Light Duty Technology Cost Analysis, Power - US Environmental ...

Contents
A. EXECUTIVE SUMMARY...............................................................................................................................1
B. INTRODUCTION...........................................................................................................................................11
B.1 OBJECTIVES .............................................................................................................................................11
B.2 PROCESS FLOW AND KEY SUPPORTING DOCUMENTS...............................................................................13
B.3 COST ANALYSIS ASSUMPTIONS................................................................................................................16
C. COSTING METHODOLOGY.......................................................................................................................19
C.1 TEARDOWN, PROCESS MAPPING, AND COSTING.......................................................................................19
C.1.1 Cost Methodology Fundamentals ......................................................................................................19
C.1.2 Serial and Parallel Manufacturing Operations and Processes .........................................................21
C.2 COST MODEL OVERVIEW.........................................................................................................................25
C.3 INDIRECT OEM COSTS.............................................................................................................................27
C.4 COSTING DATABASES ..............................................................................................................................27
C.4.1 Database Overview............................................................................................................................27
C.4.2 Material Database .............................................................................................................................28
C.4.3 Labor Database .................................................................................................................................31
C.4.4 Manufacturing Overhead Database ..................................................................................................34
C.4.5 Mark-up (Scrap, SG&A, Profit, ED&T).............................................................................................38
C.4.6 Packaging Database..........................................................................................................................42
C.5 SHIPPING COSTS.......................................................................................................................................44
C.6 MANUFACTURING ASSUMPTION AND QUOTE SUMMARY WORKSHEET ....................................................44
C.6.1 Overview............................................................................................................................................44
C.6.2 Main Sections of Manufacturing Assumption and Quote Summary Worksheet.................................45
C.7 MARKETPLACE VALIDATION....................................................................................................................51
C.8 COST MODEL ANALYSIS TEMPLATES.......................................................................................................52
C.8.1 Subsystem, System and Vehicle Cost Model Analysis Templates.......................................................52
D. 2010 FORD FUSION POWER-SPLIT HEV COST ANALYSIS, CASE STUDY #0502..........................52
D.1 VEHICLE & COST SUMMARY OVERVIEW .................................................................................................52
D.1.1 Vehicle Comparison Overview ..........................................................................................................52
D.1.2 Direct Manufacturing Cost Difference for a 2010 Ford Fusion Power-Split HEV compared to a
2010 Ford Fusion SE Baseline Vehicle.............................................................................................................57
D.2 ENGINE SYSTEM AND COST SUMMARY OVERVIEW..................................................................................59
D.2.1 Engine Hardware Overview ..............................................................................................................59
D.2.2 Engine System Cost Impact................................................................................................................60
D.3 TRANSMISSION SYSTEM AND COST SUMMARY OVERVIEW ......................................................................61
D.3.1 Transmission Hardware Overview ....................................................................................................61
D.3.2 Transmission System Cost Impact......................................................................................................78
D.4 BODY SYSTEM AND COST SUMMARY OVERVIEW ....................................................................................83
D.4.1 Body Hardware Overview..................................................................................................................83
D.4.2 Body System Cost Impact...................................................................................................................91
D.5 BRAKE SYSTEM AND COST SUMMARY OVERVIEW ..................................................................................92
D.5.1 Brake Hardware Overview ................................................................................................................92
D.5.2 Brake System Cost Impact .................................................................................................................98
D.6 CLIMATE CONTROL SYSTEM AND COST SUMMARY OVERVIEW .............................................................100
D.6.1 Climate Control Hardware Overview..............................................................................................100
D.6.2 Climate Control Cost Impact...........................................................................................................107
D.7 ELECTRICAL POWER SUPPLY SYSTEM AND COST SUMMARY OVERVIEW...............................................109
D.7.1 Electrical Power Supply Hardware Overview.................................................................................109
D.7.2 Electrical Power Supply Cost Impact ..............................................................................................117
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