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

D.1.2 Direct Manufacturing Cost Difference for a 2010 Ford Fusion Power-Split HEV
compared to a 2010 Ford Fusion SE Baseline Vehicle
A summary of the calculated, net incremental, direct manufacturing costs for producing a
Ford Fusion Hybrid vehicle over the baseline Ford Fusion SE is presented in Table D-4.
The costs, captured only for vehicle differences having an overall positive or negative
cost impact, are broken out for each of the major systems in both the Fusion HEV (New
Technology Configuration) and Fusion SE (Baseline Technology Configuration). At the
bottom of the table, the baseline configuration costs are subtracted from the new
technology configuration costs resulting in a net incremental cost
From the cost element breakdown within the table, approximately 71% of the incremental
direct manufacturing costs (i.e., $2,865.06) are material costs, 14% labor costs, and 15%
overhead costs. Relative to the net incremental direct manufacturing cost of $3,435,
approximately 83.5% are total manufacturing costs (i.e., material, labor, overhead) and
the remaining 16.5% is applicable mark-up.
More than 95% of the costs for adding the power-split technology to the baseline
configuration originate from the transmission (34%) and electrical power supply (63%)
systems.
In the sections which follow, additional details on the components evaluated within each
vehicle system and their associated costs will be discussed.
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