging
Cost
(Component/
Assembly)



$ (0.06!

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$ (0.06)
Net
Component/
Assembly Cosl
Impact to OEM



$ 61.68

$

$

$

$

$

$

$

$

$

$ 2.83

$

$

$

$ 5.92

$ 70.43
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                  Apdx. C.2 Exhaust, Page: 27 of 45
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0104
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
        Study Case*: 0104  ( N0104 New Technology Configuration)
                     ( B0104 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0113 Lubrication Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13



|01 Oil Pans (Oil Sump)

|02 Oil Pumps

|05 Pressure Regulators

|06 Oil Filter

|65 Adapter for Oil Filters

I Pipes, Hoses: Suction Pipe for Oil Pump, Oil Return, High Pressure,
Low Pressure.

|75 Brackets

|80 Boltings & Clamps

|85 Sealing Elements: Oil Pan Gasket,...

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine & Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP
































NEW TECHNOLOGY PACKAGE COST INFORMATION
3.5L.V6 DOHC, Turbo Dl
Manufacturing
Material



$ 13.43

$

$

$ 2.94

$

$ 20.03

$

$

$ 0.04

$

$

$ 6.50

$ 1.30

$ 44.25
Labor



$ 2.87

$

$

$ 2.23

$

$ 3.34

$

$

$ 0.12

$

$

$

$ 7.98

$ 16.54
Burden



$ 18.14

$

$

$ 4.61

$

$ 8.04

$

$

$ 0.17

$

$

$

$ 8.35

$ 39.30
Total
Cost
(Component/
Assembly)



$ 34.44

$

$

$ 9.78

$

$ 31.41

$

$

$ 0.32

$

$

$ 6.50

$ 17.63

$ 100.09
Markup
End Item
Scrap



$ 0.18

$

$

$ 0.07

$

$ 0.12

$

$

$ 0.00

$

$

$

$

$ 0.37
SGSA



$ 2.34

$

$

$ 1.08

$

$ 1.59

$

$

$ 0.02

$

$

$

$

$ 5.03
Profit



$ 2.14

$

$

$ 0.90

$

$ 1.46

$

$

$ 0.02

$

$

$

$

$ 4.52
EDST-RSD



$ 0.86

$

$

$ 0.26

$

$ 0.61

$

$

$ 0.01

$

$

$

$

$ 1.75
Total Markup
Cost
(Component/
Assembly)



$ 5.52

$

$

$ 2.31

$

$ 3.78

$

$

$ 0.05

$

$

$

$

$ 11.67
Total
Packaging
Cost
(Component/
Assembly)



$ 0.32

$

$

$ 0.16

$

$ 0.78

$

$

$ 0.00

$

$

$

$

$ 1.26
Net
Component/
Assembly Cosl
Impact to OEM



$ 40.28

$

$

$ 1 2.26

$

$ 35.98

$

$

$ 0.38

$

$

$ 6.50

$ 17.63

$ 113.02
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                              Apdx. C.2 Lubrication, Page: 28 of 45
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0104
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
        Study Case*: 0104  ( N0104 New Technology Configuration)
                     ( B0104 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0113 Lubrication Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13



|01 Oil Pans (Oil Sump)

|02 Oil Pumps

|05 Pressure Regulators

|06 Oil Filter

|65 Adapter for Oil Filters

I Pipes, Hoses: Suction Pipe for Oil Pump, Oil Return, High Pressure,
Low Pressure.

|75 Brackets

|80 Boltings & Clamps

|85 Sealing Elements: Oil Pan Gasket,...

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine & Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP
































BASE TECHNOLOGY PACKAGE COST INFORMATION
5.4L V8, SOHC, NA, PR
Manufacturing
Material



$ 6.77

$

$

$

$

$

$

$

$

$

$

$

$ 0.93

$ 7.70
Labor



$ 1.39

$

$

$

$

$

$

$

$

$

$

$

$

$ 1.39
Burden



$ 6.29

$

$

$

$

$

$

$

$

$

$

$

$

$ 6.29
Total
Cost
(Component/
Assembly)



$ 14.45

$

$

$

$

$

$

$

$

$

$

$

$ 0.93

$ 15.38
Markup
End Item
Scrap



$ 0.07

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.07
SGSA



$ 0.94

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.94
Profit



$ 0.87

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.87
EDST-RSD



$ 0.36

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.36
Total Markup
Cost
(Component/
Assembly)



$ 2.24

$

$

$

$

$

$

$

$

$

$

$

$

$ 2.24
Total
Packaging
Cost
(Component/
Assembly)



$ 0.18

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.18
Net
Component/
Assembly Cosl
Impact to OEM



$ 16.87

$

$

$

$

$

$

$

$

$

$

$

$ 0.93

$ 17.79
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                              Apdx. C.2 Lubrication, Page: 29 of 45
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                        APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                 CASE STUDY #0104
                                                                                                                                             Printed: 3/2 6/2010


Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
Study Case*: 0104 ( N0104 New Technology Configuration)
( B0104 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

Sub-Subsystem

Sub-Subsystem Description

0113 Lubrication Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13



(01 Oil Pans (Oil Sump)


J02 Oil Pumps


|05 Pressure Regulators


J06 Oil Filter


J65 Adapter for Oil Filters


I Pipes, Hoses: Suction Pipe for Oil Pump, Oil Return, High Pressure,
Low Pressure.

|75 Brackets


\80 Boltings & Clamps

(85 Sealing Elements: Oil Pan Gasket,...


|90 Bearing Elements


J95 Tools


|99 Miscellaneous

|00 Engine & Vehicle Assembly


SUB-SUBSYSTEM ROLL-UP

































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
3.5L.V6 DOHC, Turbo Dl
BASE TECHNOLOGY PACKAGE COST INFORMATION
5.4L V8, SOHC, NA, PFI
Manufacturing
Material



$ 6.67

$

$

$ 2.94

$

$ 20.03

$

$

$ 0.04

$

$

$ 6.50

$ 0.37

$ 36.55
Labor



$ 1.48

$

$

$ 2.23

$

$ 3.34

$

$

$ 0.12

$

$

$

$ 7.98

$ 15.16
Burden



$ 11.85

$

$

$ 4.61

$

$ 8.04

$

$

$ 0.17

$

$

$

$ 8.35

$ 33.00
Total
Manufacturing
Cost
(Component/
Assembly)



$ 19.99

$

$

$ 9.78

$

$ 31.41

$

$

$ 0.32

$

$

$ 6.50

$ 16.70

$ 84.71
Markup
End Item
Scrap



$ 0.11

$

$

$ 0.07

$

$ 0.12

$

$

$ 0.00

$

$

$

$

$ 0.30
SGSA



$ 1.40

$

$

$ 1.08

$

$ 1.59

$

$

$ 0.02

$

$

$

$

$ 4.09
Profit



$ 1.27

$

$

$ 0.90

$

$ 1.46

$

$

$ 0.02

$

$

$

$

$ 3.65
EDST-RSD



$ 0.50

$

$

$ 0.26

$

$ 0.61

$

$

$ 0.01

$

$

$

$

$ 1.38
Total Markup
Cost
(Component/
Assembly)



$ 3.28

$

$

$ 2.31

$

$ 3.78

$

$

$ 0.05

$

$

$

$

$ 9.43
Total
Packaging
Cost
(Component/
Assembly)



$ 0.14

$

$

$ 0.16

$

$ 0.78

$

$

$ 0.00

$

$

$

$

$ 1.08
Net
Component/
Assembly Cosl
Impact to OEM



$ 23.41

$

$

$ 1 2.26

$

$ 35.98

$

$

$ 0.38

$

$

$ 6.50

$ 16.70

$ 95.22
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                  Apdx. C.2 Lubrication, Page: 30 of 45
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0104
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
        Study Case*: 0104  ( N0104 New Technology Configuration)
                     ( B0104 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
o>
-g Sub-Subsystem Description
CO
.a
CO

0114 Cooling Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14



|01 Water Pumps

|02 Thermostat Housing

|04 Heat Exchangers

|05 Pressure Regulators

|06 Expansion Tanks

|65 Adapters

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings & Clamps

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine and Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP


































NEW TECHNOLOGY PACKAGE COST INFORMATION
3.5L.V6 DOHC, Turbo Dl
Manufacturing
Material



$ 18.90

$

$

$

$

$

$ 4.41

$

$

$

$

$

$

$ 1.66

$ 24.98
Labor



$ 2.22

$

$

$

$

$

$ 3.38

$

$

$

$

$

$

$ 1.94

$ 7.54
Burden



$ 4.37

$

$

$

$

$

$ 4.68

$

$

$

$

$

$

$ 3.50

$ 12.56
Total
Cost
(Component/
Assembly)



$ 25.50

$

$

$

$

$

$ 12.47

$

$

$

$

$

$

$ 7.11

$ 45.08
Markup
End Item
Scrap



$ 0.23

$

$

$

$

$

$ 0.02

$

$

$

$

$

$

$

$ 0.25
SGSA



$ 2.33

$

$

$

$

$

$ 0.75

$

$

$

$

$

$

$

$ 3.07
Profit



$ 2.64

$

$

$

$

$

$ 0.50

$

$

$

$

$

$

$

$ 3.14
EDST-RSD



$ 1.31

$

$

$

$

$

$

$

$

$

$

$

$

$

$ 1.31
Total Markup
Cost
(Component/
Assembly)



$ 6.51

$

$

$

$

$

$ 1.27

$

$

$

$

$

$

$

$ 7.78
Total
Packaging
Cost
(Component/
Assembly)



$ 0.08

$

$

$

$

$

$ 0.10

$

$

$

$

$

$

$

$ 0.18
Net
Component/
Assembly Cosl
Impact to OEM



$ 32.08

$

$

$

$

$

$ 13.85

$

$

$

$

$

$

$ 7.11

$ 53.04
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                               Apdx. C.2 Cooling, Page: 31 of 45
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0104
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
        Study Case*: 0104  ( N0104 New Technology Configuration)
                     ( B0104 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0114 Cooling Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14



|01 Water Pumps

|02 Thermostat Housing

|04 Heat Exchangers

|05 Pressure Regulators

|06 Expansion Tanks

|65 Adapters

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings & Clamps

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine and Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP


































BASE TECHNOLOGY PACKAGE COST INFORMATION
5.4L V8, SOHC, NA, PR
Manufacturing
Material



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
Labor



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
Burden



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
Total
Manufacturing
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Markup
End Item
Scrap



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
SGSA



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
Profit



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
EDST-RSD



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Net
Component/
Assembly Cosl
Impact to OEM



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                               Apdx. C.2 Cooling, Page: 32 of 45
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                        APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                CASE STUDY #0104
                                                                                                                                            Printed: 3/2 6/2010

Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
Study Case*: 0104 ( N0104 New Technology Configuration)
( B0104 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0114 Cooling Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14



|01 Water Pumps

|02 Thermostat Housing

|04 Heat Exchangers

|05 Pressure Regulators

|06 Expansion Tanks

|65 Adapters

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings & Clamps

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine and Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP



































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
3.5L.V6 DOHC, Turbo Dl
BASE TECHNOLOGY PACKAGE COST INFORMATION
5.4L V8, SOHC, NA, PFI
Manufacturing
Material



$ 18.90

$

$

$

$

$

$ 4.41

$

$

$

$

$

$

$ 1.66

$ 24.98
Labor



$ 2.22

$

$

$

$

$

$ 3.38

$

$

$

$

$

$

$ 1.94

$ 7.54
Burden



$ 4.37

$

$

$

$

$

$ 4.68

$

$

$

$

$

$

$ 3.50

$ 12.56
Total
Manufacturing
Cost
(Component/
Assembly)



$ 25.50

$

$

$

$

$

$ 12.47

$

$

$

$

$

$

$ 7.11

$ 45.08
Markup
End Item
Scrap



$ 0.23

$

$

$

$

$

$ 0.02

$

$

$

$

$

$

$

$ 0.25
SGSA



$ 2.33

$

$

$

$

$

$ 0.75

$

$

$

$

$

$

$

$ 3.07
Profit



$ 2.64

$

$

$

$

$

$ 0.50

$

$

$

$

$

$

$

$ 3.14
EDST-RSD



$ 1.31

$

$

$

$

$

$

$

$

$

$

$

$

$

$ 1.31
Total Markup
Cost
(Component/
Assembly)



$ 6.51

$

$

$

$

$

$ 1.27

$

$

$

$

$

$

$

$ 7.78
Total
Packaging
Cost
(Component/
Assembly)



$ 0.08

$

$

$

$

$

$ 0.10

$

$

$

$

$

$

$

$ 0.18
Net
Component/
Assembly Cosl
Impact to OEM



$ 32.08

$

$

$

$

$

$ 13.85

$

$

$

$

$

$

$ 7.11

$ 53.04
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                  Apdx. C.2 Cooling, Page: 33 of 45
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0104
                                                                                                                                                                         Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
        Study Case*: 0104 ( N0104 New Technology Configuration)
                      ( B0104 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0115 Induction Air Charging Subsystem

1

2

3

4

5

6

7

8

9

10

11

12




|01 Turbo Chargers (Assemblies)

|02 Solenoids

|05 Heat Exchanger

|07 Pins, Dowels, Plugs and Cups

|15 Snap Rings

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings, Clamps, Misc Fastening

|85 Sealing Elements

|90 Bearing Elements

|99 Miscellaneous

|00 Engine & Vehicle Assembly


SUB-SUBSYSTEM ROLL-UP































NEW TECHNOLOGY PACKAGE COST INFORMATION
3.5L.V6 DOHC, Turbo Dl
Manufacturing
Material



$ 103.57

$

$ 11.13

$

$

$ 20.02

$ 5.74

$

$

$

$ 5.19

$ 0.97


$ 146.61
Labor



$ 55.54

$

$ 3.46

$

$

$ 6.62

$ 0.27

$

$

$

$

$ 10.55


$ 76.44
Burden



$ 69.32

$

$ 10.62

$

$

$ 1 0.27

$ 0.32

$

$

$

$

$ 15.83


$ 106.36
Total
Cost
(Component/
Assembly)



$ 228.42

$

$ 25.21

$

$

$ 36.90

$ 6.33

$

$

$

$ 5.19

$ 27.35


$ 329.41
Markup
End Item
Scrap



$ 17.30

$

$ 0.33

$

$

$ 0.18

$ 0.03

$

$

$

$ 0.03

$


$ 17.87
SGSA



$ 31.41

$

$ 3.66

$

$

$ 2.40

$ 0.41

$

$

$

$ 0.34

$


$ 38.21
Profit



$ 34.07

$

$ 3.89

$

$

$ 2.21

$ 0.38

$

$

$

$ 0.31

$


$ 40.86
EDST-RSD



$ 13.46

$

$ 2.20

$

$

$ 0.42

$ 0.06

$

$

$

$ 0.13

$


$ 16.27
Total Markup
Cost
(Component/
Assembly)



$ 96.23

$

$ 10.08

$

$

$ 5.21

$ 0.89

$

$

$

$ 0.80

$


$ 113.21
Total
Packaging
Cost
(Component/
Assembly)



$ 5.17

$

$ 0.33

$

$

$ 0.63

$ 0.02

$

$

$

$ 0.02

$


$ 6.17
Net
Component/
Assembly Cosl
Impact to OEM



$ 329.82

$

$ 35.61

$

$

$ 42.75

$ 7.24

$

$

$

$ 6.02

$ 27.35


$ 448.79
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                            Apdx. C.2 Induct. Air Charging, Page: 34 of 45
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0104
                                                                                                                                                                         Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
        Study Case*: 0104 ( N0104 New Technology Configuration)
                      ( B0104 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0115 Induction Air Charging Subsystem

1

2

3

4

5

6

7

8

9

10

11

12




|01 Turbo Chargers (Assemblies)

|02 Solenoids

|05 Heat Exchanger

|07 Pins, Dowels, Plugs and Cups

|15 Snap Rings

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings, Clamps, Misc Fastening

|85 Sealing Elements

|90 Bearing Elements

|99 Miscellaneous

|00 Engine & Vehicle Assembly


SUB-SUBSYSTEM ROLL-UP































BASE TECHNOLOGY PACKAGE COST INFORMATION
5.4L V8, SOHC, NA, PR
Manufacturing
Material



$

$

$

$

$

$

$

$

$

$

$

$


$ -
Labor



$

$

$

$

$

$

$

$

$

$

$

$


$ -
Burden



$

$

$

$

$

$

$

$

$

$

$

$


$ -
Total
Manufacturing
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$


$
Markup
End Item
Scrap



$

$

$

$

$

$

$

$

$

$

$

$


$ -
SGSA



$

$

$

$

$

$

$

$

$

$

$

$


$ -
Profit



$

$

$

$

$

$

$

$

$

$

$

$


$ -
EDST-RSD



$

$

$

$

$

$

$

$

$

$

$

$


$ -
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$


$
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$


$
Net
Component/
Assembly Cosl
Impact to OEM



$

$

$

$

$

$

$

$

$

$

$

$


$
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                            Apdx. C.2 Induct. Air Charging, Page: 35 of 45
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                         APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                 CASE STUDY #0104
                                                                                                                                              Printed: 3/2 6/2010


Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
Study Case*: 0104 ( N0104 New Technology Configuration)
( B0104 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

Sub-Subsystem

Sub-Subsystem Description

0115 Induction Air Charging Subsystem

1

2

3

4

5

6

7

8

9

10

11

12




|01 Turbo Chargers (Assemblies)


J02 Solenoids


J05 Heat Exchanger


|07 Pins, Dowels, Plugs and Cups


|15 Snap Rings


|70 Pipes, Hoses, Ducting


J75 Brackets


|80 Boltings, Clamps, Misc Fastening

(85 Sealing Elements


|90 Bearing Elements


J99 Miscellaneous

|00 Engine & Vehicle Assembly



SUB-SUBSYSTEM ROLL-UP
































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
3.5L.V6 DOHC, Turbo Dl
BASE TECHNOLOGY PACKAGE COST INFORMATION
5.4L V8, SOHC, NA, PFI
Manufacturing
Material



$ 103.57

$

$ 11.13

$

$

$ 20.02

$ 5.74

$

$

$

$ 5.19

$ 0.97


$ 146.61
Labor



$ 55.54

$

$ 3.46

$

$

$ 6.62

$ 0.27

$

$

$

$

$ 1 0.55


$ 76.44
Burden



$ 69.32

$

$ 10.62

$

$

$ 1 0.27

$ 0.32

$

$

$

$

$ 1 5.83


$ 106.36
Total
Manufacturing
Cost
(Component/
Assembly)



$ 228.42

$

$ 25.21

$

$

$ 36.90

$ 6.33

$

$

$

$ 5.19

$ 27.35


$ 329.41
Markup
End Item
Scrap



$ 17.30

$

$ 0.33

$

$

$ 0.18

$ 0.03

$

$

$

$ 0.03

$


$ 17.87
SGSA



$ 31.41

$

$ 3.66

$

$

$ 2.40

$ 0.41

$

$

$

$ 0.34

$


$ 38.21
Profit



$ 34.07

$

$ 3.89

$

$

$ 2.21

$ 0.38

$

$

$

$ 0.31

$


$ 40.86
EDST-RSD



$ 13.46

$

$ 2.20

$

$

$ 0.42

$ 0.06

$

$

$

$ 0.13

$


$ 16.27
Total Markup
Cost
(Component/
Assembly)



$ 96.23

$

$ 10.08

$

$

$ 5.21

$ 0.89

$

$

$

$ 0.80

$


$ 113.21
Total
Packaging
Cost
(Component/
Assembly)



$ 5.17

$

$ 0.33

$

$

$ 0.63

$ 0.02

$

$

$

$ 0.02

$


$ 6.17
Net
Component/
Assembly Cosl
Impact to OEM



$ 329.82

$

$ 35.61

$

$

$ 42.75

$ 7.24

$

$

$

$ 6.02

$ 27.35


$ 448.79
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                Apdx. C.2 Induct. Air Charging, Page: 36 of 45
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0104
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
        Study Case*: 0104  ( N0104 New Technology Configuration)
                     ( B0104 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0117 Breather Subsystem

1

2

3

4

5

6

7

8

9

10

11



|02 Oil/Air Separator

|03 Valves

|65 Adapters

|70 Pipes, Hoses, Ducting

|75 Brackets

|60 Boltings

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine and Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP




























NEW TECHNOLOGY PACKAGE COST INFORMATION
3.5L.V6 DOHC, Turbo Dl
Manufacturing
Material



$ 12.42

$

$

$ 3.49

$

$

$

$

$

$

$ 0.08

$ 15.99
Labor



$ 2.48

$

$

$ 0.70

$

$

$

$

$

$

$ 1.05

$ 4.24
Burden



$ 9.93

$

$

$ 2.79

$

$

$

$

$

$

$ 0.19

$ 12.92
Total
Cost
(Component/
Assembly)



$ 24.84

$

$

$ 6.99

$

$

$

$

$

$

$ 1.32

$ 33.14
Markup
End Item
Scrap



$ 0.08

$

$

$ 0.02

$

$

$

$

$

$

$

$ 0.11
SGSA



$ 1.68

$

$

$ 0.47

$

$

$

$

$

$

$

$ 2.15
Profit



$ 1.12

$

$

$ 0.32

$

$

$

$

$

$

$

$ 1.44
EDST-RSD



$ 0.28

$

$

$ 0.08

$

$

$

$

$

$

$

$ 0.36
Total Markup
Cost
(Component/
Assembly)



$ 3.16

$

$

$ 0.89

$

$

$

$

$

$

$

$ 4.05
Total
Packaging
Cost
(Component/
Assembly)



$ 0.05

$

$

$

$

$

$

$

$

$

$

$ 0.05
Net
Component/
Assembly Cosl
Impact to OEM



$ 28.05

$

$

$ 7.88

$

$

$

$

$

$

$ 1.32

$ 37.25
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                               Apdx. C.2 Breather, Page: 37 of 45
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0104
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
        Study Case*: 0104  ( N0104 New Technology Configuration)
                     ( B0104 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

0117 Breather Subsystem

1

2

3

4

5

6

7

8

9

10

11



|02 Oil/Air Separator

|03 Valves

|65 Adapters

|70 Pipes, Hoses, Ducting

|75 Brackets

|60 Boltings

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine and Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP




























BASE TECHNOLOGY PACKAGE COST INFORMATION
5.4L V8, SOHC, NA, PR
Manufacturing
Material



$ 0.67

$

$ 0.50

$

$

$

$

$

$

$

$ 0.05

$ 1.21
Labor



$ 0.13

$

$

$

$

$

$

$

$

$

$ 0.30

$ 0.43
Burden



$ 0.53

$

$

$

$

$

$

$

$

$

$ 0.05

$ 0.59
Total
Cost
(Component/
Assembly)



$ 1.33

$

$ 0.50

$

$

$

$

$

$

$

$ 0.40

$ 2.23
Markup
End Item
Scrap



$ 0.00

$

$

$

$

$

$

$

$

$

$

$ 0.00
SGSA



$ 0.09

$

$

$

$

$

$

$

$

$

$

$ 0.09
Profit



$ 0.06

$

$

$

$

$

$

$

$

$

$

$ 0.06
EDST-RSD



$ 0.02

$

$

$

$

$

$

$

$

$

$

$ 0.02
Total Markup
Cost
(Component/
Assembly)



$ 0.17

$

$

$

$

$

$

$

$

$

$

$ 0.17
Total
Packaging
Cost
(Component/
Assembly)



$ 0.02

$

$

$

$

$

$

$

$

$

$

$ 0.02
Net
Component/
Assembly Cosl
Impact to OEM



$ 1.52

$

$ 0.50

$

$

$

$

$

$

$

$ 0.40

$ 2.42
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                               Apdx. C.2 Breather, Page: 38 of 45
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                        APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                CASE STUDY #0104
                                                                                                                                             Printed: 3/2 6/2010


Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
Study Case*: 0104 ( N0104 New Technology Configuration)
( B0104 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

Sub-Subsystem

Sub-Subsystem Description

0117 Breather Subsystem

1

2

3

4

5

6

7

8

9

10

11



(02 Oil/Air Separator


J03 Valves


J65 Adapters


|70 Pipes, Hoses, Ducting


J75 Brackets


|so Boltings

(85 Sealing Elements


|90 Bearing Elements


J95 Tools


|99 Miscellaneous

|00 Engine and Vehicle Assembly


SUB-SUBSYSTEM ROLL-UP





























INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
3.5L.V6 DOHC, Turbo Dl
BASE TECHNOLOGY PACKAGE COST INFORMATION
5.4L V8, SOHC, NA, PFI
Manufacturing
Material



$ 11.75

$

$ (0.50J

$ 3.49

$

$

$

$

$

$

$ 0.03

$ 14.78
Labor



$ 2.35

$

$

$ 0.70

$

$

$

$

$

$

$ 0.75

$ 3.80
Burden



$ 9.40

$

$

$ 2.79

$

$

$

$

$

$

$ 0.14

$ 12.33
Total
Manufacturing
Cost
(Component/
Assembly)



$ 23.51

$

$ (0.50)

$ 6.99

$

$

$

$

$

$

$ 0.92

$ 30.91
Markup
End Item
Scrap



$ 0.08

$

$

$ 0.02

$

$

$

$

$

$

$

$ 0.10
SGSA



$ 1.59

$

$

$ 0.47

$

$

$

$

$

$

$

$ 2.06
Profit



$ 1.06

$

$

$ 0.32

$

$

$

$

$

$

$

$ 1.38
EDST-RSD



$ 0.27

$

$

$ 0.08

$

$

$

$

$

$

$

$ 0.34
Total Markup
Cost
(Component/
Assembly)



$ 2.99

$

$

$ 0.89

$

$

$

$

$

$

$

$ 3.88
Total
Packaging
Cost
(Component/
Assembly)



$ 0.03

$

$

$

$

$

$

$

$

$

$

$ 0.03
Net
Component/
Assembly Cosl
Impact to OEM



$ 26.53

$

f (0.50)

$ 7.88

$

$

$

$

$

$

$ 0.92

$ 34.83
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                  Apdx. C.2 Breather, Page: 39 of 45
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                              CASE STUDY #0104
                                                                                                                                                                          Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
        Study Case*: 0104 ( N0104 New Technology Configuration)
                      ( B0104 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO




NEW TECHNOLOGY PACKAGE COST INFORMATION
3.5L.V6 DOHC, Turbo Dl
Manufacturing
Material

Labor

Burden

Total
Manufacturing
Cost
(Component/
Assembly)

0160 Engine Management, Engine Electronic, and Electrical Subsystems

1

2

3

4

5

6

7

8

9

10

11

12



|01 Spark Plugs, Glow Plugs

|02 Engine Management Systems, Engine Electronic Systems






|03 Engine Electrical Systems (including Wiring Harnesses, Earth Straps, I

|65 Adapters

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine and Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP





















$ 4.06

$ 24.09

$ 46.95

$

$

$

$

$

$

$

$

$ 0.10

$ 75.20

$ 0.81

$ 4.82

$ 24.66

$

$

$

$

$

$

$

$

$ 2.41

$ 32.70

$ 3.24

$ 1 9.27

$ 34.29

$

$

$

$

$

$

$

$

$ 1.25

$ 58.06

$ 8.11

$ 48.1 8

$ 105.90

$

$

$

$

$

$

$

$

$ 3.75

$ 165.95
Markup
End Item
Scrap



$ 0.05

$ 0.42

$ 0.46

$

$

$

$

$

$

$

$

$

$ 0.92
SGSA



$ 0.62

$ 4.20

$ 7.16

$

$

$

$

$

$

$

$

$

$ 11.98
Profit



$ 0.58

$ 4.80

$ 5.71

$

$

$

$

$

$

$

$

$

$ 11.08
EDST-RSD



$ 0.24

$ 2.40

$ 1.99

$

$

$

$

$

$

$

$

$

$ 4.63
Total Markup
Cost
(Component/
Assembly)



$ 1.49

$ 11.82

$ 15.31

$

$

$

$

$

$

$

$

$

$ 28.61
Total
Packaging
Cost
(Component/
Assembly)



$

$

$ 0.11

$

$

$

$

$

$

$

$

$

$ 0.11
Net
Component/
Assembly Cosl
Impact to OEM



$ 9.60

$ 60.00

$ 121.32

$

$

$

$

$

$

$

$

$ 3.75

$ 194.68
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                            Apdx. C.2 Electronic-Electrical, Page: 40 of 45
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                              CASE STUDY #0104
                                                                                                                                                                          Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
        Study Case*: 0104 ( N0104 New Technology Configuration)
                      ( B0104 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
o>
-g Sub-Subsystem Description
CO
.a
CO




0160 Engine Management, Engine Electronic, and E

1

2

3

4

5

6

7

8

9

10

11

12



|01 Spark Plugs, Glow Plugs

|02 Engine Management Systems, Engine Electronic Systems






|03 Engine Electrical Systems (including Wiring Harnesses, Earth Straps,

|65 Adapters

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine and Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP




















BASE TECHNOLOGY PACKAGE COST INFORMATION
5.4L V8, SOHC, NA, PR
Manufacturing
Material



$ 4.00

$

$ 38.39

$

$

$

$

$

$

$

$

$ 0.10

$ 42.49
Labor



$ 0.80

$

$ 20.61

$

$

$

$

$

$

$

$

$ 2.41

$ 23.81
Burden



$ 3.20

$

$ 37.88

$

$

$

$

$

$

$

$

$ 0.83

$ 41.91
Total
Cost
(Component/
Assembly)



$ 8.00

$

$ 96.88

$

$

$

$

$

$

$

$

$ 3.34

$ 108.22
Markup
End Item
Scrap



$ 0.04

$

$ 0.46

$

$

$

$

$

$

$

$

$

$ 0.50
SGSA



$ 0.52

$

$ 6.77

$

$

$

$

$

$

$

$

$

$ 7.29
Profit



$ 0.48

$

$ 5.62

$

$

$

$

$

$

$

$

$

$ 6.10
EDST-RSD



$ 0.20

$

$ 2.07

$

$

$

$

$

$

$

$

$

$ 2.27
Total Markup
Cost
(Component/
Assembly)



$ 1.24

$

$ 14.92

$

$

$

$

$

$

$

$

$

$ 16.16
Total
Packaging
Cost
(Component/
Assembly)



$

$

$ 0.15

$

$

$

$

$

$

$

$

$

$ 0.15
Net
Component/
Assembly Cosl
Impact to OEM



$ 9.24

$

$ 111.95

$

$

$

$

$

$

$

$

$ 3.34

$ 124.52
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                            Apdx. C.2 Electronic-Electrical, Page: 41 of 45
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                         APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                  CASE STUDY #0104
                                                                                                                                                Printed: 3/2 6/2010

Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
Study Case*: 0104 ( N0104 New Technology Configuration)
( B0104 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO





0160 Engine Management, Engine Electronic, and E

1

2

3

4

5

6

7

8

9

10

11

12



|01 Spark Plugs, Glow Plugs

|02 Engine Management Systems, Engine Electronic Systems


0

0

|03 Engine Electrical Systems (including Wiring Harnesses, Earth Straps, o

|65 Adapters

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine and Vehicle Assembly

SUB-SUBSYSTEM ROLL-UP

0

0

0

0

0

0

0

0

0


INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
3.5L.V6 DOHC, Turbo Dl
BASE TECHNOLOGY PACKAGE COST INFORMATION
5.4L V8, SOHC, NA, PFI
Manufacturing
Material



$

$

$

$

$

$

$

$

$

$

$

$

$ -
Labor



$

$

$

$

$

$

$

$

$

$

$

$

$ -
Burden



$ 0.04

$ 1 9.27

$ (3.58)

$

$

$

$

$

$

$

$

$ 0.42

$ 16.15
Total
Manufacturing
Cost
(Component/
Assembly)



$ 0.11

$ 48.1 8

$ 9.03

$

$

$

$

$

$

$

$

$ 0.42

$ 57.73
Markup
End Item
Scrap



$ 0.01

$ 0.42

$ 0.00

$

$

$

$

$

$

$

$

$

$ 0.43
SGSA



$ 0.10

$ 4.20

$ 0.39

$

$

$

$

$

$

$

$

$

$ 4.69
Profit



$ 0.10

$ 4.80

$ 0.08

$

$

$

$

$

$

$

$

$

$ 4.98
EDST-RSD



$ 0.04

$ 2.40

$ (0.09)

$

$

$

$

$

$

$

$

$

$ 2.35
Total Markup
Cost
(Component/
Assembly)



$ 0.25

$ 11.82

$ 0.39

$

$

$

$

$

$

$

$

$

$ 12.46
Total
Packaging
Cost
(Component/
Assembly)



$

$

$ (0.04)

$

$

$

$

$

$

$

$

$

$ ;o,o4)
Net
Component/
Assembly Cosl
Impact to OEM



$ 0.36

$ 60.00

$ 9.38

$

$

$

$

$

$

$

$

$ 0.42

$ 70.15
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                 Apdx. C.2 Electronic-Electrical, Page: 42 of 45
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0104
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
        Study Case*: 0104  ( N0104 New Technology Configuration)
                     ( B0104 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO




NEW TECHNOLOGY PACKAGE COST INFORMATION
3.5L.V6 DOHC, Turbo Dl
Manufacturing
Material

Labor

Burden

Total
Manufacturing
Cost
(Component/
Assembly)

Markup
End Item
Scrap

0170 Accessory Subsystem (Starter Motor, Alternators, Power Steering Pumps, etc)

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17



|01 Starter Motors

|02 Alternators

|03 Power Steering Pumps

|04 Vacuum Pumps

|05 Air Conditioning Compressors

|06 Hydraulic Pumps

|07 Ventilator

|10 Other Accessories

|65 Adapters

|70 Pipes, Hoses, Ducting

|75 Brackets

|60 Boltings

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine & Vehicle Assembly of Accessory Components

SUB-SUBSYSTEM ROLL-UP





































$

$

$

$ 3.98

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.13

$ 4.11

$

$

$

$ 2.18

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.74

$ 2.92

$

$

$

$ 7.34

$

$

$

$

$

$

$

$

$

$

$

$

$ 1.34

$ 8.67

$

$

$

$ 1 3.49

$

$

$

$

$

$

$

$

$

$

$

$

$ 2.20

$ 15.69

$

$

$

$ 0.11

$

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.11
SGSA



$

$

$

$ 1.62

$

$

$

$

$

$

$

$

$

$

$

$

$

$ 1.62
Profit



$

$

$

$ 1.32

$

$

$

$

$

$

$

$

$

$

$

$

$

$ 1.32
EDST-RSD



$

$

$

$ 0.37

$

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.37
Total Markup
Cost
(Component/
Assembly)



$

$

$

$ 3.41

$

$

$

$

$

$

$

$

$

$

$

$

$

$ 3.41
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$ 0.11

$

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.11
Net
Component/
Assembly Cosl
Impact to OEM



$

$

$

$ 1 7.01

$

$

$

$

$

$

$

$

$

$

$

$

$ 2.20

$ 19.22
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                              Apdx. C.2 Accessory, Page: 43 of 45
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                             CASE STUDY #0104
                                                                                                                                                                        Printed: 3/2 6/2010
     Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
        Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
        Study Case*: 0104  ( N0104 New Technology Configuration)
                     ( B0104 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

01 70 Accessory Subsystem (Starter Motor, Alternat

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17



|01 Starter Motors

|02 Alternators

|03 Power Steering Pumps

|04 Vacuum Pumps

|05 Air Conditioning Compressors

|06 Hydraulic Pumps

|07 Ventilator

|10 Other Accessories

|65 Adapters

|70 Pipes, Hoses, Ducting

|75 Brackets

|60 Boltings

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine & Vehicle Assembly of Accessory Components

SUB-SUBSYSTEM ROLL-UP








































BASE TECHNOLOGY PACKAGE COST INFORMATION
5.4L V8, SOHC, NA, PR
Manufacturing
Material



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
Labor



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Burden



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Total
Manufacturing
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Markup
End Item
Scrap



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
SGSA



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Profit



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
EDST-RSD



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Net
Component/
Assembly Cosl
Impact to OEM



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                              Apdx. C.2 Accessory, Page: 44 of 45
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                        APPENDIX C.2 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                 CASE STUDY #0104
                                                                                                                                             Printed: 3/2 6/2010

Technology Level: 01-Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine
Vehicle Class: 04-Small to Midsize Truck, Passenger + Midsize Towing Capability
Study Case*: 0104 ( N0104 New Technology Configuration)
( B0104 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

E
0)
w5
-g Sub-Subsystem Description
CO
.a
CO

01 70 Accessory Subsystem (Starter Motor, Alternat

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17



|01 Starter Motors

|02 Alternators

|03 Power Steering Pumps

|04 Vacuum Pumps

|05 Air Conditioning Compressors

|06 Hydraulic Pumps

|07 Ventilator

|10 Other Accessories

|65 Adapters

|70 Pipes, Hoses, Ducting

|75 Brackets

|60 Boltings

|85 Sealing Elements

|90 Bearing Elements

|95 Tools

|99 Miscellaneous

|00 Engine & Vehicle Assembly of Accessory Components

SUB-SUBSYSTEM ROLL-UP









































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
3.5L.V6 DOHC, Turbo Dl
BASE TECHNOLOGY PACKAGE COST INFORMATION
5.4L V8, SOHC, NA, PFI
Manufacturing
Material



$

$

$

$ 3.98

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.13

$ 4.11
Labor



$

$

$

$ 2.18

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.74

$ 2.92
Burden



$

$

$

$ 7.34

$

$

$

$

$

$

$

$

$

$

$

$

$ 1.34

$ 8.67
Total
Manufacturing
Cost
(Component/
Assembly)



$

$

$

$ 1 3.49

$

$

$

$

$

$

$

$

$

$

$

$

$ 2.20

$ 15.69
Markup
End Item
Scrap



$

$

$

$ 0.11

$

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.11
SGSA



$

$

$

$ 1.62

$

$

$

$

$

$

$

$

$

$

$

$

$

$ 1.62
Profit



$

$

$

$ 1.32

$

$

$

$

$

$

$

$

$

$

$

$

$

$ 1.32
EDST-RSD



$

$

$

$ 0.37

$

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.37
Total Markup
Cost
(Component/
Assembly)



$

$

$

$ 3.41

$

$

$

$

$

$

$

$

$

$

$

$

$

$ 3.41
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$ 0.11

$

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.11
Net
Component/
Assembly Cosl
Impact to OEM



$

$

$

$ 1 7.01

$

$

$

$

$

$

$

$

$

$

$

$

$ 2.20

$ 19.22
File: Subsystem CMAT, CS0104, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                  Apdx. C.2 Accessory, Page: 45 of 45
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                               APPENDIX C.3 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                            CASE STUDY #0802
                                                                                                                                                                     Printed: 3/2 6/2010
     Technology Level: 08 - 6 Speed Automatic versus 5 Speed Automatic Transmission
       Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case#: 0802 ( N0802 New Technology Configuration)
                     ( B0802 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

£
5,
01
-§ Sub-Subsystem Description
w
^
(ft

0202 Case(s) Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13



| 01 Transaxle Case

I 02 Transaxle Housing

| 03 Covers

I 04 OPEN

| 05 OPEN

I 10 Plugs

| 70 Pipes, Hoses, Ducting

I 75 Brackets

| 80 Boltings

| 85 Sealing Elements

1 90 Bearing Elements

| 99 Miscellaneous

1 99 Transmission Assembly of Case Componments

SUB-SUBSYSTEM ROLL-UP
































NEW TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Automatic Transmission: 2007-2009 Toyota Camry
Manufacturing
Material



$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
Labor



$

$

$

$

$

$

$

$

$

$

$

$

$

$
Burden



$

$

$

$

$

$

$

$

$

$

$

$

$

$
Total
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$

$
Markup
End Item
Scrap



$

$

$

$

$

$

$

$

$

$

$

$

$

$
SG&A



$

$

$

$

$

$

$

$

$

$

$

$

$

$
Profit



$

$

$

$

$

$

$

$

$

$

$

$

$

$
ED&T-R&D



$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$

$
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$

$
Net
Component/
Assembly Cost
Impact to OEM



$

$

$

$

$

$

$

$

$

$

$

$

$

$
File: Subsystem CMAT, CS0802, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                               Apdx. C.3 Cases, Page: 1 of 12
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                               APPENDIX C.3 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                            CASE STUDY #0802
                                                                                                                                                                     Printed: 3/2 6/2010
     Technology Level: 08 - 6 Speed Automatic versus 5 Speed Automatic Transmission
       Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case#: 0802 ( N0802 New Technology Configuration)
                     ( B0802 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

£
5,
01
-§ Sub-Subsystem Description
w
^
(ft

0202 Case(s) Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13



| 01 Transaxle Case

I 02 Transaxle Housing

| 03 Covers

I 04 OPEN

| 05 OPEN

I 10 Plugs

| 70 Pipes, Hoses, Ducting

I 75 Brackets

| 80 Boltings

I 85 Sealing Elements

| 90 Bearing Elements

I 99 Miscellaneous

| 99 Transmission Assembly of Case Componments

SUB-SUBSYSTEM ROLL-UP
































BASE TECHNOLOGY PACKAGE COST INFORMATION
5 Speed Automatic Transmission: 2004-2006 Toyota Camry
Manufacturing
Material



$ 0.83

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.83
Labor



$ 0.53

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.53
Burden



$ 4.68

$

$

$

$

$

$

$

$

$

$

$

$

$ 4.68
Total
Cost
(Component/
Assembly)



$ 6.03

$

$

$

$

$

$

$

$

$

$

$

$

$ 6.03
Markup
End Item
Scrap



$

$

$

$

$

$

$

$

$

$

$

$

$

$
SG&A



$

$

$

$

$

$

$

$

$

$

$

$

$

$
Profit



$

$

$

$

$

$

$

$

$

$

$

$

$

$
ED&T-R&D



$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$

$
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$

$
Net
Component/
Assembly Cost
Impact to OEM



$ 6.03

$

$

$

$

$

$

$

$

$

$

$

$

$ 6.03
File: Subsystem CMAT, CS0802, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                               Apdx. C.3 Cases, Page: 2 of 12
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                        APPENDIX C.3 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                CASE STUDY #0802
                                                                                                                                           Printed: 3/2 6/2010

Technology Level: 08 - 6 Speed Automatic versus 5 Speed Automatic Transmission
Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
Study Case#: 0802 ( N0802 New Technology Configuration)
( B0802 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

£
5,
01
-§ Sub-Subsystem Description
w
^
(ft

0202 Case(s) Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13



| 01 Transaxle Case

I 02 Transaxle Housing

| 03 Covers

I 04 OPEN

| 05 OPEN

I 10 Plugs

| 70 Pipes, Hoses, Ducting

I 75 Brackets

| 80 Boltings

I 85 Sealing Elements

| 90 Bearing Elements

I 99 Miscellaneous

| 99 Transmission Assembly of Case Componments

SUB-SUBSYSTEM ROLL-UP

































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Automatic Transmission: 2007-2009 Toyota Camry
BASE TECHNOLOGY PACKAGE COST INFORMATION
5 Speed Automatic Transmission: 2004-2006 Toyota Camry
Manufacturing
Material



I (0.83)

$

$

$

$

$

$

$

$

$

$

$

$

$ (0,83)
Labor



I (0.531

$

$

$

$

$

$

$

$

$

$

$

$

$ (0,53)
Burden



$ (4.88)

$

$

$

$

$

$

$

$

$

$

$

$

$ (4,68)
Total
Manufacturing
Cost
(Component/
Assembly)



$ (8.03!

$

$

$

$

$

$

$

$

$

$

$

$

$ (6,03)
Markup
End Item
Scrap



$

$

$

$

$

$

$

$

$

$

$

$

$

$
SG&A



$

$

$

$

$

$

$

$

$

$

$

$

$

$
Profit



$

$

$

$

$

$

$

$

$

$

$

$

$

$
ED&T-R&D



$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$

$
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$

$
Net
Component/
Assembly Cost
Impact to OEM



$ (8.03!

$

$

$

$

$

$

$

$

$

$

$

$

$ (6,03)
File: Subsystem CMAT, CS0802, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                  Apdx. C.3 Cases, Page: 3 of 12
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                               APPENDIX C.3 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                            CASE STUDY #0802
                                                                                                                                                                      Printed: 3/2 6/2010
     Technology Level: 08 - 6 Speed Automatic versus 5 Speed Automatic Transmission
       Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case#: 0802 ( N0802 New Technology Configuration)
                     ( B0802 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

£
5,
01
-§ Sub-Subsystem Description
w
^
(ft

0203 Geartrain Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17



| 01 Sun Gears

I 02 Planetary Gears

| 03 Ring Gears

I 04 Counter Gears

| 05 Differential Gears

I 10 Gears Misc

| 15 Snap Rings

I 70 Pipes, Hoses, Ducting

I 75 Brackets

1 80 Boltings (Includes Nuts & Washers)

1 85 Sealing Elements

| 90 Bearings Elements Misc

1 91 Bearing/Bushings

| 92 Roller Bearings

1 93 Thrust Bearings/Washers

| 94 Thrust Roller/Needle Bearings

1 00 Transmission Assembly of Gear Componments

SUB-SUBSYSTEM ROLL-UP








































NEW TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Automatic Transmission: 2007-2009 Toyota Camry
Manufacturing
Material



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
Labor



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Burden



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Total
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Markup
End Item
Scrap



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
SG&A



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Profit



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
ED&T-R&D



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Net
Component/
Assembly Cost
Impact to OEM



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
File: Subsystem CMAT, CS0802, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                              Apdx. C.3 Geartrain, Page: 4 of 12
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
      I  f
                                               APPENDIX C.3 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                            CASE STUDY #0802
                                                                                                                                                                      Printed: 3/2 6/2010
     Technology Level: 08 - 6 Speed Automatic versus 5 Speed Automatic Transmission
       Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case#: 0802 ( N0802 New Technology Configuration)
                     ( B0802 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

£
5,
01
-§ Sub-Subsystem Description
w
^
w

0203 Geartrain Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17



| 01 Sun Gears

I 02 Planetary Gears

| 03 Ring Gears

I 04 Counter Gears

| 05 Differential Gears

I 10 Gears Misc

| 15 Snap Rings

I 70 Pipes, Hoses, Ducting

I 75 Brackets

I 80 Boltings (Includes Nuts & Washers)

| 85 Sealing Elements

I 90 Bearings Elements Misc

| 91 Bearing/Bushings

I 92 Roller Bearings

| 93 Thrust Bearings/Washers

I 94 Thrust Roller/Needle Bearings

| 00 Transmission Assembly of Gear Componments

SUB-SUBSYSTEM ROLL-UP








































BASE TECHNOLOGY PACKAGE COST INFORMATION
5 Speed Automatic Transmission: 2004-2006 Toyota Camry
Manufacturing
Material



$

$

$ 1.22

$

$

$ 0.61

$

$

$

$

$

$

$

$

$

$

$

$ 1.83
Labor



$

$

$ 3.95

$

$

$ 0.74

$

$

$

$

$

$

$

$

$

$

$

$ 4.69
Burden



$

$

$ 11.79

$

$

$ 1.89

$

$

$

$

$

$

$

$

$

$

$

$ 13.67
Total
Cost
(Component/
Assembly)



$

$

$ 16.96

$

$

$ 3.23

$

$

$

$

$

$

$

$

$

$

$

$ 20.19
Markup
End Item
Scrap



$

$

$ 0.12

$

$

$ 0.02

$

$

$

$

$

$

$

$

$

$

$

$ 0.14
SG&A



$

$

$ 1.19

$

$

$ 0.26

$

$

$

$

$

$

$

$

$

$

$

$ 1.45
Profit



$

$

$ 1.36

$

$

$ 0.29

$

$

$

$

$

$

$

$

$

$

$

$ 1.64
ED&T-R&D



$

$

$ 0.68

$

$

$ 0.13

$

$

$

$

$

$

$

$

$

$

$

$ 0.81
Total Markup
Cost
(Component/
Assembly)



$

$

$ 3.34

$

$

$ 0.71

$

$

$

$

$

$

$

$

$

$

$

$ 4.05
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Net
Component/
Assembly Cost
Impact to OEM



$

$

$ 20.30

$

$

$ 3.94

$

$

$

$

$

$

$

$

$

$

$

$ 24.24
File: Subsystem CMAT, CS0802, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                              Apdx. C.3 Geartrain, Page: 5 of 12
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
     I.
                                        APPENDIX C.3 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                CASE STUDY #0802
                                                                                                                                            Printed: 3/2 6/2010

Technology Level: 08 - 6 Speed Automatic versus 5 Speed Automatic Transmission
Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
Study Case#: 0802 ( N0802 New Technology Configuration)
( B0802 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
£

£
5,
01
-§ Sub-Subsystem Description
w
^
(ft

0203 Geartrain Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17



| 01 Sun Gears

I 02 Planetary Gears

| 03 Ring Gears

I 04 Counter Gears

| 05 Differential Gears

I 10 Gears Misc

| 15 Snap Rings

I 70 Pipes, Hoses, Ducting

I 75 Brackets

I 80 Boltings (Includes Nuts & Washers)

| 85 Sealing Elements

I 90 Bearings Elements Misc

| 91 Bearing/Bushings

I 92 Roller Bearings

| 93 Thrust Bearings/Washers

I 94 Thrust Roller/Needle Bearings

| 00 Transmission Assembly of Gear Componments

SUB-SUBSYSTEM ROLL-UP









































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Automatic Transmission: 2007-2009 Toyota Camry
BASE TECHNOLOGY PACKAGE COST INFORMATION
5 Speed Automatic Transmission: 2004-2006 Toyota Camry
Manufacturing
Material



$

$

t (1.22)

$

$

t (0.61)

$

$

$

$

$

$

$

$

$

$

$

$ (1.83)
Labor



$

$

$ (3.35)

$

$

$ (0.74)

$

$

$

$

$

$

$

$

$

$

$

$ (4,69)
Burden



$

$

$ (11,79!

$

$

t (1.88)

$

$

$

$

$

$

$

$

$

$

$

$ (13,67)
Total
Manufacturing
Cost
(Component/
Assembly)



$

$

$ (18.36)

$

$

$ (3.23)

$

$

$

$

$

$

$

$

$

$

$

$ (20,19)
Markup
End Item
Scrap



$

$

$ fO.1l!

$

$

$ (0.02)

$

$

$

$

$

$

$

$

$

$

$

$ (0,14)
SG&A



$

$

$ (1.13)

$

$

$ (0.26)

$

$

$

$

$

$

$

$

$

$

$

$ (1,45)
Profit



$

$

I (1.36)

$

$

$ (0.28)

$

$

$

$

$

$

$

$

$

$

$

$ (1,64)
ED&T-R&D



$

$

$ (0.68)

$

$

t (0.13)

$

$

$

$

$

$

$

$

$

$

$

$ (0,81)
Total Markup
Cost
(Component/
Assembly)



$

$

$ (3.34)

$

$

t (0.71)

$

$

$

$

$

$

$

$

$

$

$

$ (4,05)
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Net
Component/
Assembly Cost
Impact to OEM



$

$

$ (20.30)

$

$

$ (3.S4)

$

$

$

$

$

$

$

$

$

$

$

$ (24,24)
File: Subsystem CMAT, CS0802, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                  Apdx. C.3 Geartrain, Page: 6 of 12
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.3 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                            CASE STUDY #0802
                                                                                                                                                                      Printed: 3/2 6/2010
     Technology Level: 08 - 6 Speed Automatic versus 5 Speed Automatic Transmission
       Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case#: 0802 ( N0802 New Technology Configuration)
                     ( B0802 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

£
5,
01
-§ Sub-Subsystem Description
w
^
(ft

0204 Internal Clutches Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17



| 01 Sprague/One Way Clutches

I 02 Clutch Assembly

I 03 Clutch & Brake Hubs

I 04 Sleeve & Couplers

I 05 Disc & Plates

I 09 Pistons

| 15 Snap Rings

I 70 Pipes, Hoses, Ducting

I 75 Brackets

| 80 Boltings

1 85 Sealing Elements

| 90 Bearing Elements Misc

1 91 Bearing/Bushings

| 92 Roller Bearings

1 93 Thrust Bearings/Washers

| 94 Thrust Roller/Needle Bearings

1 00 Transmission Assembly of Internal Clutches

SUB-SUBSYSTEM ROLL-UP








































NEW TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Automatic Transmission: 2007-2009 Toyota Camry
Manufacturing
Material



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
Labor



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Burden



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Total
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Markup
End Item
Scrap



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
SG&A



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Profit



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
ED&T-R&D



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Net
Component/
Assembly Cost
Impact to OEM



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
File: Subsystem CMAT, CS0802, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                            Apdx. C.3 Internal Clutches, Page: 7 of 12
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.3 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                            CASE STUDY #0802
                                                                                                                                                                      Printed: 3/2 6/2010
     Technology Level: 08 - 6 Speed Automatic versus 5 Speed Automatic Transmission
       Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case#: 0802 ( N0802 New Technology Configuration)
                     ( B0802 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

£
5,
01
-§ Sub-Subsystem Description
w
^
(ft

0204 Internal Clutches Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17



| 01 Sprague/One Way Clutches

I 02 Clutch Assembly

I 03 Clutch & Brake Hubs

I 04 Sleeve & Couplers

I 05 Disc & Plates

I 09 Pistons

| 15 Snap Rings

I 70 Pipes, Hoses, Ducting

I 75 Brackets

I 80 Boltings

| 85 Sealing Elements

I 90 Bearing Elements Misc

| 91 Bearing/Bushings

I 92 Roller Bearings

| 93 Thrust Bearings/Washers

I 94 Thrust Roller/Needle Bearings

| 00 Transmission Assembly of Internal Clutches

SUB-SUBSYSTEM ROLL-UP








































BASE TECHNOLOGY PACKAGE COST INFORMATION
5 Speed Automatic Transmission: 2004-2006 Toyota Camry
Manufacturing
Material



$ 1.61

$ 2.03

$

$

$ 13.03

$ 2.19

$

$

$

$

$

$

$

$

$

$

$ 0.61

$ 19.46
Labor



$ 2.74

$ 1.74

$

$

$ 1.57

$ 0.97

$

$

$

$

$

$

$

$

$

$

$ 1.85

$ 8.87
Burden



$ 12.12

$ 5.73

$

$

$ 11.70

$ 4.44

$

$

$

$

$

$

$

$

$

$

$ 0.47

$ 34.46
Total
Cost
(Component/
Assembly)



$ 16.47

$ 9.50

$

$

$ 26.29

$ 7.60

$

$

$

$

$

$

$

$

$

$

$ 2.93

$ 62.80
Markup
End Item
Scrap



$ 0.12

$ 0.07

$

$

$ 0.13

$ 0.15

$

$

$

$

$

$

$

$

$

$

$

$ 0.47
SG&A



$ 1.15

$ 0.67

$

$

$ 1.71

$ 0.74

$

$

$

$

$

$

$

$

$

$

$

$ 4.27
Profit



$ 1.32

$ 0.76

$

$

$ 1.58

$ 0.63

$

$

$

$

$

$

$

$

$

$

$

$ 4.28
ED&T-R&D



$ 0.66

$ 0.38

$

$

$ 0.66

$ 0.20

$

$

$

$

$

$

$

$

$

$

$

$ 1.90
Total Markup
Cost
(Component/
Assembly)



$ 3.24

$ 1.87

$

$

$ 4.08

$ 1.72

$

$

$

$

$

$

$

$

$

$

$

$ 10.91
Total
Packaging
Cost
(Component/
Assembly)



$ 0.05

$

$

$

$ 0.10

$ 0.11

$

$

$

$

$

$

$

$

$

$

$

$ 0.26
Net
Component/
Assembly Cost
Impact to OEM



$ 19.77

$ 11.38

$

$

$ 30.46

$ 9.44

$

$

$

$

$

$

$

$

$

$

$ 2.93

$ 73.98
File: Subsystem CMAT, CS0802, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                            Apdx. C.3 Internal Clutches, Page: 8 of 12
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                         APPENDIX C.3 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                 CASE STUDY #0802
                                                                                                                                              Printed: 3/2 6/2010

Technology Level: 08 - 6 Speed Automatic versus 5 Speed Automatic Transmission
Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
Study Case#: 0802 ( N0802 New Technology Configuration)
( B0802 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

£
5,
01
-§ Sub-Subsystem Description
w
^
(ft

0204 Internal Clutches Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17



| 01 Sprague/One Way Clutches

I 02 Clutch Assembly

I 03 Clutch & Brake Hubs

I 04 Sleeve & Couplers

I 05 Disc & Plates

I 09 Pistons

| 15 Snap Rings

I 70 Pipes, Hoses, Ducting

I 75 Brackets

I 80 Boltings

| 85 Sealing Elements

I 90 Bearing Elements Misc

| 91 Bearing/Bushings

I 92 Roller Bearings

| 93 Thrust Bearings/Washers

I 94 Thrust Roller/Needle Bearings

| 00 Transmission Assembly of Internal Clutches

SUB-SUBSYSTEM ROLL-UP









































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Automatic Transmission: 2007-2009 Toyota Camry
BASE TECHNOLOGY PACKAGE COST INFORMATION
5 Speed Automatic Transmission: 2004-2006 Toyota Camry
Manufacturing
Material



$ (1.61)

t (2.03)

$

$

$ (13.03)

t (2.19)

$

$

$

$

$

$

$

$

$

$

$ (0.61)

$ (19,46)
Labor



$ (2.74)

t (1.74)

$

$

$ (1.57)

$ (0.97)

$

$

$

$

$

$

$

$

$

$

$ (1.85)

$ (8.87)
Burden



$ (12.12)

$ (5.73)

$

$

$ (11.70)

$ (4.44)

$

$

$

$

$

$

$

$

$

$

$ (0.47)

$ (34,46)
Total
Manufacturing
Cost
(Component/
Assembly)



$ (16.47)

$ (9.50)

$

$

$ (26.29)

$ (7.60)

$

$

$

$

$

$

$

$

$

$

t (2.93)

$ (62,80)
Markup
End Item
Scrap



$ (0.12)

$ (o.o?)

$

$

$ (0.13)

$ (0.15)

$

$

$

$

$

$

$

$

$

$

$

t (0,47)
SG&A



t (1.15)

$ (0.67)

$

$

t (1.71)

t (0.74)

$

$

$

$

$

$

$

$

$

$

$

$ (4,27)
Profit



t (1.32)

t (O.T8J

$

$

t (1.58)

$ JO. 83)

$

$

$

$

$

$

$

$

$

$

$

$ (4,28)
ED&T-R&D



$

$ (0.38)

$

$

$

$ (0.20)

$

$

$

$

$

$

$

$

$

$

$

$ (1,90)
Total Markup
Cost
(Component/
Assembly)



$ (3.24)

$ (1 .87)

$

$

$ (4.08)

$ (1.72)

$

$

$

$

$

$

$

$

$

$

$

$ (10,91)
Total
Packaging
Cost
(Component/
Assembly)



$ (0.05)

$

$

$

$ (0.10)

f (0.11)

$

$

$

$

$

$

$

$

$

$

$

$ (0,26)
Net
Component/
Assembly Cost
Impact to OEM



$ (19.77)

$ (11.38)

$

$

$ (30.46)

t (9.44)

$

$

$

$

$

$

$

$

$

$

$ (2.93)

t (73,98)
File: Subsystem CMAT, CS0802, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                 Apdx. C.3 Internal Clutches, Page: 9 of 12
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                               APPENDIX C.3 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                            CASE STUDY #0802
                                                                                                                                                                      Printed: 3/2 6/2010
     Technology Level: 08 - 6 Speed Automatic versus 5 Speed Automatic Transmission
       Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case#: 0802 ( N0802 New Technology Configuration)
                     ( B0802 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

£
5,
01
-§ Sub-Subsystem Description
w
^
(ft

0207 Mechanical Controls Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17



| 01 Valve Body Assembly

I 02 Valve Body

I 03 Valves - Mechanical (Spool)

I 04 Valves - Electro-Mechanical (Solenoids)

| 07 Plugs and Cups

I 09 Piston

| 10 Accumulator Assemblies

I 15 Shafts/Rods/Pins

| 20 Springs

| 25 Retainers (Spring Clips, Push Nuts, Cotter Pins, etc)

1 70 Pipes, Hoses, Ducting

1 75 Brackets

1 80 Boltings (Includes Nuts, Washers, etc)

| 85 Sealing Elements

1 90 Bearing Elements

| 99 Miscellaneous

1 00 Transmission Assembly of Mechanical Control Components

SUB-SUBSYSTEM ROLL-UP








































NEW TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Automatic Transmission: 2007-2009 Toyota Camry
Manufacturing
Material



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
Labor



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Burden



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Total
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Markup
End Item
Scrap



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
SG&A



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Profit



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
ED&T-R&D



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
Net
Component/
Assembly Cost
Impact to OEM



$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$

$
File: Subsystem CMAT, CS0802, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                            Apdx. C.3 Mech. Controls, Page: 10 of 12
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
      I  f
                                               APPENDIX C.3 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                            CASE STUDY #0802
                                                                                                                                                                      Printed: 3/2 6/2010
     Technology Level: 08 - 6 Speed Automatic versus 5 Speed Automatic Transmission
       Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case#: 0802 ( N0802 New Technology Configuration)
                     ( B0802 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

£
5,
01
-§ Sub-Subsystem Description
w
^
w

0207 Mechanical Controls Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17



| 01 Valve Body Assembly

I 02 Valve Body

I 03 Valves - Mechanical (Spool)

I 04 Valves - Electro-Mechanical (Solenoids)

| 07 Plugs and Cups

I 09 Piston

| 10 Accumulator Assemblies

I 15 Shafts/Rods/Pins

| 20 Springs

I 25 Retainers (Spring Clips, Push Nuts, Cotter Pins, etc)

| 70 Pipes, Hoses, Ducting

I 75 Brackets

I 80 Boltings (Includes Nuts, Washers, etc)

I 85 Sealing Elements

| 90 Bearing Elements

I 99 Miscellaneous

| 00 Transmission Assembly of Mechanical Control Components

SUB-SUBSYSTEM ROLL-UP








































BASE TECHNOLOGY PACKAGE COST INFORMATION
5 Speed Automatic Transmission: 2004-2006 Toyota Camry
Manufacturing
Material



$

$

$

$

$

$

$

$

$

$

$ 0.12

$

$

$

$

$

$ 0.05

$ 0.17
Labor



$

$

$

$

$

$

$

$

$

$

$ 0.10

$

$

$

$

$

$ 0.42

$ 0.52
Burden



$

$

$

$

$

$

$

$

$

$

$ 0.43

$

$

$

$

$

$ 0.08

$ 0.50
Total
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$ 0.65

$

$

$

$

$

$ 0.54

$ 1.19
Markup
End Item
Scrap



$

$

$

$

$

$

$

$

$

$

$ 0.00

$

$

$

$

$

$

$ 0.00
SG&A



$

$

$

$

$

$

$

$

$

$

$ 0.04

$

$

$

$

$

$

$ 0.04
Profit



$

$

$

$

$

$

$

$

$

$

$ 0.03

$

$

$

$

$

$

$ 0.03
ED&T-R&D



$

$

$

$

$

$

$

$

$

$

$ 0.01

$

$

$

$

$

$

$ 0.01
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$ 0.07

$

$

$

$

$

$

$ 0.07
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$ 0.02

$

$

$

$

$

$

$ 0.02
Net
Component/
Assembly Cost
Impact to OEM



$

$

$

$

$

$

$

$

$

$

$ 0.74

$

$

$

$

$

$ 0.54

$ 1.28
File: Subsystem CMAT, CS0802, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                            Apdx. C.3 Mech. Controls, Page: 11 of 12
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                        APPENDIX C.3 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                 CASE STUDY #0802
                                                                                                                                             Printed: 3/2 6/2010

Technology Level: 08 - 6 Speed Automatic versus 5 Speed Automatic Transmission
Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
Study Case#: 0802 ( N0802 New Technology Configuration)
( B0802 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

£
5,
01
-§ Sub-Subsystem Description
w
^
(ft

0207 Mechanical Controls Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17



| 01 Valve Body Assembly

I 02 Valve Body

I 03 Valves - Mechanical (Spool)

I 04 Valves - Electro-Mechanical (Solenoids)

| 07 Plugs and Cups

I 09 Piston

| 10 Accumulator Assemblies

I 15 Shafts/Rods/Pins

| 20 Springs

I 25 Retainers (Spring Clips, Push Nuts, Cotter Pins, etc)

| 70 Pipes, Hoses, Ducting

I 75 Brackets

I 80 Boltings (Includes Nuts, Washers, etc)

I 85 Sealing Elements

| 90 Bearing Elements

I 99 Miscellaneous

| 00 Transmission Assembly of Mechanical Control Components

SUB-SUBSYSTEM ROLL-UP









































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Automatic Transmission: 2007-2009 Toyota Camry
BASE TECHNOLOGY PACKAGE COST INFORMATION
5 Speed Automatic Transmission: 2004-2006 Toyota Camry
Manufacturing
Material



$

$

$

$

$

$

$

$

$

$

t (0.12)

$

$

$

$

$

$ (0,05)

$ (0,17)
Labor



$

$

$

$

$

$

$

$

$

$

$ (0,10)

$

$

$

$

$

t (0.42)

$ (0,52)
Burden



$

$

$

$

$

$

$

$

$

$

$ {0,431

$

$

$

$

$

$ (0.08)

$ (0,50)
Total
Manufacturing
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$ (0,65)

$

$

$

$

$

$ (0.54)

$ (1,19)
Markup
End Item
Scrap



$

$

$

$

$

$

$

$

$

$

$ (0,00)

$

$

$

$

$

$

$ (0,00)
SG&A



$

$

$

$

$

$

$

$

$

$

t (0,04)

$

$

$

$

$

$

$ (0,04)
Profit



$

$

$

$

$

$

$

$

$

$

t 10,03)

$

$

$

$

$

$

$ (0,03)
ED&T-R&D



$

$

$

$

$

$

$

$

$

$

$ (0.01)

$

$

$

$

$

$

$ (0,01)
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$ |0,,07)

$

$

$

$

$

$

$ (0,07)
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

t 10,02)

$

$

$

$

$

$

$ (0,02)
Net
Component/
Assembly Cost
Impact to OEM



$

$

$

$

$

$

$

$

$

$

t (0.74)

$

$

$

$

$

$ (0.54)

$ (1,28)
File: Subsystem CMAT, CS0802, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                 Apdx. C.3 Mech. Controls, Page: 12 of 12
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                               APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                            CASE STUDY #0902
                                                                                                                                                                     Printed: 3/2 6/2010
     Technology Level: 09 - 6 Speed Automatic versus 6 Speed Direct Shift Transmission
       Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case#: 0902 ( N0902 New Technology Configuration)
                     ( B0902 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

£
5,
01
-§ Sub-Subsystem Description
w
^
(ft

0202 Case(s) Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13



|01 Transaxle Case

|02 Transaxle Housing

|03 Covers

|04 Actuators

|05 TBD

|10 Plugs

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings

|85 Sealing Elements

|90 Bearing Elements

|99 Miscellaneous

|00 Transmission Assembly of Case Components

SUB-SUBSYSTEM ROLL-UP
































NEW TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagen
Manufacturing
Material



$ 33.84

$ 29.57

$

$

$

$

$

$

$

$ 0.04

$

$

$ 1.41

$ 64.85
Labor



$ 2.90

$ 3.49

$

$

$

$

$

$

$

$ 0.21

$

$

$ 0.69

$ 7.28
Burden



$ 4.81

$ 5.46

$

$

$

$

$

$

$

$ 0.39

$

$

$ 2.43

$ 13.09
Total
Cost
(Component/
Assembly)



$ 41.54

$ 38.52

$

$

$

$

$

$

$

$ 0.63

$

$

$ 4.53

$ 85.22
Markup
End Item
Scrap



$ 2.12

$ 1.93

$

$

$

$

$

$

$

$ 0.00

$

$

$

$ 4.05
SG&A



$ 2.75

$ 2.50

$

$

$

$

$

$

$

$ 0.04

$

$

$

$ 5.30
Profit



$ 2.54

$ 2.31

$

$

$

$

$

$

$

$ 0.04

$

$

$

$ 4.89
ED&T-R&D



$ 0.42

$ 0.39

$

$

$

$

$

$

$

$ 0.01

$

$

$

$ 0.81
Total Markup
Cost
(Component/
Assembly)



$ 7.83

$ 7.13

$

$

$

$

$

$

$

$ 0.09

$

$

$

$ 15.05
Total
Packaging
Cost
(Component/
Assembly)



$ 0.47

$ 0.47

$

$

$

$

$

$

$

$ 0.00

$

$

$

$ 0.95
Net
Component/
Assembly Cost
Impact to OEM



$ 49.84

$ 46.12

$

$

$

$

$

$

$

$ 0.72

$

$

$ 4.53

$ 101.21
File: Subsystem CMAT, CS0902, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                               Apdx. C.4 Cases, Page: 1 of 24
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
      I  f
                                               APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                            CASE STUDY #0902
                                                                                                                                                                     Printed: 3/2 6/2010
     Technology Level: 09 - 6 Speed Automatic versus 6 Speed Direct Shift Transmission
       Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case#: 0902 ( N0902 New Technology Configuration)
                     ( B0902 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

£
5,
01
-§ Sub-Subsystem Description
w
^
w

0202 Case(s) Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13



|01 Transaxle Case

|02 Transaxle Housing

|03 Covers

|04 Actuators

|05 TBD

|10 Plugs

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings

|85 Sealing Elements

|90 Bearing Elements

|99 Miscellaneous

|00 Transmission Assembly of Case Components

SUB-SUBSYSTEM ROLL-UP
































BASE TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Automatic Transmission: 2007-2009 Toyota Camry
Manufacturing
Material



$ 28.33

$ 21.00

$ 7.03

$

$

$

$

$

$

$

$

$

$ 2.67

$ 59.04
Labor



$ 1.88

$ 6.02

$ 1.16

$

$

$

$

$

$

$

$

$

$ 1.40

$ 10.47
Burden



$ 12.85

$ 26.78

$ 5.13

$

$

$

$

$

$

$

$

$

$ 1.18

$ 45.95
Total
Cost
(Component/
Assembly)



$ 43.06

$ 53.81

$ 13.33

$

$

$

$

$

$

$

$

$

$ 5.26

$ 115.46
Markup
End Item
Scrap



$ 0.22

$ 0.27

$ 0.07

$

$

$

$

$

$

$

$

$

$

$ 0.55
SG&A



$ 2.80

$ 3.50

$ 0.88

$

$

$

$

$

$

$

$

$

$

$ 7.18
Profit



$ 2.58

$ 3.23

$ 0.81

$

$

$

$

$

$

$

$

$

$

$ 6.62
ED&T-R&D



$ 1.08

$ 1.35

$ 0.33

$

$

$

$

$

$

$

$

$

$

$ 2.76
Total Markup
Cost
(Component/
Assembly)



$ 6.67

$ 8.34

$ 2.09

$

$

$

$

$

$

$

$

$

$

$ 17.11
Total
Packaging
Cost
(Component/
Assembly)



$ 0.22

$ 0.22

$ 0.11

$

$

$

$

$

$

$

$

$

$

$ 0.56
Net
Component/
Assembly Cost
Impact to OEM



$ 49.96

$ 62.37

$ 15.53

$

$

$

$

$

$

$

$

$

$ 5.26

$ 133.12
File: Subsystem CMAT, CS0902, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                               Apdx. C.4 Cases, Page: 2 of 24
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                        APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                CASE STUDY #0902
                                                                                                                                           Printed: 3/2 6/2010

Technology Level: 09 - 6 Speed Automatic versus 6 Speed Direct Shift Transmission
Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
Study Case#: 0902 ( N0902 New Technology Configuration)
( B0902 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

£
5,
01
-§ Sub-Subsystem Description
w
^
(ft

0202 Case(s) Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13



|01 Transaxle Case

|02 Transaxle Housing

|03 Covers

|04 Actuators

|05 TBD

|10 Plugs

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings

|85 Sealing Elements

|90 Bearing Elements

|99 Miscellaneous

|00 Transmission Assembly of Case Components

SUB-SUBSYSTEM ROLL-UP

































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagen
BASE TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Automatic Transmission: 2007-2009 Toyota Camry
Manufacturing
Material



$ 5.51

$ 8.56

t (7.03)

$

$

$

$

$

$

$ 0.04

$

$

$ (1.26)

$ 5.82
Labor



$ 1.02

$ (2.54)

$ (1.16)

$

$

$

$

$

$

$ 0.21

$

$

$ (0.71)

$ (3,19)
Burden



$ (8.05)

$ (21.32)

$ (5.13)

$

$

$

$

$

$

$ 0.39

$

$

$ 1.25

$ (32,86)
Total
Manufacturing
Cost
(Component/
Assembly)



$ (1.53)

$ (15.2S)

$ (13.33)

$

$

$

$

$

$

$ 0.63

$

$

$ (0.73)

$ (30,24)
Markup
End Item
Scrap



$ 1.90

$ 1.66

I (0.07)

$

$

$

$

$

$

$ 0.00

$

$

$

$ 3.49
SG&A



$ (0.05)

$ (0.99)

$ (0.88)

$

$

$

$

$

$

$ 0.04

$

$

$

$ (1,88)
Profit



$ (0,04!

$ (0.92)

$ (0.81)

$

$

$

$

$

$

$ 0.04

$

$

$

$ (1,73)
ED&T-R&D



$

$ (0.96)

$ (0.33)

$

$

$

$

$

$

$ 0.01

$

$

$

$ (1,94)
Total Markup
Cost
(Component/
Assembly)



$ 1.16

$ (1.21)

t (2.09)

$

$

$

$

$

$

$ 0.09

$

$

$

$ (2,06)
Total
Packaging
Cost
(Component/
Assembly)



$ 0.25

$ 0.25

t (0.11)

$

$

$

$

$

$

$ 0.00

$

$

$

$ 0.39
Net
Component/
Assembly Cost
Impact to OEM



$ (0.12)

$ (16.26)

$ (15,53)

$

$

$

$

$

$

$ 0.72

$

$

$ (O.TS)

$ (31,91)
File: Subsystem CMAT, CS0902, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                  Apdx. C.4 Cases, Page: 3 of 24
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------

                                         APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                     CASE STUDY #0902
                                                                                                                                                        Printed: 3/26/2010
    Technology Level: 09 - 6 Speed Automatic versus 6 Speed Direct Shift Transmission
       Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
       Study Case*: 0902 ( N0902 New Technology Configuration)
                     ( B0902 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
.ffi

£
1
-§ Sub-Subsystem Description
CO
i
CO

0203 Geartrain Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19


|01 Sun Gears

1 02 Lepelletier Planetary Set

1 03 Ring Gears

1 04 Counter Gears

1 05 Differential Gears

1 06 Carriers

1 07 Pins/Journals

|10 Gears Misc

1 11 Shafts

|12 Input Shaft Outer

|13 Output Shaft, 1 thru 4

|14 Output Shaft, 5,6 & Reverse

|15 Snap Rings

|16 Reverse Transfer Shaft

|17 Drive Adapter

|18 Synchronizers

|70 Pipes, Hoses, Ducting

1 75 Brackets

1 80 Boltings (Includes Nuts & Washers)












































NEW TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagen
Manufacturing
Material



$

$

$

$

$

$

$

$

$ 7.23

$ 6.57

$ 14.09

$ 9.24

$

$ 4.52

$

$ 2.32

$

$

$

Labor



$

$

$

$

$

$

$

$

$ 4.68

$ 3.20

$ 5.39

$ 4.05

$

$ 0.90

$

$ 2.75

$

$

$

Burden



$

$

$

$

$

$

$

$

$ 14.07

$ 9.29

$ 21.64

$ 15.87

$

$ 4.76

$

$ 6.65

$

$

$

Total
Manufacturing
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$ 25.99

$ 19.05

$ 41.12

$ 29.16

$

$ 10.17

$

$ 11.72

$

$

$

Markup
End Item
Scrap



$

$

$

$

$

$

$

$

$ 0.28

$

$ 0.29

$ 0.20

$

$ 0.07

$

$ 0.08

$

$

$

SG&A



$

$

$

$

$

$

$

$

$ 2.76

$

$ 2.88

$ 2.04

$

$ 0.71

$

$ 0.82

$

$

$

Profit



$

$

$

$

$

$

$

$

$ 3.15

$

$ 3.29

$ 2.33

$

$ 0.81

$

$ 0.94

$

$

$

ED&T-R&D



$

$

$

$

$

$

$

$

$ 0.79

$

$ 0.82

$ 0.58

$

$ 0.20

$

$ 0.23

$

$

$

Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$ 6.97

$

$ 7.28

$ 5.16

$

$ 1.80

$

$ 2.07

$

$

$

Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$ 0.37

$ 0.02

$ 0.46

$ 0.44

$

$ 0.55

$

$ 0.55

$

$

$

Net
Component/
Assembly Cost
Impact to OEM



$

$

$

$

$

$

$

$

$ 33.33

$ 19.07

$ 48.85

$ 34.76

$

$ 12.53

$

$ 14.35

$

$

$

File: Subsystem CMAT, CS0902, RPT2-032510.xls
EPAContract:EP-C-07-069WA1-3
                                                                       Apdx. C.4 Geartrain, Page: 4 of 24
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                         APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                     CASE STUDY #0902
                                                                                                                                                        Printed: 3/26/2010
    Technology Level: 09 - 6 Speed Automatic versus 6 Speed Direct Shift Transmission
       Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
       Study Case*: 0902 ( N0902 New Technology Configuration)
                     ( B0902 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
.ffi

£
1
-§ Sub-Subsystem Description
CO
i
CO

0203 Geartrain Subsystem
20

21

22

23

25

26

27

28


|85 Sealing Elements

|90 Bearings Elements Misc

|91 Bearing/Bushings

1 92 Roller Bearings

1 93 Thrust Bearings/Washers

1 94 Thrust Roller/Needle Bearings

1 99 Miscellaneous

|100 Transmission Assembly of Gear Components

SUB-SUBSYSTEM ROLL-UP





















NEW TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagen
Manufacturing
Material


$

$ 0.09

$

$

$

$

$

$ 13.26

$ 57.31
Labor


$

$ 0.39

$

$

$

$

$

$ 3.86

$ 25.22
Burden


$

$ 1.01

$

$

$

$

$

$ 2.37

$ 75.67
Total
Manufacturing
Cost
(Component/
Assembly)


$

$ 1.50

$

$

$

$

$

$ 19.49

$ 158.20
Markup
End Item
Scrap


$

$ 0.01

$

$

$

$

$

$

$ 0.93
SG&A


$

$ 0.10

$

$

$

$

$

$

$ 9.31
Profit


$

$ 0.12

$

$

$

$

$

$

$ 10.64
ED&T-R&D


$

$ 0.03

$

$

$

$

$

$

$ 2.66
Total Markup
Cost
(Component/
Assembly)


$

$ 0.26

$

$

$

$

$

$

$ 23.55
Total
Packaging
Cost
(Component/
Assembly)


$

$ 0.06

$

$

$

$

$

$

$ 2.45
Net
Component/
Assembly Cost
Impact to OEM


$

$ 1.82

$

$

$

$

$

$ 19.49

$ 184.21
File: Subsystem CMAT, CS0902, RPT2-032510.xls
EPAContract:EP-C-07-069WA1-3
                                                                       Apdx. C.4 Geartrain, Page: 5 of 24
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------

                                         APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                     CASE STUDY #0902
                                                                                                                                                        Printed: 3/26/2010
    Technology Level: 09 - 6 Speed Automatic versus 6 Speed Direct Shift Transmission
       Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
       Study Case*: 0902 ( N0902 New Technology Configuration)
                     ( B0902 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
.ffi

£
1
-§ Sub-Subsystem Description
CO
i
CO

0203 Geartrain Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19


|01 Sun Gears

|02 Lepelletier Planetary Set

|03 Ring Gears

|04 Counter Gears

|05 Differential Gears

|06 Carriers

|07 Pins/Journals

|10 Gears Misc

|11 Shafts

|12 Input Shaft Outer

|13 Output Shaft, 1 thru 4

|14 Output Shaft, 5,6 & Reverse

|15 Snap Rings

|16 Reverse Transfer Shaft

|17 Drive Adapter

|18 Synchronizers

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings (Includes Nuts & Washers)












































BASE TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Automatic Transmission: 2007-2009 Toyota Camry
Manufacturing
Material



$ 3.19

$ 13.50

$ 1.03

$

$ 11.76

$

$ 1.58

$ 2.85

$ 0.96

$

$

$

$ 0.35

$

$

$

$

$

$ 0.15

Labor



$ 5.29

$ 8.61

$ 2.65

$

$ 5.93

$

$ 2.46

$ 7.61

$ 0.71

$

$

$

$ 0.51

$

$

$

$

$

$ 0.41

Burden



$ 14.08

$ 14.25

$ 5.15

$

$ 18.34

$

$ 6.83

$ 17.28

$ 3.85

$

$

$

$ 1.67

$

$

$

$

$

$ 1.01

Total
Manufacturing
Cost
(Component/
Assembly)



$ 22.57

$ 36.37

$ 8.84

$

$ 36.04

$

$ 10.87

$ 27.74

$ 5.52

$

$

$

$ 2.53

$

$

$

$

$

$ 1.57

Markup
End Item
Scrap



$ 0.17

$ 2.18

$ 0.07

$

$ 0.20

$

$ 0.05

$ 0.14

$ 0.03

$

$

$

$ 0.01

$

$

$

$

$

$ 0.01

SG&A



$ 2.17

$ 6.36

$ 0.86

$

$ 2.88

$

$ 0.71

$ 1.80

$ 0.36

$

$

$

$ 0.16

$

$

$

$

$

$ 0.10

Profit



$ 2.00

$ 5.87

$ 0.79

$

$ 2.44

$

$ 0.65

$ 1.66

$ 0.33

$

$

$

$ 0.15

$

$

$

$

$

$ 0.09

ED&T-R&D



$ 0.33

$ 0.98

$ 0.13

$

$ 0.31

$

$ 0.11

$ 0.28

$ 0.06

$

$

$

$ 0.03

$

$

$

$

$

$ 0.02

Total Markup
Cost
(Component/
Assembly)



$ 4.67

$ 15.40

$ 1.84

$

$ 5.83

$

$ 1.52

$ 3.88

$ 0.77

$

$

$

$ 0.35

$

$

$

$

$

$ 0.22

Total
Packaging
Cost
(Component/
Assembly)



$ 0.20

$ 0.10

$ 0.07

$

$ 0.14

$

$ 0.00

$ 0.03

$ 0.02

$

$

$

$ 0.01

$

$

$

$

$

$ 0.02

Net
Component/
Assembly Cost
Impact to OEM



$ 27.43

$ 51.86

$ 10.75

$

$ 42.01

$

$ 12.40

$ 31.65

$ 6.32

$

$

$

$ 2.89

$

$

$

$

$

$ 1.81

File: Subsystem CMAT, CS0902, RPT2-032510.xls
EPAContract:EP-C-07-069WA1-3
                                                                       Apdx. C.4 Geartrain, Page: 6 of 24
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                         APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                     CASE STUDY #0902
                                                                                                                                                        Printed: 3/26/2010
    Technology Level: 09 - 6 Speed Automatic versus 6 Speed Direct Shift Transmission
       Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
       Study Case*: 0902 ( N0902 New Technology Configuration)
                     ( B0902 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
.ffi

£
1
-§ Sub-Subsystem Description
CO
i
CO

0203 Geartrain Subsystem
20

21

22

23

25

26

27

28


|85 Sealing Elements

|90 Bearings Elements Misc

|91 Bearing/Bushings

|92 Roller Bearings

|93 Thrust Bearings/Washers

|94 Thrust Roller/Needle Bearings

|99 Miscellaneous

|100 Transmission Assembly of Gear Components

SUB-SUBSYSTEM ROLL-UP





















BASE TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Automatic Transmission: 2007-2009 Toyota Camry
Manufacturing
Material


$

$ 2.00

$ 0.77

$

$ 0.07

$

$

$ 9.71

$ 47.93
Labor


$

$ 1.64

$ 1.68

$

$ 1.10

$

$

$ 4.10

$ 42.72
Burden


$

$ 3.37

$ 3.05

$

$ 1.81

$

$

$ 1.23

$ 91.92
Total
Manufacturing
Cost
(Component/
Assembly)


$

$ 7.00

$ 5.50

$

$ 2.99

$

$

$ 15.04

$ 182.57
Markup
End Item
Scrap


$

$ 0.04

$ 0.02

$

$ 0.01

$

$

$

$ 2.92
SG&A


$

$ 0.46

$ 0.34

$

$ 0.19

$

$

$

$ 16.39
Profit


$

$ 0.42

$ 0.25

$

$ 0.18

$

$

$

$ 14.85
ED&T-R&D


$

$ 0.07

$ 0.02

$

$ 0.03

$

$

$

$ 2.35
Total Markup
Cost
(Component/
Assembly)


$

$ 0.98

$ 0.63

$

$ 0.42

$

$

$

$ 36.51
Total
Packaging
Cost
(Component/
Assembly)


$

$ 0.02

$ 0.03

$

$ 0.01

$

$

$ 0.04

$ 0.69
Net
Component/
Assembly Cost
Impact to OEM


$

$ 8.00

$ 6.16

$

$ 3.42

$

$

$ 15.07

$ 219.77
File: Subsystem CMAT, CS0902, RPT2-032510.xls
EPAContract:EP-C-07-069WA1-3
                                                                       Apdx. C.4 Geartrain, Page: 7 of 24
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                   APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                           CASE STUDY #0902
                                                                                                                                 Printed: 3/26/2010

Technology Level: 09 - 6 Speed Automatic versus 6 Speed Direct Shift Transmission
Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
Study Case*: 0902 ( N0902 New Technology Configuration)
( B0902 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
.ffi

£
1
-§ Sub-Subsystem Description
CO
i
CO

0203 Geartrain Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19


|01 Sun Gears

|02 Lepelletier Planetary Set

|03 Ring Gears

|04 Counter Gears

|05 Differential Gears

|06 Carriers

|07 Pins/Journals

|10 Gears Misc

|11 Shafts

|12 Input Shaft Outer

|13 Output Shaft, 1 thru 4

|14 Output Shaft, 5,6 & Reverse

|15 Snap Rings

|16 Reverse Transfer Shaft

|17 Drive Adapter

|18 Synchronizers

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings (Includes Nuts & Washers)













































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagen
BASE TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Automatic Transmission: 2007-2009 Toyota Camry
Manufacturing
Material



$ |3.19)

$ (13.50)

$ (1.03)

$

$ (11.76)

$

$ (1.58)

$

$ 6.27

$ 6.57

$ 14.09

$ 9.24

$

$ 4.52

$

$ 2.32

$

$

$ (0.15)

Labor



$ (5.29)

$ (8.61)

$ (2.65)

$

$ (5.93)

$

$ (2.46)

$ (7.61)

$ 3.97

$ 3.20

$ 5.39

$ 4.05

$ (0.51)

$ 0.90

$

$ 2.75

$

$

$ (0.41)

Burden



$ (14.08)

$ (14.25)

$ (5.15)

$

$ (18.34)

$

$ (S.83)

t (17.28)

$ 10.23

$ 9.29

$ 21.64

$ 15.87

$ (1.67)

$ 4.76

$

$ 6.65

$

$

$ (1.01)

Total
Manufacturing
Cost
(Component/
Assembly)



$ S22.5?)

$ (36.3?)

$ (8.84)

$

$

$

$ (10.8?)

t (27.74)

$ 20.47

$ 19.05

$ 41.12

$ 29.16

$ (2.53)

$ 10.17

$

$ 11.72

$

$

$ (1.57)

Markup
End Item
Scrap



$ (0.17)

$ (2.18)

$ (0.0?)

$

$ (0.20)

$

$ (0.05)

$ (0.14)

$ 0.25

$

$ 0.29

$ 0.20

$ (0.01)

$ 0.07

$

$ 0.08

$

$

$ (0.01)

SG&A



$ (2.17)

$

$ (0.86)

$

$ (2.88)

$

$ (0.71)

$ (1.80)

$ 2.40

$

$ 2.88

$ 2.04

$ (0.16)

$ 0.71

$

$ 0.82

$

$

$ (0.10)

Profit



$ (2.00|

$ (5.87)

$ (0.79)

$

$ (2.44|

$

$

$ (1.S6)

$ 2.82

$

$ 3.29

$ 2.33

$ (0.15)

$ 0.81

$

$ 0.94

$

$

$ (0.09)

ED&T-R&D



$ (0.33I

$ (0.98)

$ (0.13)

$

$ (0.311

$

$ (0.11)

$ (0.28)

$ 0.73

$

$ 0.82

$ 0.58

$ (0.03I

$ 0.20

$

$ 0.23

$

$

$ (0.02)

Total Markup
Cost
(Component/
Assembly)



$ (4.67)

$ (15.40)

$ (1.84)

$

$ (5.83)

$

$ (1.52)

$

$ 6.20

$

$ 7.28

$ 5.16

$ (0.35)

$ 1.80

$

$ 2.07

$

$

$ (0.22)

Total
Packaging
Cost
(Component/
Assembly)



$ (0.20)

t (0.10)

$ (0.07)

$

$ (0.14)

$

$ (0.00)

$ (0.03)

$ 0.35

$ 0.02

$ 0.46

$ 0.44

$ (0.01)

$ 0.55

$

$ 0.55

$

$

$ (0.02)

Net
Component/
Assembly Cost
Impact to OEM



$ (27.43)

t (51.86)

$ (10.75)

$

$ (42.01)

$

$ (12.40)

$ (31.65)

$ 27.01

$ 19.07

$ 48.85

$ 34.76

$ (2.89)

$ 12.53

$

$ 14.35

$

$

$ (1.81)

File: Subsystem CMAT, CS0902, RPT2-032510.xls
EPAContract:EP-C-07-069WA1-3
                                                             Apdx. C.4 Geartrain, Page: 8 of 24
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                   APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                           CASE STUDY #0902
                                                                                                                                 Printed: 3/26/2010


Technology Level: 09 - 6 Speed Automatic versus 6 Speed Direct Shift Transmission
Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
Study Case*: 0902 ( N0902 New Technology Configuration)
( B0902 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
.ffi

Sub-Subsystem

Sub-Subsystem Description

0203 Geartrain Subsystem
20

21

22

23

25

26

27

28


|85 Sealing Elements


|90 Bearings Elements Misc


|91 Bearing/Bushings


J92 Roller Bearings


|93 Thrust Bearings/Washers


J94 Thrust Roller/Needle Bearings


J99 Miscellaneous


|100 Transmission Assembly of Gear Components


SUB-SUBSYSTEM ROLL-UP






















INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagen
BASE TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Automatic Transmission: 2007-2009 Toyota Camry
Manufacturing
Material


$

$ (1.90)

,$ (0.77)

$

,$ (0.07)

$

$

$ 3.55

$ 9.38
Labor


$

$ (1.25)

,$ (1.68)

$

,$ (1.10)

$

$

$ f0.24J

$ (17.50)
Burden


$

$ |2.35|

$ |3.05j

$

$ (1.81)

$

$

$ 1.14

$ (16,25)
Total
Manufacturing
Cost
(Component/
Assembly)


$

$ (5.51|

$ (5.50)

$

$ (2.99)

$

$

$ 4.46

$ 124.37)
Markup
End Item
Scrap


$

$ (0.02)

$ (0.02)

$

$ (0.01)

$

$

$

$
SG&A


$

$ (0.35)

$ (0.34)

$

$ (0.19)

$

$

$

$
Profit


$

$ (0.30)

$ (0.25)

$

$ (0.18|

$

$

$

$
ED&T-R&D


$

$ (0.04)

$ (0.02|

$

$ (0.03|

$

$

$

$ 0.31
Total Markup
Cost
(Component/
Assembly)


$

$ (0.72)

$ (0.63)

$

,$ (0.42)

$

$

$

$ {12,96)
Total
Packaging
Cost
(Component/
Assembly)


$

$ 0.04

$ (0.03)

$

$ (0.01)

$

$

$ |0.04J

$ 1.76
Net
Component/
Assembly Cost
Impact to OEM


$

$ (6.19)

$ (6.16)

$

$ (3.421

$

$

$ 4.42

$ (35.57)
File: Subsystem CMAT, CS0902, RPT2-032510.xls
EPAContract:EP-C-07-069WA1-3
                                                             Apdx. C.4 Geartrain, Page: 9 of 24
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                            CASE STUDY #0902
                                                                                                                                                                       Printed: 3/2 6/2010
     Technology Level: 09 - 6 Speed Automatic versus 6 Speed Direct Shift Transmission
        Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case#: 0902  ( N0902 New Technology Configuration)
                     ( B0902 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

£
5,
01
-§ Sub-Subsystem Description
w
^
(ft

0204 Internal Clutches Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20



|01 Sprague/One Way Clutches

|02 Clutch Assembly

|03 Clutch & Brake Hubs

|04 Sleeve & Couplers

|05 Disc & Plates

|06 TBD

|07 Synchronizers

|09 Pistons

|15 Snap Rings

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings

|85 Sealing Elements

|90 Bearing Elements Misc

|91 Bearing/Bushings

|92 Roller Bearings

|93 Thrust Bearings/Washers

|94 Thrust Roller/Needle Bearings

|99 Miscellaneous

|00 Transmission Assembly of Internal Clutches

SUB-SUBSYSTEM ROLL-UP














































NEW TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagen
Manufacturing
Material



$

$

$

$

$

$

$ 10.01

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.80

$ 10.81
Labor



$

$

$

$

$

$

$ 10.75

$

$

$

$

$

$

$

$

$

$

$

$

$ 4.47

$ 15.21
Burden



$

$

$

$

$

$

$ 28.11

$

$

$

$

$

$

$

$

$

$

$

$

$ 1.60

$ 29.71
Total
Cost
(Component/
Assembly)



$

$

$

$

$

$

$ 48.87

$

$

$

$

$

$

$

$

$

$

$

$

$ 6.87

$ 55.73
Markup
End Item
Scrap



$

$

$

$

$

$

$ 0.26

$

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.26
SG&A



$

$

$

$

$

$

$ 3.35

$

$

$

$

$

$

$

$

$

$

$

$

$

$ 3.35
Profit



$

$

$

$

$

$

$ 3.09

$

$

$

$

$

$

$

$

$

$

$

$

$

$ 3.09
ED&T-R&D



$

$

$

$

$

$

$ 0.51

$

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.51
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$

$ 7.20

$

$

$

$

$

$

$

$

$

$

$

$

$

$ 7.20
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$

$ 0.52

$

$

$

$

$

$

$

$

$

$

$

$

$ 0.03

$ 0.55
Net
Component/
Assembly Cost
Impact to OEM



$

$

$

$

$

$

$ 56.59

$

$

$

$

$

$

$

$

$

$

$

$

$ 6.90

$ 63.48
File: Subsystem CMAT, CS0902, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                            Apdx. C.4 Internal Clutches, Page: 10 of 24
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                            CASE STUDY #0902
                                                                                                                                                                       Printed: 3/2 6/2010
     Technology Level: 09 - 6 Speed Automatic versus 6 Speed Direct Shift Transmission
       Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case#: 0902 ( N0902 New Technology Configuration)
                     ( B0902 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

£
5,
01
-§ Sub-Subsystem Description
w
^
(ft

0204 Internal Clutches Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20



|01 Sprague/One Way Clutches

|02 Clutch Assembly

|03 Clutch & Brake Hubs

|04 Sleeve & Couplers

|05 Disc & Plates

|06 TBD

|07 Synchronizers

|09 Pistons

|15 Snap Rings

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings

|85 Sealing Elements

|90 Bearing Elements Misc

|91 Bearing/Bushings

|92 Roller Bearings

|93 Thrust Bearings/Washers

|94 Thrust Roller/Needle Bearings

|99 Miscellaneous

|00 Transmission Assembly of Internal Clutches

SUB-SUBSYSTEM ROLL-UP














































BASE TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Automatic Transmission: 2007-2009 Toyota Camry
Manufacturing
Material



$ 3.46

$ 3.15

$ 2.18

$

$ 26.35

$

$

$ 12.18

$ 0.21

$

$

$

$ 0.12

$ 1.59

$

$

$

$

$

$ 5.63

$ 54.86
Labor



$ 4.20

$ 3.87

$ 1.93

$

$ 16.92

$

$

$ 3.92

$ 0.37

$

$

$

$ 0.56

$ 0.32

$

$

$

$

$

$ 5.76

$ 37.85
Burden



$ 9.43

$ 5.64

$ 6.38

$

$ 31.98

$

$

$ 10.61

$ 0.62

$

$

$

$ 1.28

$ 0.21

$

$

$

$

$

$ 1.30

$ 67.45
Total
Cost
(Component/
Assembly)



$ 17.09

$ 12.65

$ 10.49

$

$ 75.24

$

$

$ 26.71

$ 1.20

$

$

$

$ 1.95

$ 2.13

$

$

$

$

$

$ 12.69

$ 160.16
Markup
End Item
Scrap



$ 0.15

$ 0.59

$ 0.05

$

$ 0.41

$

$

$ 0.34

$ 0.01

$

$

$

$ 0.01

$ 0.01

$

$

$

$

$

$

$ 1.57
SG&A



$ 2.09

$ 5.85

$ 0.68

$

$ 5.38

$

$

$ 1.82

$ 0.08

$

$

$

$ 0.13

$ 0.14

$

$

$

$

$

$

$ 16.17
Profit



$ 1.86

$ 6.69

$ 0.63

$

$ 4.97

$

$

$ 1.68

$ 0.07

$

$

$

$ 0.12

$ 0.13

$

$

$

$

$

$

$ 16.15
ED&T-R&D



$ 0.28

$ 3.34

$ 0.10

$

$ 0.74

$

$

$ 0.28

$ 0.01

$

$

$

$ 0.02

$ 0.02

$

$

$

$

$

$

$ 4.81
Total Markup
Cost
(Component/
Assembly)



$ 4.39

$ 16.46

$ 1.47

$

$ 11.51

$

$

$ 4.13

$ 0.17

$

$

$

$ 0.27

$ 0.30

$

$

$

$

$

$

$ 38.70
Total
Packaging
Cost
(Component/
Assembly)



$ 0.48

$ 0.05

$ 0.03

$

$ 1.08

$

$

$ 0.85

$ 0.03

$

$

$

$ 0.18

$ 0.11

$

$

$

$

$

$

$ 2.81
Net
Component/
Assembly Cost
Impact to OEM



$ 21.96

$ 29.17

$ 12.00

$

$ 87.83

$

$

$ 31.69

$ 1.40

$

$

$

$ 2.41

$ 2.53

$

$

$

$

$

$ 12.69

$ 201.67
File: Subsystem CMAT, CS0902, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                            Apdx. C.4 Internal Clutches, Page: 11 of 24
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                         APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                 CASE STUDY #0902
                                                                                                                                              Printed: 3/2 6/2010

Technology Level: 09 - 6 Speed Automatic versus 6 Speed Direct Shift Transmission
Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
Study Case#: 0902 ( N0902 New Technology Configuration)
( B0902 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

£
5,
01
-§ Sub-Subsystem Description
w
^
(ft

0204 Internal Clutches Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20



|01 Sprague/One Way Clutches

|02 Clutch Assembly

|03 Clutch & Brake Hubs

|04 Sleeve & Couplers

|05 Disc & Plates

|06 TBD

|07 Synchronizers

|09 Pistons

|15 Snap Rings

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings

|85 Sealing Elements

|90 Bearing Elements Misc

|91 Bearing/Bushings

|92 Roller Bearings

|93 Thrust Bearings/Washers

|94 Thrust Roller/Needle Bearings

|99 Miscellaneous

|00 Transmission Assembly of Internal Clutches

SUB-SUBSYSTEM ROLL-UP















































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagen
BASE TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Automatic Transmission: 2007-2009 Toyota Camry
Manufacturing
Material



$ (3.48)

t (3.15)

$ (2.18J

$

$

$

$ 10.01

$ (12.18)

$ (0.21)

$

$

$

$ (0.12)

$ (1.59)

$

$

$

$

$

$ (4.83)

$ (44.06)
Labor



$

t (3.87)

$ (1.93)

$

$ (16.92)

$

$ 10.75

$ (3.92)

$ {0.37}

$

$

$

$ (0.56)

$ (0.32)

$

$

$

$

$

$ (1.30)

$ (22.63)
Burden



$ (9.43)

t (8.84)

$

$

$ (31.98)

$

$ 28.11

$ (10.61)

$

$

$

$

$ (1.28)

$ (0.21)

$

$

$

$

$

$ 0.30

$ (37.74)
Total
Manufacturing
Cost
(Component/
Assembly)



$ (17.09)

t (12.88)

$ (10.49)

$

$ (15.24)

$

$ 48.87

$ (28.71)

$ (1.20)

$

$

$

$ (1.S5)

$ (2.1S)

$

$

$

$

$

$

$ (104.43)
Markup
End Item
Scrap



$ (0.15)

t (0.59)

$ (0.05)

$

$ (O.il)

$

$ 0.26

$ (0.34)

$ (0.01)

$

$

$

$ (0.01)

$ (0.01)

$

$

$

$

$

$

$ (1.32)
SG&A



$

$

$ (0.88J

$

$

$

$ 3.35

t (1.82)

$

$

$

$

t (0.13)

$ (0.14)

$

$

$

$

$

$

$ (12.82)
Profit



$ (1.86)

$

$

$

$ (4.17)

$

$ 3.09

$ (1.88)

$

$

$

$

$ (0.12)

$ (0.13)

$

$

$

$

$

$

$ (13.06)
ED&T-R&D



$

$ (3.31)

$ (0.10)

$

$ (0.74)

$

$ 0.51

I

$ (0.01)

$

$

$

I

$

$

$

$

$

$

$

$ (4,30)
Total Markup
Cost
(Component/
Assembly)



$ (4.39)

$

$ (1.47)

$

$ (11.51)

$

$ 7.20

$ (4.13)

$ (0.17)

$

$

$

$ (0.2?)

$

$

$

$

$

$

$

$ (31.49)
Total
Packaging
Cost
(Component/
Assembly)



$ (0.48)

t (0.08)

$ (0.03)

$

$ (1.08)

$

$ 0.52

$ (0.85)

$ (0.03)

$

$

$

$ (0.18)

$ (0.11)

$

$

$

$

$

$ 0.03

$ (2.26)
Net
Component/
Assembly Cost
Impact to OEM



$ (21.96)

t (28.17)

$ (12.00)

$

$

$

$ 56.59

$ (31.69)

$ (1.40)

$

$

$

$ (2.41)

$ (2.5S)

$

$

$

$

$

$

$ (138.19)
File: Subsystem CMAT, CS0902, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                 Apdx. C.4 Internal Clutches, Page: 12 of 24
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                            CASE STUDY #0902
                                                                                                                                                                       Printed: 3/2 6/2010
     Technology Level: 09 - 6 Speed Automatic versus 6 Speed Direct Shift Transmission
       Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case#: 0902 ( N0902 New Technology Configuration)
                     ( B0902 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

£
5,
01
-§ Sub-Subsystem Description
w
^
(ft

0205 Launch Clutches Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13



|01 Torque Converter Assembly

|02 Clutch Assembly C1/C2

|03 Fly Wheels/Flex Plates/Starter Rings

|04 TBD

|15 Snap Rings and Retainers

|20 Springs

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings

|85 Sealing Elements

|90 Bearing Elements

|99 Miscellaneous

|00 Transmission Assembly of Launch Clutches

SUB-SUBSYSTEM ROLL-UP
































NEW TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagen
Manufacturing
Material



$

$ 22.97

$ 20.93

$

$ 1.49

$

$

$

$

$ 0.03

$ 0.07

$

$ 1.12

$ 46.61
Labor



$

$ 11.41

$ 11.40

$

$ 0.97

$

$

$

$

$ 0.19

$ 0.11

$

$ 4.44

$ 28.52
Burden



$

$ 40.60

$ 15.35

$

$ 1.91

$

$

$

$

$ 0.13

$ 0.10

$

$ 3.46

$ 61.55
Total
Cost
(Component/
Assembly)



$

$ 74.97

$ 47.67

$

$ 4.37

$

$

$

$

$ 0.35

$ 0.28

$

$ 9.03

$ 136.68
Markup
End Item
Scrap



$

$ 0.45

$ 0.51

$

$ 0.02

$

$

$

$

$ 0.00

$ 0.00

$

$

$ 0.99
SG&A



$

$ 5.65

$ 1.96

$

$ 0.28

$

$

$

$

$ 0.02

$ 0.02

$

$

$ 7.94
Profit



$

$ 5.37

$ 1.81

$

$ 0.26

$

$

$

$

$ 0.02

$ 0.02

$

$

$ 7.48
ED&T-R&D



$

$ 0.96

$ 0.30

$

$ 0.04

$

$

$

$

$ 0.00

$ 0.00

$

$

$ 1.31
Total Markup
Cost
(Component/
Assembly)



$

$ 12.43

$ 4.59

$

$ 0.61

$

$

$

$

$ 0.05

$ 0.04

$

$

$ 17.71
Total
Packaging
Cost
(Component/
Assembly)



$

$ 0.35

$ 0.24

$

$ 0.06

$

$

$

$

$ 0.05

$ 0.02

$

$

$ 0.72
Net
Component/
Assembly Cost
Impact to OEM



$

$ 87.76

$ 52.51

$

$ 5.04

$

$

$

$

$ 0.44

$ 0.34

$

$ 9.03

$ 155.11
File: Subsystem CMAT, CS0902, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                            Apdx. C.4 Launch Clutches, Page: 13 of 24
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                            CASE STUDY #0902
                                                                                                                                                                       Printed: 3/2 6/2010
     Technology Level: 09 - 6 Speed Automatic versus 6 Speed Direct Shift Transmission
       Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case#: 0902 ( N0902 New Technology Configuration)
                     ( B0902 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

£
5,
01
-§ Sub-Subsystem Description
w
^
(ft

0205 Launch Clutches Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13



|01 Torque Converter Assembly

|02 Clutch Assembly C1/C2

|03 Fly Wheels/Flex Plates/Starter Rings

|04 TBD

|15 Snap Rings and Retainers

|20 Springs

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings

|85 Sealing Elements

|90 Bearing Elements

|99 Miscellaneous

|00 Transmission Assembly of Launch Clutches

SUB-SUBSYSTEM ROLL-UP
































BASE TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Automatic Transmission: 2007-2009 Toyota Camry
Manufacturing
Material



$

$

$

$

$

$

$

$

$

$

$

$

$ 89.44

$ 89.44
Labor



$

$

$

$

$

$

$

$

$

$

$

$

$ 0.46

$ 0.46
Burden



$

$

$

$

$

$

$

$

$

$

$

$

$ 0.83

$ 0.83
Total
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$ 90.74

$ 90.74
Markup
End Item
Scrap



$

$

$

$

$

$

$

$

$

$

$

$

$

$
SG&A



$

$

$

$

$

$

$

$

$

$

$

$

$

$
Profit



$

$

$

$

$

$

$

$

$

$

$

$

$

$
ED&T-R&D



$

$

$

$

$

$

$

$

$

$

$

$

$

$ -
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$

$
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$

$
Net
Component/
Assembly Cost
Impact to OEM



$

$

$

$

$

$

$

$

$

$

$

$

$ 90.74

$ 90.74
File: Subsystem CMAT, CS0902, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                            Apdx. C.4 Launch Clutches, Page: 14 of 24
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                         APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                 CASE STUDY #0902
                                                                                                                                              Printed: 3/2 6/2010

Technology Level: 09 - 6 Speed Automatic versus 6 Speed Direct Shift Transmission
Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
Study Case#: 0902 ( N0902 New Technology Configuration)
( B0902 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

£
5,
01
-§ Sub-Subsystem Description
w
^
(ft

0205 Launch Clutches Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13



|01 Torque Converter Assembly

|02 Clutch Assembly C1/C2

|03 Fly Wheels/Flex Plates/Starter Rings

|04 TBD

|15 Snap Rings and Retainers

|20 Springs

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings

|85 Sealing Elements

|90 Bearing Elements

|99 Miscellaneous

|00 Transmission Assembly of Launch Clutches

SUB-SUBSYSTEM ROLL-UP

































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagen
BASE TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Automatic Transmission: 2007-2009 Toyota Camry
Manufacturing
Material



$

$ 22.97

$ 20.93

$

$ 1.49

$

$

$

$

$ 0.03

$ 0.07

$

$ (88.32)

$ (42.83)
Labor



$

$ 11.41

$ 11.40

$

$ 0.97

$

$

$

$

$ 0.19

$ 0.11

$

$ 3.98

$ 28.06
Burden



$

$ 40.60

$ 15.35

$

$ 1.91

$

$

$

$

$ 0.13

$ 0.10

$

$ 2.63

$ 60.71
Total
Manufacturing
Cost
(Component/
Assembly)



$

$ 74.97

$ 47.67

$

$ 4.37

$

$

$

$

$ 0.35

$ 0.28

$

t (81.71)

$ 45.94
Markup
End Item
Scrap



$

$ 0.45

$ 0.51

$

$ 0.02

$

$

$

$

$ 0.00

$ 0.00

$

$

$ 0.99
SG&A



$

$ 5.65

$ 1.96

$

$ 0.28

$

$

$

$

$ 0.02

$ 0.02

$

$

$ 7.94
Profit



$

$ 5.37

$ 1.81

$

$ 0.26

$

$

$

$

$ 0.02

$ 0.02

$

$

$ 7.48
ED&T-R&D



$

$ 0.96

$ 0.30

$

$ 0.04

$

$

$

$

$ 0.00

$ 0.00

$

$

$ 1.31
Total Markup
Cost
(Component/
Assembly)



$

$ 12.43

$ 4.59

$

$ 0.61

$

$

$

$

$ 0.05

$ 0.04

$

$

$ 17.71
Total
Packaging
Cost
(Component/
Assembly)



$

$ 0.35

$ 0.24

$

$ 0.06

$

$

$

$

$ 0.05

$ 0.02

$

$

$ 0.72
Net
Component/
Assembly Cost
Impact to OEM



$

$ 87.76

$ 52.51

$

$ 5.04

$

$

$

$

$ 0.44

$ 0.34

$

t (81.71)

$ 64.37
File: Subsystem CMAT, CS0902, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                 Apdx. C.4 Launch Clutches, Page: 15 of 24
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                            CASE STUDY #0902
                                                                                                                                                                      Printed: 3/2 6/2010
     Technology Level: 09 - 6 Speed Automatic versus 6 Speed Direct Shift Transmission
       Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case#: 0902 ( N0902 New Technology Configuration)
                     ( B0902 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

£
5,
(f)
-§ Sub-Subsystem Description
W
A
w

0207 Mechanical Controls Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20



|01 Valve Body Assembly

|02 Solenoids

|03 Sensors

|04 Switches

|05 Wiring Harnesses

|06 Mechanical Controls

|07 Plugs and Cups

|10 Accumulator Assemblies

|15 Shafts/Rods/Pins

|20 Springs

|25 Retainers (Spring Clips, Push Nuts, Cotter Pins, etc)

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings

|85 Sealing Elements

|90 Bearing Elements

|99 Miscellaneous

|00 Transmission Assembly of Mechanical Control Components

i

i

SUB-SUBSYSTEM ROLL-UP














































NEW TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagen
Manufacturing
Material



$ 9.93

$

$

$

$

$ 7.54

$ 0.12

$

$

$

$ 0.17

$

$

$

$

$ 0.65

$ 0.03

$ 5.42

$

$

$ 23.85
Labor



$ 5.27

$

$

$

$

$ 5.08

$ 0.87

$

$

$

$ 0.71

$

$

$

$

$ 4.05

$ 0.04

$ 7.68

$

$

$ 23.71
Burden



$ 12.05

$

$

$

$

$ 11.47

$ 1.28

$

$

$

$ 1.79

$

$

$

$

$ 8.12

$ 0.03

$ 7.71

$

$

$ 42.44
Total
Cost
(Component/
Assembly)



$ 27.24

$

$

$

$

$ 24.08

$ 2.27

$

$

$

$ 2.67

$

$

$

$

$ 12.82

$ 0.10

$ 20.82

$

$

$ 90.00
Markup
End Item
Scrap



$ 0.69

$

$

$

$

$ 0.21

$ 0.01

$

$

$

$ 0.01

$

$

$

$

$ 0.04

$ 0.00

$

$

$

$ 0.96
SG&A



$ 1.80

$

$

$

$

$ 2.79

$ 0.15

$

$

$

$ 0.17

$

$

$

$

$ 0.77

$ 0.01

$

$

$

$ 5.68
Profit



$ 1.73

$

$

$

$

$ 2.58

$ 0.14

$

$

$

$ 0.16

$

$

$

$

$ 0.51

$ 0.00

$

$

$

$ 5.12
ED&T-R&D



$ 0.32

$

$

$

$

$ 0.46

$ 0.02

$

$

$

$ 0.03

$

$

$

$

$

$

$

$

$

$ 0.83
Total Markup
Cost
(Component/
Assembly)



$ 4.54

$

$

$

$

$ 6.05

$ 0.32

$

$

$

$ 0.37

$

$

$

$

$ 1.32

$ 0.01

$

$

$

$ 12.61
Total
Packaging
Cost
(Component/
Assembly)



$ 0.25

$

$

$

$

$ 0.37

$ 0.00

$

$

$

$ 0.00

$

$

$

$

$ 0.01

$ 0.00

$

$

$

$ 0.63
Net
Component/
Assembly Cost
Impact to OEM



$ 32.02

$

$

$

$

$ 30.50

$ 2.59

$

$

$

$ 3.04

$

$

$

$

$ 14.15

$ 0.11

$ 20.82

$

$

$ 103.23
File: Subsystem CMAT, CS0902, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                            Apdx. C.4Mech. Controls, Page: 16 of 24
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                            CASE STUDY #0902
                                                                                                                                                                      Printed: 3/2 6/2010
     Technology Level: 09 - 6 Speed Automatic versus 6 Speed Direct Shift Transmission
       Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case#: 0902 ( N0902 New Technology Configuration)
                     ( B0902 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

£
5,
01
-§ Sub-Subsystem Description
w
^
(ft

0207 Mechanical Controls Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20



|01 Valve Body Assembly

|02 Solenoids

|03 Sensors

|04 Switches

|05 Wiring Harnesses

|06 Mechanical Controls

|07 Plugs and Cups

|10 Accumulator Assemblies

|15 Shafts/Rods/Pins

|20 Springs

|25 Retainers (Spring Clips, Push Nuts, Cotter Pins, etc)

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings

|85 Sealing Elements

|90 Bearing Elements

|99 Miscellaneous

|00 Transmission Assembly of Mechanical Control Components

1

1

SUB-SUBSYSTEM ROLL-UP














































BASE TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Automatic Transmission: 2007-2009 Toyota Camry
Manufacturing
Material



$ 14.13

$

$

$

$

$

$

$ 0.09

$

$

$ 0.20

$ 0.43

$ 0.02

$

$ 0.03

$

$

$ 0.53

$

$

$ 15.44
Labor



$ 26.14

$

$

$

$

$

$

$ 0.10

$

$

$ 2.09

$ 0.29

$ 0.06

$

$ 0.31

$

$

$ 2.50

$

$

$ 31.49
Burden



$ 34.65

$

$

$

$

$

$

$ 0.23

$

$

$ 4.80

$ 0.51

$ 0.09

$

$ 0.56

$

$

$ 0.40

$

$

$ 41.23
Total
Cost
(Component/
Assembly)



$ 74.92

$

$

$

$

$

$

$ 0.42

$

$

$ 7.09

$ 1.24

$ 0.17

$

$ 0.90

$

$

$ 3.43

$

$

$ 88.16
Markup
End Item
Scrap



$ 0.53

$

$

$

$

$

$

$ 0.00

$

$

$ 0.04

$ 0.01

$ 0.00

$

$ 0.00

$

$

$

$

$

$ 0.59
SG&A



$ 6.95

$

$

$

$

$

$

$ 0.03

$

$

$ 0.53

$ 0.08

$ 0.01

$

$ 0.06

$

$

$

$

$

$ 7.66
Profit



$ 6.42

$

$

$

$

$

$

$ 0.03

$

$

$ 0.49

$ 0.07

$ 0.01

$

$ 0.05

$

$

$

$

$

$ 7.07
ED&T-R&D



$ 1.07

$

$

$

$

$

$

$ 0.00

$

$

$ 0.08

$ 0.01

$ 0.00

$

$ 0.01

$

$

$

$

$

$ 1.18
Total Markup
Cost
(Component/
Assembly)



$ 14.98

$

$

$

$

$

$

$ 0.06

$

$

$ 1.14

$ 0.17

$ 0.02

$

$ 0.13

$

$

$

$

$

$ 16.50
Total
Packaging
Cost
(Component/
Assembly)



$ 0.19

$

$

$

$

$

$

$ 0.03

$

$

$ 0.01

$ 0.01

$ 0.01

$

$ 0.01

$

$

$ 0.00

$

$

$ 0.26
Net
Component/
Assembly Cost
Impact to OEM



$ 90.09

$

$

$

$

$

$

$ 0.50

$

$

$ 8.24

$ 1.42

$ 0.20

$

$ 1.04

$

$

$ 3.43

$

$

$ 104.92
File: Subsystem CMAT, CS0902, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                            Apdx. C.4Mech. Controls, Page: 17 of 24
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                        APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                 CASE STUDY #0902
                                                                                                                                             Printed: 3/2 6/2010

Technology Level: 09 - 6 Speed Automatic versus 6 Speed Direct Shift Transmission
Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
Study Case#: 0902 ( N0902 New Technology Configuration)
( B0902 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

£
5,
01
-§ Sub-Subsystem Description
w
^
(ft

0207 Mechanical Controls Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20



|01 Valve Body Assembly

|02 Solenoids

|03 Sensors

|04 Switches

|05 Wiring Harnesses

|06 Mechanical Controls

|07 Plugs and Cups

|10 Accumulator Assemblies

|15 Shafts/Rods/Pins

|20 Springs

|25 Retainers (Spring Clips, Push Nuts, Cotter Pins, etc)

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings

|85 Sealing Elements

|90 Bearing Elements

|99 Miscellaneous

|00 Transmission Assembly of Mechanical Control Components

1

1

SUB-SUBSYSTEM ROLL-UP















































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagen
BASE TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Automatic Transmission: 2007-2009 Toyota Camry
Manufacturing
Material



$ (4.21)

$

$

$

$

$ 7.54

$ 0.12

$ (0.09)

$

$

$

$ (0.43)

$ (0.02)

$

$ (0.03)

$ 0.65

$ 0.03

$ 4.89

$

$

$ 8.41
Labor



$

$

$

$

$

$ 5.08

$ 0.87

$ (0.10)

$

$

$ (1.3!)

$

$ (0.06)

$

t (0.31)

$ 4.05

$ 0.04

$ 5.18

$

$

$ (7.79)
Burden



$

$

$

$

$

$ 11.47

$ 1.28

$ (0.23)

$

$

f (3,01)

$ (0.51)

$ (0.09)

$

$ (0.56)

$ 8.12

$ 0.03

$ 7.31

$

$

$ 1.21
Total
Manufacturing
Cost
(Component/
Assembly)



$

$

$

$

$

$ 24.08

$ 2.27

$ (0.42)

$

$

$ (4.42)

$ (1.24)

$ (0.17)

$

$

$ 12.82

$ 0.10

$ 17.39

$

$

$ 1.83
Markup
End Item
Scrap



$ 0.15

$

$

$

$

$ 0.21

$ 0.01

$

$

$

$ (0.03)

$ (0.01)

$

$

$

$ 0.04

$ 0.00

$

$

$

$ 0.37
SG&A



$ (5.18)

$

$

$

$

$ 2.79

$ 0.15

$ (0.03)

$

$

t (0.36)

t (0.08)

$ (0.01)

$

$ (0.08)

$ 0.77

$ 0.01

$

$

$

$ (1 ,98)
Profit



$

$

$

$

$

$ 2.58

$ 0.14

$ (0.03)

$

$

$ (0.33)

t (0.07)

$ (0.01)

$

t (0.05)

$ 0.51

$ 0.00

$

$

$

$ (1,95)
ED&T-R&D



$ (0,75)

$

$

$

$

$ 0.46

$ 0.02

$

$

$

$

$ (0.01)

$

$

$ (0.01)

$

$

$

$

$

$ (0,34)
Total Markup
Cost
(Component/
Assembly)



$ (10.44)

$

$

$

$

$ 6.05

$ 0.32

$

$

$

$ (0.77)

$ (0.17)

$

$

$ (0.13)

$ 1.32

$ 0.01

$

$

$

$ (3,89)
Total
Packaging
Cost
(Component/
Assembly)



$ 0.06

$

$

$

$

$ 0.37

$ 0.00

$ (0.03)

$

$

f (0.00)

$ (0.01)

$ (0.01)

$

$ (0.01)

$ 0.01

$ 0.00

$

$

$

$ 0.37
Net
Component/
Assembly Cost
Impact to OEM



$

$

$

$

$

$ 30.50

$ 2.59

$ (O.SO)

$

$

t (5.20)

$ (1.42)

$ (0.20)

$

$ (1.04)

$ 14.15

$ 0.11

$ 17.39

$

$

$ (1,69)
File: Subsystem CMAT, CS0902, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                 Apdx. C.4Mech. Controls, Page: 18 of 24
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                            CASE STUDY #0902
                                                                                                                                                                       Printed: 3/2 6/2010
     Technology Level: 09 - 6 Speed Automatic versus 6 Speed Direct Shift Transmission
       Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case#: 0902 ( N0902 New Technology Configuration)
                     ( B0902 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

£
5,
01
-§ Sub-Subsystem Description
w
^
(ft

0208 Electrical Controls Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18



|01 Controller

|02 Solenoids

|03 Sensors

|04 Switches

|05 Wiring Harness

|06 Valves

|09 Pistons

|10 TBD

|15 TBD

|20 Springs

|25 Retainers (Spring Clips, Push Nuts, Cotter Pins, etc)

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings

|85 Sealing Elements

|90 Bearing Elements

|99 Miscellaneous

|00 Transmission Assembly of Electrical Control Components

SUB-SUBSYSTEM ROLL-UP










































NEW TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagen
Manufacturing
Material



$

$

$

$

$

$

$

$

$

$

$

$

$ 0.13

$

$ 0.03

$

$

$ 95.59

$ 95.75
Labor



$

$

$

$

$

$

$

$

$

$

$

$

$ 0.19

$

$ 0.24

$

$

$ 5.95

$ 6.38
Burden



$

$

$

$

$

$

$

$

$

$

$

$

$ 0.60

$

$ 0.44

$

$

$ 7.91

$ 8.95
Total
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$ 0.92

$

$ 0.71

$

$

$ 109.45

$ 111.09
Markup
End Item
Scrap



$

$

$

$

$

$

$

$

$

$

$

$

$ 0.00

$

$ 0.00

$

$

$

$ 0.01
SG&A



$

$

$

$

$

$

$

$

$

$

$

$

$ 0.06

$

$ 0.05

$

$

$

$ 0.11
Profit



$

$

$

$

$

$

$

$

$

$

$

$

$ 0.06

$

$ 0.04

$

$

$

$ 0.10
ED&T-R&D



$

$

$

$

$

$

$

$

$

$

$

$

$ 0.01

$

$ 0.01

$

$

$

$ 0.02
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$ 0.13

$

$ 0.10

$

$

$

$ 0.23
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$ 0.01

$

$ 0.00

$

$

$

$ 0.01
Net
Component/
Assembly Cost
Impact to OEM



$

$

$

$

$

$

$

$

$

$

$

$

$ 1.06

$

$ 0.82

$

$

$ 109.45

$ 111.33
File: Subsystem CMAT, CS0902, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                             Apdx. C.4 Elec. Controls, Page: 19 of 24
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                            CASE STUDY #0902
                                                                                                                                                                       Printed: 3/2 6/2010
     Technology Level: 09 - 6 Speed Automatic versus 6 Speed Direct Shift Transmission
       Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case#: 0902 ( N0902 New Technology Configuration)
                     ( B0902 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

£
5,
01
-§ Sub-Subsystem Description
w
^
(ft

0208 Electrical Controls Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18



|01 Controller

|02 Solenoids

|03 Sensors

|04 Switches

|05 Wiring Harness

|06 Valves

|09 Pistons

|10 TBD

|15 TBD

|20 Springs

|25 Retainers (Spring Clips, Push Nuts, Cotter Pins, etc)

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings

|85 Sealing Elements

|90 Bearing Elements

|99 Miscellaneous

|00 Transmission Assembly of Electrical Control Components

SUB-SUBSYSTEM ROLL-UP










































BASE TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Automatic Transmission: 2007-2009 Toyota Camry
Manufacturing
Material



$

$

$

$

$

$

$

$

$

$

$

$

$ 0.46

$

$

$

$

$ 104.40

$ 104.86
Labor



$

$

$

$

$

$

$

$

$

$

$

$

$ 0.57

$

$

$

$

$ 3.37

$ 3.94
Burden



$

$

$

$

$

$

$

$

$

$

$

$

$ 1.74

$

$

$

$

$ 4.28

$ 6.01
Total
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$ 2.77

$

$

$

$

$ 112.05

$ 114.82
Markup
End Item
Scrap



$

$

$

$

$

$

$

$

$

$

$

$

$ 0.02

$

$

$

$

$

$ 0.02
SG&A



$

$

$

$

$

$

$

$

$

$

$

$

$ 0.24

$

$

$

$

$

$ 0.24
Profit



$

$

$

$

$

$

$

$

$

$

$

$

$ 0.22

$

$

$

$

$

$ 0.22
ED&T-R&D



$

$

$

$

$

$

$

$

$

$

$

$

$ 0.04

$

$

$

$

$

$ 0.04
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$ 0.51

$

$

$

$

$

$ 0.51
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$ 0.01

$

$

$

$

$

$ 0.01
Net
Component/
Assembly Cost
Impact to OEM



$

$

$

$

$

$

$

$

$

$

$

$

$ 3.29

$

$

$

$

$ 112.05

$ 115.34
File: Subsystem CMAT, CS0902, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                             Apdx. C.4 Elec. Controls, Page: 20 of 24
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                        APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                 CASE STUDY #0902
                                                                                                                                             Printed: 3/2 6/2010

Technology Level: 09 - 6 Speed Automatic versus 6 Speed Direct Shift Transmission
Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
Study Case#: 0902 ( N0902 New Technology Configuration)
( B0902 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

£
5,
01
-§ Sub-Subsystem Description
w
^
(ft

0208 Electrical Controls Subsystem

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18



|01 Controller

|02 Solenoids

|03 Sensors

|04 Switches

|05 Wiring Harness

|06 Valves

|09 Pistons

|10 TBD

|15 TBD

|20 Springs

|25 Retainers (Spring Clips, Push Nuts, Cotter Pins, etc)

|70 Pipes, Hoses, Ducting

|75 Brackets

|80 Boltings

|85 Sealing Elements

|90 Bearing Elements

|99 Miscellaneous

|00 Transmission Assembly of Electrical Control Components

SUB-SUBSYSTEM ROLL-UP











































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagen
BASE TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Automatic Transmission: 2007-2009 Toyota Camry
Manufacturing
Material



$

$

$

$

$

$

$

$

$

$

$

$

$ J0.33)

$

$ 0.03

$

$

I (8,81!

$ (9,12)
Labor



$

$

$

$

$

$

$

$

$

$

$

$

$ (0,37)

$

$ 0.24

$

$

$ 2.57

$ 2.44
Burden



$

$

$

$

$

$

$

$

$

$

$

$

$ (1,14)

$

$ 0.44

$

$

$ 3.64

$ 2.94
Total
Manufacturing
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$ (1,85)

$

$ 0.71

$

$

$ (2.60)

$ (3,73)
Markup
End Item
Scrap



$

$

$

$

$

$

$

$

$

$

$

$

$ (0,01)

$

$ 0.00

$

$

$

$ (0,01)
SG&A



$

$

$

$

$

$

$

$

$

$

$

$

$ (0,18)

$

$ 0.05

$

$

$

$ (0,13)
Profit



$

$

$

$

$

$

$

$

$

$

$

$

$ (0,1 8)

$

$ 0.04

$

$

$

$ (0,12)
ED&T-R&D



$

$

$

$

$

$

$

$

$

$

$

$

I (0,03)

$

$ 0.01

$

$

$

$ (0,02)
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

I (0.38)

$

$ 0.10

$

$

$

$ (0,28)
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$ (0.00)

$

$ 0.00

$

$

$

$ 0.00
Net
Component/
Assembly Cost
Impact to OEM



$

$

$

$

$

$

$

$

$

$

$

$

$ (2,23)

$

$ 0.82

$

$

$ (2.60)

$ (4,01)
File: Subsystem CMAT, CS0902, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                 Apdx. C.4 Elec. Controls, Page: 21 of 24
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                            CASE STUDY #0902
                                                                                                                                                                      Printed: 3/2 6/2010
     Technology Level: 09 - 6 Speed Automatic versus 6 Speed Direct Shift Transmission
       Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case#: 0902 ( N0902 New Technology Configuration)
                     ( B0902 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

£
5,
01
-§ Sub-Subsystem Description
w
^
(ft

0209 Park Mechanism Subsystem

1

2

3

4

5

6

7

8

9

10

11

12



|01 Rods/Shafts/Pins

|02 Springs

|03 Pawls

|04 TBD

|25 Retainers (Spring Clips, Push Nuts, Cotter Pins, etc)

|70 Pipes, Hoses, Ducting

|75 Brackets (& Levers)

|80 Boltings (Includes Nuts, Clips, Retainers, etc)

|85 Sealing Elements

|90 Bearing Elements

|99 Miscellaneous

|00 Transmission Assembly of Park Brake Control Components

SUB-SUBSYSTEM ROLL-UP






























NEW TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagen
Manufacturing
Material



$

$

$

$

$

$

$

$

$

$

$

$ 0.10

$ 0.10
Labor



$

$

$

$

$

$

$

$

$

$

$

$ 0.85

$ 0.85
Burden



$

$

$

$

$

$

$

$

$

$

$

$ 0.76

$ 0.76
Total
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$ 1.71

$ 1.71
Markup
End Item
Scrap



$

$

$

$

$

$

$

$

$

$

$

$ 0.01

$ 0.01
SG&A



$

$

$

$

$

$

$

$

$

$

$

$ 0.11

$ 0.11
Profit



$

$

$

$

$

$

$

$

$

$

$

$ 0.13

$ 0.13
ED&T-R&D



$

$

$

$

$

$

$

$

$

$

$

$ 0.10

$ 0.10
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$ 0.35

$ 0.35
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$
Net
Component/
Assembly Cost
Impact to OEM



$

$

$

$

$

$

$

$

$

$

$

$ 2.06

$ 2.06
File: Subsystem CMAT, CS0902, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                            Apdx. C.4 Park Mechanism, Page: 22 of 24
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
                                                APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                            CASE STUDY #0902
                                                                                                                                                                      Printed: 3/2 6/2010
     Technology Level: 09 - 6 Speed Automatic versus 6 Speed Direct Shift Transmission
       Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
        Study Case#: 0902 ( N0902 New Technology Configuration)
                     ( B0902 Baseline Technology Configuration)
SYSTEM & SUBSYSTEM DESCRIPTION
1

£
5,
01
-§ Sub-Subsystem Description
w
^
(ft

0209 Park Mechanism Subsystem

1

2

3

4

5

6

7

8

9

10

11

12



|01 Rods/Shafts/Pins

|02 Springs

|03 Pawls

|04 TBD

|25 Retainers (Spring Clips, Push Nuts, Cotter Pins, etc)

|70 Pipes, Hoses, Ducting

|75 Brackets (& Levers)

|80 Boltings (Includes Nuts, Clips, Retainers, etc)

|85 Sealing Elements

|90 Bearing Elements

|99 Miscellaneous

|00 Transmission Assembly of Park Brake Control Components

SUB-SUBSYSTEM ROLL-UP






























BASE TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Automatic Transmission: 2007-2009 Toyota Camry
Manufacturing
Material



$

$

$

$

$

$

$

$

$

$

$

$ 0.30

$ 0.30
Labor



$

$

$

$

$

$

$

$

$

$

$

$ 1.02

$ 1.02
Burden



$

$

$

$

$

$

$

$

$

$

$

$ 0.72

$ 0.72
Total
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$ 2.03

$ 2.03
Markup
End Item
Scrap



$

$

$

$

$

$

$

$

$

$

$

$ 0.01

$ 0.01
SG&A



$

$

$

$

$

$

$

$

$

$

$

$ 0.12

$ 0.12
Profit



$

$

$

$

$

$

$

$

$

$

$

$ 0.14

$ 0.14
ED&T-R&D



$

$

$

$

$

$

$

$

$

$

$

$ 0.10

$ 0.10
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$ 0.38

$ 0.38
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$
Net
Component/
Assembly Cost
Impact to OEM



$

$

$

$

$

$

$

$

$

$

$

$ 2.41

$ 2.41
File: Subsystem CMAT, CS0902, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                            Apdx. C.4 Park Mechanism, Page: 23 of 24
    Author: G. Kolwich
(248)373-6000 Ext. 2411

-------
     I f
                                        APPENDIX C.4 - SUBSYSTEM COST MODEL ANALYSIS TEMPLATE
                                                                 CASE STUDY #0902
                                                                                                                                             Printed: 3/2 6/2010

Technology Level: 09 - 6 Speed Automatic versus 6 Speed Direct Shift Transmission
Vehicle Class: 02 - Mid to Large Size Passenger Vehicle, 4-6 Passengers
Study Case#: 0902 ( N0902 New Technology Configuration)
( B0902 Baseline Technology Configuration)

SYSTEM & SUBSYSTEM DESCRIPTION
1

£
5,
01
-§ Sub-Subsystem Description
w
^
w

0209 Park Mechanism Subsystem

1

2

3

4

5

6

7

8

9

10

11

12



|01 Rods/Shafts/Pins

|02 Springs

|03 Pawls

|04 TBD

|25 Retainers (Spring Clips, Push Nuts, Cotter Pins, etc)

|70 Pipes, Hoses, Ducting

|75 Brackets (& Levers)

|80 Boltings (Includes Nuts, Clips, Retainers, etc)

|85 Sealing Elements

|90 Bearing Elements

|99 Miscellaneous

|00 Transmission Assembly of Park Brake Control Components

SUB-SUBSYSTEM ROLL-UP































INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
NEW TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Direct Shift Gearbox (dual clutch): 2007-2009 VW Jetta SportWagen
BASE TECHNOLOGY PACKAGE COST INFORMATION
6 Speed Automatic Transmission: 2007-2009 Toyota Camry
Manufacturing
Material



$

$

$

$

$

$

$

$

$

$

$

I (0,20!

$ (0,20)
Labor



$

$

$

$

$

$

$

$

$

$

$

I (0.16)

$ (0,16)
Burden



$

$

$

$

$

$

$

$

$

$

$

$ 0.04

$ 0.04
Total
Manufacturing
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$ (0.32)

$ (0,32)
Markup
End Item
Scrap



$

$

$

$

$

$

$

$

$

$

$

I (0.00)

$ (0,00)
SG&A



$

$

$

$

$

$

$

$

$

$

$

I (0.01)

$ (0,01)
Profit



$

$

$

$

$

$

$

$

$

$

$

I (0.01 j

$ (0,01)
ED&T-R&D



$

$

$

$

$

$

$

$

$

$

$

$ (0.01 j

$ (0,01)
Total Markup
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$ (0.03)

$ (0,03)
Total
Packaging
Cost
(Component/
Assembly)



$

$

$

$

$

$

$

$

$

$

$

$

$
Net
Component/
Assembly Cost
Impact to OEM



$

$

$

$

$

$

$

$

$

$

$

$ (0.34)

$ (0,34)
File: Subsystem CMAT, CS0902, RPT2-032510.xls
EPA Contract:EP-C-07-069 WA1 -3
                                                                Apdx. C.4 Park Mechanism, Page: 24 of 24
   Author: G. Kolwich
(248)373-6000 Ext. 2411

-------