Ulsab Model 9

8/13/2019 Ulsab Model 9

1/81


2/81

Equipment Cost 88.17Tooling Cost 51.21

Overhead Labor Cost 26.48Building Cost 7.33

Maintenance Cost 14.67Working Capital Cost 1.40

Total Fixed Costs 189.27

TOTAL COST OF STAMPED PARTS 583.58

COST BREAKDOWN: ASSEMBLYMaterial Cost 0.49

Labor Cost 45.06Energy Cost 9.87

Total Variable Costs 55.41

Equipment Cost 49.88Tooling Cost 23.40Overhead Labor Cost 125.31

Building Cost 17.74Maintenance Cost 9.10

Working Capital Cost 0.63Total Fixed Costs 226.07

TOTAL COST OF ASSEMBLY 281.48


3/81

ems Labora tory sheet for details)


4/81

COST SUMMARY CALCULATION SHEET

TOTAL COST FOR ASSEMBLED BODY STRUCTURE: 946.87

PARTS FABRICATION

STAMPINGTotal

Part ID Part Name Parts CostUnits $ / parts

001 Reinf Radiator Support Upper 7.22002/003 Reinf Front Rail Extension 4.86008/009 Rail Front Outer RH/LH 19.43010/011 Rail Front Inner RH/LH 26.42012/013 Rail Front Extension 9.89014/015 Bracket Roof Rail Mount Lower 3.53

021 Panel Dash 13.89022 Panel Dash Insert (laminate) 6.74026 Member Dash Front 7.07028 Panel Cowl Lower 4.94032 Panel Cowl Upper 6.21034 Member Front Floor Support 6.92038 Reinf Floor Front Seat Rear Outer 0.91040 Pan Front Floor 25.43

042/043 Panel Rocker Inner 33.28045 Member Rear Suspension 4.44

046/047 Rail Rear Inner 28.42048/049 Rail Rear Outer 16.70

050 Panel Spare Tire Tub (laminate) 17.24055 Member Panel Back 5.72057 Panel Back 7.58060 Panel Body Side Outer RH 61.92

061 Panel Body Side Outer LH 61.91062/063 Panel A-Pillar Inner Lower 9.32064/065 Panel B-Pillar Inner 19.69

066 Reinf B-Pillar Lower 5.96068/069 Panel Wheelhouse Inner 10.05070/071 Panel Wheelhouse Outer 17.94074/075 Panel A-Pillar Inner Upper 7.06

080 Panel Package Tray Upper 6.69081 Panel Package Tray Lower 6.84

082/083 Support Package Tray RH 0.71


5/81

085 Panel Roof - Hydromechanical Forming Step 18.38085 Panel Roof - Trimming & Flanging Steps 3.31086 Panel Front Header 4.59087 Panel Rear Header 3.78091 Member Kick Up 6.17

094/095 Reinf Radiator Rail Closeout 5.97096/097 Panel Skirt 12.52

098/099 Panel Gutter Deck Lid 4.82102/103 Support Panel Rear Header 0.69104/105 Rail Fender Support Inner 13.27106/107 Rail Fender Support Outer 9.22108/109 Reinf Front Rail 5.32

110 Plate Rear Spring Upper 1.17115 Reinf Panel Dash Brake Booster 1.50

116/117 Bracket Rear Shock Absorber Mount 1.71120 Reinf Floor Front Seat Rear Center 0.78122 Reinf Rear Seat Inner Belt Mount 0.98128 Bracket Member Pass Through Lower 0.65

130/152 Bracket Member Pass Through Up Fr & R 0.82136 Reinf Panel Dash Upper 0.43140 Pan Rear Floor 13.25142 Reinf Hinge Decklid 0.85

144/145 Reinf A-Pillar 1.14164/165 Closeout Fender Support Rail 0.86170/171 Reinf Rail Dash 3.61

172 Assy Reinf Cowl Lower 0.54180/181 Bracket Trailing Arm Mount Inner 1.48

190 Reinf Seat Belt Retractor Rear 0.85

n/a none 0.00n/a none 0.00n/a none 0.00n/a none 0.00n/a none 0.00n/a none 0.00n/a none 0.00n/a none 0.00n/a none 0.00n/a none 0.00

n/a none 0.00n/a none 0.00n/a none 0.00n/a none 0.00n/a none 0.00n/a none 0.00n/a none 0.00n/a none 0.00n/a none 0.00n/a none 0.00


6/81

n/a none 0.00n/a none 0.00

STAMPING TOTALS 583.58

TUBULAR & PURCHASED PARTSTotal

Part ID Part Name Part CostUnits $ / part

072 Rail Side Roof RH 20.42073 Rail Side Roof LH 20.44090 Member Pass Through 0.75188 Brace Radiator 0.20XXX Hinges 24.00

XXX Small Brackets 15.00XXX Weld Studs 1.00n/a none 0.00n/a none 0.00n/a none 0.00n/a none 0.00n/a none 0.00n/a none 0.00

TUBULAR & PURCHASED PARTS TOTALS 81.81

PARTS FABRICATION TOTALS 665.38

ASSEMBLY

COST/VEHICLE

AREA # AREA NAME $ / vehicle410 Final 55.12

411/412 Body Side Outer 26.92414 Framing 38.92415 Underbody Complete 15.08

416/417 Body Side Inner 35.28421 Front End 15.12422 Front Ladder Complete 32.57428 Underbody Floor 27.10431 Underbody Inner 13.91


7/81

439 Dash 7.56XXX Hinge Assembly 5.06XXX Miscellaneous Brackets 8.83n/a none 0.00n/a none 0.00n/a none 0.00n/a none 0.00

n/a none 0.00ASSEMBLY TOTALS 281.48

TOTAL BODY STRUCTURE COST 946.87


8/81

Overhead WorkingMaterial Labor Energy Equip. Tooling Labor Building Maint. Capital

Cost Cost Cost Cost Cost Cost Cost Cost Cost$ / parts $ / parts $ / parts $ / parts $ / parts $ / parts $ / parts $ / parts $ / parts

4.17 0.61 0.14 1.06 0.56 0.39 0.10 0.17 0.022.10 0.56 0.10 0.97 0.53 0.36 0.07 0.16 0.01

11.96 1.33 0.18 2.76 1.32 1.03 0.35 0.44 0.0518.24 1.18 0.19 3.15 1.63 1.06 0.38 0.52 0.07

6.58 0.42 0.14 1.06 0.99 0.34 0.10 0.22 0.030.75 0.55 0.10 0.96 0.58 0.35 0.07 0.16 0.018.92 0.25 0.09 2.17 1.74 0.22 0.07 0.40 0.035.70 0.21 0.04 0.21 0.25 0.26 0.03 0.05 0.004.10 0.56 0.13 1.03 0.60 0.36 0.09 0.17 0.022.11 0.56 0.10 0.80 0.75 0.36 0.07 0.16 0.013.34 0.56 0.10 0.80 0.78 0.36 0.07 0.17 0.022.39 1.11 0.20 1.56 0.59 0.69 0.14 0.23 0.020.36 0.12 0.02 0.12 0.10 0.15 0.01 0.02 0.00

17.19 1.52 0.20 2.29 2.85 0.64 0.14 0.53 0.0725.39 0.89 0.10 3.53 1.76 0.71 0.26 0.56 0.09

1.93 0.61 0.11 0.81 0.38 0.39 0.08 0.13 0.0119.08 1.08 0.11 4.07 2.04 0.96 0.36 0.65 0.07

9.27 0.58 0.10 3.17 2.12 0.62 0.25 0.55 0.0412.19 1.23 0.24 1.62 0.76 0.75 0.15 0.25 0.05

2.35 0.61 0.11 1.24 0.72 0.39 0.08 0.20 0.014.14 0.24 0.06 1.68 0.92 0.21 0.05 0.27 0.02

39.42 3.45 0.37 8.46 4.93 2.64 1.04 1.44 0.16

39.41 3.45 0.37 8.46 4.93 2.64 1.04 1.44 0.165.88 0.24 0.07 1.62 0.96 0.21 0.06 0.26 0.0215.14 0.24 0.07 2.13 1.43 0.21 0.06 0.36 0.05

1.46 1.11 0.20 1.46 0.66 0.69 0.14 0.23 0.016.20 0.24 0.07 1.62 1.33 0.21 0.06 0.30 0.029.13 0.87 0.10 4.07 1.68 0.99 0.44 0.62 0.043.89 0.24 0.07 1.62 0.72 0.21 0.06 0.24 0.023.52 0.56 0.13 1.03 0.78 0.36 0.09 0.19 0.023.48 0.61 0.14 1.12 0.78 0.39 0.10 0.20 0.020.27 0.06 0.01 0.06 0.20 0.08 0.01 0.03 0.00


9/81

9.15 2.34 0.16 4.24 0.45 1.40 0.11 0.48 0.050.00 0.84 0.08 1.10 0.65 0.42 0.05 0.18 0.011.81 0.67 0.12 0.89 0.43 0.42 0.09 0.14 0.011.41 0.56 0.07 0.74 0.45 0.36 0.05 0.12 0.013.10 0.56 0.13 1.03 0.70 0.36 0.09 0.18 0.012.62 0.61 0.14 1.06 0.84 0.39 0.10 0.20 0.016.78 0.51 0.10 2.97 0.96 0.54 0.22 0.41 0.03

1.68 0.61 0.14 1.06 0.65 0.39 0.10 0.18 0.010.25 0.06 0.01 0.06 0.20 0.08 0.01 0.03 0.009.67 0.24 0.06 1.68 1.06 0.21 0.05 0.28 0.035.73 0.24 0.06 1.68 0.97 0.21 0.05 0.27 0.022.67 0.61 0.11 0.81 0.50 0.39 0.08 0.14 0.010.61 0.12 0.02 0.12 0.10 0.15 0.01 0.02 0.001.11 0.06 0.01 0.06 0.15 0.08 0.01 0.02 0.001.23 0.10 0.02 0.10 0.10 0.12 0.01 0.02 0.000.47 0.06 0.01 0.06 0.09 0.08 0.01 0.02 0.000.44 0.12 0.02 0.12 0.09 0.15 0.01 0.02 0.000.10 0.12 0.02 0.12 0.10 0.15 0.01 0.02 0.000.49 0.06 0.01 0.06 0.10 0.08 0.01 0.02 0.000.13 0.06 0.01 0.06 0.07 0.08 0.01 0.01 0.009.14 0.24 0.06 2.13 1.06 0.21 0.05 0.32 0.030.35 0.12 0.02 0.12 0.05 0.15 0.01 0.02 0.000.80 0.06 0.01 0.06 0.11 0.08 0.01 0.02 0.000.40 0.06 0.01 0.06 0.22 0.08 0.01 0.03 0.001.00 0.61 0.11 0.81 0.47 0.39 0.08 0.14 0.010.18 0.06 0.01 0.06 0.12 0.08 0.01 0.02 0.001.07 0.10 0.02 0.10 0.05 0.12 0.01 0.02 0.000.33 0.12 0.02 0.12 0.07 0.15 0.01 0.02 0.00

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00


10/81

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

352.84 35.83 5.63 88.17 51.21 26.48 7.33 14.67 1.40


Cost Cost Cost Cost Cost Cost Cost Cost Cost$ / part $ / part $ / part $ / part $ / part $ / part $ / part $ / part $ / part

11.08 1.53 0.11 4.87 0.82 1.23 0.15 0.58 0.0511.09 1.53 0.11 4.87 0.82 1.23 0.15 0.58 0.05

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

22.17 3.05 0.22 9.74 1.64 2.46 0.31 1.17 0.10

375.00 38.88 5.86 97.91 52.85 28.95 7.64 15.84 1.50


Cost Cost Cost Cost Cost Cost Cost Cost Cost$ / vehicle $ / vehicle $ / vehicle $ / vehicle $ / vehicle $ / vehicle $ / vehicle $ / vehicle $ / vehicle

0.11 4.93 3.62 11.90 5.60 24.64 2.24 1.97 0.120.00 3.52 0.31 4.49 1.60 13.38 2.69 0.88 0.060.08 4.93 1.51 9.61 3.70 15.49 2.00 1.53 0.080.01 2.11 0.39 2.42 1.37 6.34 1.86 0.56 0.030.04 5.63 0.64 6.04 4.30 13.38 3.77 1.41 0.070.02 2.82 0.42 3.06 0.71 7.04 0.58 0.44 0.040.01 8.45 0.64 3.27 2.18 16.19 1.10 0.65 0.090.03 4.22 1.86 4.40 0.99 13.38 1.46 0.69 0.070.00 2.11 0.13 2.96 0.99 5.63 1.52 0.55 0.03


11/81

0.18 2.82 0.01 0.06 0.12 4.22 0.10 0.03 0.020.01 1.41 0.02 0.74 0.62 2.11 0.00 0.14 0.010.00 2.11 0.34 0.92 1.23 3.52 0.42 0.26 0.020.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.49 45.06 9.87 49.88 23.40 125.31 17.74 9.10 0.63


12/81

Effective Machine RENTTotal Machine Tooling Building Model ASSUMPTIONS ONLY

Investment Investment Investment Investment Blanking Stamping$ $ $ $ $/hr $/hr

2,411,629 1,774,832 456,590 180,208 138 4842,185,617 1,629,428 426,590 129,600 138 4596,335,219 4,637,498 1,072,349 625,372 138 4847,292,414 5,289,144 1,326,074 677,196 159 5262,761,629 1,774,832 806,590 180,208 138 4842,206,220 1,608,961 471,590 125,670 138 4595,182,818 3,641,327 1,413,179 128,312 265 1,446

592,173 347,671 200,000 44,502 74 1332,387,902 1,731,768 489,884 166,250 201 4842,089,479 1,349,995 609,884 129,600 201 3742,114,479 1,349,995 634,884 129,600 201 3743,344,226 2,618,118 474,768 251,339 201 374

310,796 204,607 80,000 26,190 74 1336,404,400 3,845,133 2,313,179 246,089 265 8077,822,293 5,933,449 1,424,799 464,045 265 1,4461,803,367 1,356,708 306,590 140,069 138 3749,137,447 6,839,233 1,654,799 643,415 180 1,4467,490,753 5,332,250 1,722,349 436,154 138 1,4463,607,384 2,719,863 616,590 270,931 138 3742,811,185 2,086,232 584,884 140,069 201 5023,655,376 2,823,003 749,884 82,489 201 1,141

20,063,842 14,222,606 4,000,000 1,841,237 189 942

20,063,842 14,222,606 4,000,000 1,841,237 189 9423,600,689 2,720,664 776,590 103,436 138 1,1664,846,538 3,579,924 1,163,179 103,436 265 1,4213,238,894 2,454,376 533,179 251,339 138 3743,905,689 2,720,664 1,081,590 103,436 138 1,1668,977,335 6,837,524 1,364,900 774,911 138 1,1903,405,689 2,720,664 581,590 103,436 138 1,1662,532,902 1,731,768 634,884 166,250 201 4842,692,263 1,877,171 634,884 180,208 201 484

275,398 102,303 160,000 13,095 74 133


13/81

7,679,061 7,130,024 363,179 185,857 265 4102,468,250 1,854,246 525,000 89,004 74 4341,997,768 1,493,024 351,590 153,155 138 3741,702,195 1,247,656 361,590 92,949 138 3492,462,902 1,731,768 564,884 166,250 201 4842,636,629 1,774,832 681,590 180,208 138 4846,151,086 4,986,563 782,161 382,362 138 1,446

2,481,629 1,774,832 526,590 180,208 138 484275,398 102,303 160,000 13,095 74 1333,765,376 2,823,003 859,884 82,489 201 1,1413,690,376 2,823,003 784,884 82,489 201 1,1411,903,367 1,356,708 406,590 140,069 138 374

315,796 204,607 85,000 26,190 74 133235,398 102,303 120,000 13,095 74 133269,592 163,645 85,000 20,947 74 133185,398 102,303 70,000 13,095 74 133300,796 204,607 70,000 26,190 74 133310,796 204,607 80,000 26,190 74 133195,398 102,303 80,000 13,095 74 133175,398 102,303 60,000 13,095 74 133

4,525,591 3,579,924 863,179 82,489 265 1,397267,796 204,607 37,000 26,190 74 133205,398 102,303 90,000 13,095 74 133295,398 102,303 180,000 13,095 74 133

1,878,367 1,356,708 381,590 140,069 138 374215,398 102,303 100,000 13,095 74 133226,592 163,645 42,000 20,947 74 133290,796 204,607 60,000 26,190 74 133

0 0 0 0 74 440 0 0 0 74 440 0 0 0 74 440 0 0 0 74 440 0 0 0 74 440 0 0 0 74 440 0 0 0 74 440 0 0 0 74 440 0 0 0 74 440 0 0 0 74 44

0 0 0 0 74 440 0 0 0 74 440 0 0 0 74 440 0 0 0 74 440 0 0 0 74 440 0 0 0 74 440 0 0 0 74 440 0 0 0 74 440 0 0 0 74 440 0 0 0 74 44


14/81


15/81

330,000 50,000 100,000 180,0001,100,000 600,000 500,000 02,500,000 750,000 1,000,000 750,000

0 0 0 00 0 0 00 0 0 00 0 0 0

0 0 0 090,736,900 40,460,400 18,979,000 31,297,500


16/81

COST BREAKDOWN BY PROCESS STEP

STAMPED PARTS

Material Blanking Welding StampingPart ID Part Name Cost Cost Cost Cost

Units $ / part $ / part $ / part $ / part 001 Reinf Radiator Support Upper 4.17 0.29 0.00 2.77

002/003 Reinf Front Rail Extension 2.10 0.28 0.00 2.48008/009 Rail Front Outer RH/LH 11.96 0.75 2.75 3.97010/011 Rail Front Inner RH/LH 18.24 0.99 3.02 4.16012/013 Rail Front Extension 6.58 0.29 0.00 3.01014/015 Bracket Roof Rail Mount Lower 0.75 0.23 0.00 2.54

021 Panel Dash 8.92 0.58 0.00 4.39022 Panel Dash Insert (laminate) 5.70 0.00 0.00 1.04026 Member Dash Front 4.10 0.39 0.00 2.58028 Panel Cowl Lower 2.11 0.38 0.00 2.44032 Panel Cowl Upper 3.34 0.39 0.00 2.47034 Member Front Floor Support 2.39 0.65 0.00 3.87038 Reinf Floor Front Seat Rear Outer 0.36 0.00 0.00 0.55040 Pan Front Floor 17.19 0.61 0.00 7.63

042/043 Panel Rocker Inner 25.39 1.07 2.20 4.63

045 Member Rear Suspension 1.93 0.28 0.00 2.23046/047 Rail Rear Inner 19.08 1.10 3.30 4.94048/049 Rail Rear Outer 9.27 0.74 1.95 4.74

050 Panel Spare Tire Tub (laminate) 12.19 0.31 0.00 4.73055 Member Panel Back 2.35 0.38 0.00 2.98057 Panel Back 4.14 0.39 0.00 3.05060 Panel Body Side Outer RH 39.42 1.90 9.53 11.06061 Panel Body Side Outer LH 39.41 1.90 9.53 11.06

062/063 Panel A-Pillar Inner Lower 5.88 0.29 0.00 3.15064/065 Panel B-Pillar Inner 15.14 0.53 0.00 4.02

066 Reinf B-Pillar Lower 1.46 0.47 0.00 4.03068/069 Panel Wheelhouse Inner 6.20 0.29 0.00 3.56070/071 Panel Wheelhouse Outer 9.13 0.50 4.40 3.91074/075 Panel A-Pillar Inner Upper 3.89 0.28 0.00 2.88

080 Panel Package Tray Upper 3.52 0.39 0.00 2.78081 Panel Package Tray Lower 3.48 0.39 0.00 2.97

082/083 Support Package Tray RH 0.27 0.00 0.00 0.44085 Panel Roof - Hydromechanical Formin 9.15 0.58 0.00 8.65085 Panel Roof - Trimming & Flanging Ste 0.00 0.00 0.00 3.31086 Panel Front Header 1.81 0.28 0.00 2.50


17/81

087 Panel Rear Header 1.41 0.28 0.00 2.09091 Member Kick Up 3.10 0.39 0.00 2.68

094/095 Reinf Radiator Rail Closeout 2.62 0.28 0.00 3.07096/097 Panel Skirt 6.78 0.49 1.64 3.61098/099 Panel Gutter Deck Lid 1.68 0.28 0.00 2.86102/103 Support Panel Rear Header 0.25 0.00 0.00 0.44104/105 Rail Fender Support Inner 9.67 0.41 0.00 3.19

106/107 Rail Fender Support Outer 5.73 0.40 0.00 3.09108/109 Reinf Front Rail 2.67 0.28 0.00 2.37110 Plate Rear Spring Upper 0.61 0.00 0.00 0.56115 Reinf Panel Dash Brake Booster 1.11 0.00 0.00 0.38

116/117 Bracket Rear Shock Absorber Mount 1.23 0.00 0.00 0.47120 Reinf Floor Front Seat Rear Center 0.47 0.00 0.00 0.32122 Reinf Rear Seat Inner Belt Mount 0.44 0.00 0.00 0.54128 Bracket Member Pass Through Lower 0.10 0.00 0.00 0.55

130/152 Bracket Member Pass Through Up Fr 0.49 0.00 0.00 0.33136 Reinf Panel Dash Upper 0.13 0.00 0.00 0.30140 Pan Rear Floor 9.14 0.51 0.00 3.59142 Reinf Hinge Decklid 0.35 0.00 0.00 0.49

144/145 Reinf A-Pillar 0.80 0.00 0.00 0.34164/165 Closeout Fender Support Rail 0.40 0.00 0.00 0.47170/171 Reinf Rail Dash 1.00 0.27 0.00 2.34

172 Assy Reinf Cowl Lower 0.18 0.00 0.00 0.36180/181 Bracket Trailing Arm Mount Inner 1.07 0.00 0.00 0.41

190 Reinf Seat Belt Retractor Rear 0.33 0.00 0.00 0.52n/a none 0.00 0.00 0.00 0.00n/a none 0.00 0.00 0.00 0.00n/a none 0.00 0.00 0.00 0.00

n/a none 0.00 0.00 0.00 0.00n/a none 0.00 0.00 0.00 0.00n/a none 0.00 0.00 0.00 0.00n/a none 0.00 0.00 0.00 0.00n/a none 0.00 0.00 0.00 0.00n/a none 0.00 0.00 0.00 0.00n/a none 0.00 0.00 0.00 0.00n/a none 0.00 0.00 0.00 0.00n/a none 0.00 0.00 0.00 0.00n/a none 0.00 0.00 0.00 0.00

n/a none 0.00 0.00 0.00 0.00n/a none 0.00 0.00 0.00 0.00n/a none 0.00 0.00 0.00 0.00n/a none 0.00 0.00 0.00 0.00n/a none 0.00 0.00 0.00 0.00n/a none 0.00 0.00 0.00 0.00n/a none 0.00 0.00 0.00 0.00n/a none 0.00 0.00 0.00 0.00n/a none 0.00 0.00 0.00 0.00


18/81

STAMPED PARTS TOTALS 352.84 21.49 38.33 170.92


19/81



4.48 0.05 0.01 0.06 0.07 0.06 0.01 0.01 0.022.24 0.05 0.01 0.06 0.07 0.06 0.01 0.01 0.01

12.70 0.11 0.02 0.15 0.21 0.14 0.03 0.04 0.0419.17 0.14 0.03 0.25 0.25 0.18 0.03 0.05 0.07

6.90 0.05 0.01 0.06 0.07 0.06 0.01 0.01 0.020.81 0.04 0.01 0.05 0.07 0.05 0.01 0.01 0.009.41 0.06 0.01 0.22 0.14 0.07 0.01 0.04 0.035.74 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.004.26 0.05 0.01 0.12 0.10 0.06 0.01 0.02 0.012.24 0.05 0.01 0.12 0.10 0.06 0.01 0.02 0.013.62 0.05 0.01 0.12 0.10 0.06 0.01 0.02 0.012.47 0.07 0.02 0.19 0.21 0.09 0.02 0.04 0.010.39 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

17.76 0.06 0.01 0.22 0.14 0.07 0.01 0.04 0.0626.92 0.09 0.02 0.37 0.28 0.12 0.02 0.07 0.09

2.01 0.05 0.01 0.06 0.07 0.06 0.01 0.01 0.0120.16 0.14 0.03 0.31 0.28 0.18 0.03 0.06 0.079.80 0.11 0.02 0.15 0.21 0.14 0.03 0.04 0.03

12.25 0.05 0.01 0.06 0.07 0.06 0.01 0.01 0.042.51 0.05 0.01 0.12 0.10 0.06 0.01 0.02 0.014.46 0.05 0.01 0.12 0.10 0.06 0.01 0.02 0.02

42.49 0.24 0.05 0.57 0.43 0.30 0.06 0.11 0.1442.49 0.24 0.05 0.57 0.43 0.30 0.06 0.11 0.14

6.27 0.05 0.01 0.06 0.07 0.06 0.01 0.01 0.0216.12 0.05 0.01 0.18 0.14 0.06 0.01 0.03 0.05

1.55 0.07 0.02 0.10 0.14 0.09 0.02 0.03 0.016.56 0.05 0.01 0.06 0.07 0.06 0.01 0.01 0.029.89 0.07 0.02 0.10 0.14 0.09 0.02 0.03 0.034.03 0.05 0.01 0.06 0.07 0.06 0.01 0.01 0.013.76 0.05 0.01 0.12 0.10 0.06 0.01 0.02 0.013.76 0.05 0.01 0.12 0.10 0.06 0.01 0.02 0.010.29 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.009.35 0.06 0.01 0.22 0.14 0.07 0.01 0.04 0.030.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.001.95 0.05 0.01 0.06 0.07 0.06 0.01 0.01 0.01


20/81

1.53 0.05 0.01 0.06 0.07 0.06 0.01 0.01 0.013.23 0.05 0.01 0.12 0.10 0.06 0.01 0.02 0.012.80 0.05 0.01 0.06 0.07 0.06 0.01 0.01 0.016.97 0.09 0.02 0.12 0.07 0.12 0.02 0.02 0.021.83 0.05 0.01 0.06 0.07 0.06 0.01 0.01 0.010.26 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

10.12 0.05 0.01 0.12 0.10 0.06 0.01 0.02 0.03

6.11 0.05 0.01 0.12 0.10 0.06 0.01 0.02 0.022.80 0.05 0.01 0.06 0.07 0.06 0.01 0.01 0.010.62 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.001.19 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.001.31 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.49 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.46 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.11 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.52 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.13 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.009.85 0.05 0.01 0.18 0.14 0.06 0.01 0.03 0.030.37 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.84 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.42 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.001.05 0.05 0.01 0.06 0.07 0.06 0.01 0.01 0.000.19 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.001.12 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.36 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00


21/81

373.50 2.80 0.61 6.02 5.45 3.50 0.68 1.22 1.22


22/81



0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

-0.01 0.37 0.00 1.50 0.00 0.47 0.23 0.17 0.00-0.02 0.41 0.00 1.65 0.00 0.51 0.25 0.19 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

-0.03 0.30 0.00 1.20 0.00 0.37 0.18 0.14 0.00

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00-0.02 0.45 0.00 1.80 0.00 0.56 0.27 0.21 0.00-0.01 0.27 0.00 1.07 0.00 0.33 0.16 0.12 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

-0.12 1.30 0.01 5.21 0.00 1.62 0.78 0.60 0.01-0.12 1.30 0.01 5.21 0.00 1.62 0.78 0.60 0.010.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

-0.01 0.60 0.00 2.40 0.00 0.75 0.36 0.28 0.010.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00


23/81

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

-0.01 0.22 0.00 0.90 0.00 0.28 0.13 0.10 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00


24/81

-0.35 5.22 0.04 20.94 0.00 6.52 3.15 2.41 0.05


25/81



-0.31 0.57 0.13 1.00 0.49 0.33 0.09 0.16 0.00-0.14 0.52 0.09 0.91 0.46 0.30 0.06 0.14 0.00-0.72 0.84 0.15 1.11 1.11 0.42 0.10 0.23 0.00-0.91 0.63 0.15 1.25 1.39 0.37 0.10 0.27 0.00-0.31 0.38 0.13 1.00 0.92 0.28 0.09 0.20 0.00-0.05 0.52 0.09 0.91 0.51 0.30 0.06 0.15 0.00-0.49 0.20 0.08 1.95 1.60 0.15 0.06 0.36 0.00-0.03 0.21 0.04 0.21 0.25 0.26 0.03 0.05 0.00-0.16 0.52 0.12 0.91 0.50 0.30 0.08 0.15 0.00-0.13 0.52 0.09 0.68 0.65 0.30 0.06 0.14 0.00-0.28 0.52 0.09 0.68 0.68 0.30 0.06 0.14 0.00-0.08 1.03 0.18 1.36 0.38 0.60 0.12 0.19 0.01-0.03 0.12 0.02 0.12 0.10 0.15 0.01 0.02 0.00-0.57 1.46 0.19 2.07 2.71 0.57 0.13 0.49 0.01-1.50 0.49 0.08 1.96 1.47 0.22 0.06 0.35 0.00

-0.08 0.57 0.10 0.75 0.31 0.33 0.07 0.11 0.00-1.06 0.49 0.08 1.96 1.76 0.22 0.06 0.38 0.00-0.52 0.20 0.08 1.96 1.91 0.15 0.06 0.39 0.00-0.06 1.18 0.23 1.56 0.69 0.69 0.14 0.24 0.01-0.16 0.57 0.10 1.12 0.62 0.33 0.07 0.18 0.00-0.31 0.20 0.05 1.56 0.82 0.15 0.04 0.24 0.00-2.95 1.91 0.31 2.68 4.50 0.72 0.20 0.74 0.00-2.96 1.91 0.31 2.68 4.50 0.72 0.20 0.74 0.00-0.39 0.20 0.06 1.56 0.89 0.15 0.05 0.25 0.00-0.99 0.20 0.06 1.95 1.29 0.15 0.05 0.33 0.00-0.08 1.03 0.18 1.36 0.52 0.60 0.12 0.20 0.01-0.37 0.20 0.06 1.56 1.26 0.15 0.05 0.29 0.00-0.75 0.20 0.08 1.57 1.54 0.15 0.06 0.32 0.00-0.14 0.20 0.06 1.56 0.65 0.15 0.05 0.23 0.00-0.24 0.52 0.12 0.91 0.68 0.30 0.08 0.17 0.00-0.28 0.57 0.13 1.00 0.68 0.33 0.09 0.18 0.00-0.02 0.06 0.01 0.06 0.20 0.08 0.01 0.03 0.00-0.20 2.28 0.15 4.02 0.31 1.33 0.09 0.44 0.010.00 0.84 0.08 1.10 0.65 0.42 0.05 0.18 0.01

-0.13 0.63 0.11 0.83 0.36 0.37 0.08 0.13 0.00


26/81

-0.12 0.52 0.06 0.68 0.38 0.30 0.04 0.11 0.00-0.13 0.52 0.12 0.91 0.59 0.30 0.08 0.16 0.00-0.18 0.57 0.13 1.00 0.77 0.33 0.09 0.19 0.00-0.18 0.20 0.08 1.95 0.89 0.15 0.06 0.29 0.00-0.14 0.57 0.13 1.00 0.58 0.33 0.09 0.17 0.00-0.01 0.06 0.01 0.06 0.20 0.08 0.01 0.03 0.00-0.45 0.20 0.05 1.56 0.96 0.15 0.04 0.25 0.00

-0.39 0.20 0.05 1.56 0.86 0.15 0.04 0.25 0.00-0.13 0.57 0.10 0.75 0.43 0.33 0.07 0.12 0.00-0.01 0.12 0.02 0.12 0.10 0.15 0.01 0.02 0.00-0.08 0.06 0.01 0.06 0.15 0.08 0.01 0.02 0.00-0.07 0.10 0.02 0.10 0.10 0.12 0.01 0.02 0.00-0.03 0.06 0.01 0.06 0.09 0.08 0.01 0.02 0.00-0.02 0.12 0.02 0.12 0.09 0.15 0.01 0.02 0.00-0.01 0.12 0.02 0.12 0.10 0.15 0.01 0.02 0.00-0.03 0.06 0.01 0.06 0.10 0.08 0.01 0.02 0.000.00 0.06 0.01 0.06 0.07 0.08 0.01 0.01 0.00

-0.70 0.20 0.05 1.95 0.92 0.15 0.04 0.29 0.00-0.02 0.12 0.02 0.12 0.05 0.15 0.01 0.02 0.00-0.04 0.06 0.01 0.06 0.11 0.08 0.01 0.02 0.00-0.02 0.06 0.01 0.06 0.22 0.08 0.01 0.03 0.00-0.05 0.57 0.10 0.75 0.40 0.33 0.07 0.12 0.00-0.01 0.06 0.01 0.06 0.12 0.08 0.01 0.02 0.00-0.05 0.10 0.02 0.10 0.05 0.12 0.01 0.02 0.00-0.03 0.12 0.02 0.12 0.07 0.15 0.01 0.02 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.000.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00


27/81

-20.31 27.82 4.99 61.21 45.76 16.47 3.50 11.05 0.13


28/81

INVESTMENT BREAKDOWN BY PROCESS STEP(investments take into account the time the equipment is used for the particular part)

STAMPED PARTS

Blanking Welding StampingTotal Total Total

Part ID Part Name Investment Investment InvestmentUnits $ $ $

001 Reinf Radiator Support Upper 178,578 0 2,233,052002/003 Reinf Front Rail Extension 178,578 0 2,007,040008/009 Rail Front Outer RH/LH 469,572 2,922,753 2,942,894010/011 Rail Front Inner RH/LH 676,497 3,215,029 3,400,888012/013 Rail Front Extension 178,578 0 2,583,052014/015 Bracket Roof Rail Mount Lower 154,180 0 2,052,040

021 Panel Dash 505,179 0 4,677,639022 Panel Dash Insert (laminate) 0 0 592,173026 Member Dash Front 309,212 0 2,078,690028 Panel Cowl Lower 309,212 0 1,780,267032 Panel Cowl Upper 309,212 0 1,805,267034 Member Front Floor Support 528,691 0 2,815,535038 Reinf Floor Front Seat Rear Outer 0 0 310,796040 Pan Front Floor 505,179 0 5,899,221

042/043 Panel Rocker Inner 893,064 2,338,203 4,591,026045 Member Rear Suspension 178,578 0 1,624,789046/047 Rail Rear Inner 809,117 3,507,304 4,821,026048/049 Rail Rear Outer 469,572 2,075,155 4,946,026

050 Panel Spare Tire Tub (laminate) 178,578 0 3,428,806055 Member Panel Back 309,212 0 2,501,973057 Panel Back 309,212 0 3,346,164060 Panel Body Side Outer RH 1,411,434 10,139,224 8,513,185061 Panel Body Side Outer LH 1,411,434 10,139,224 8,513,185

062/063 Panel A-Pillar Inner Lower 178,578 0 3,422,111064/065 Panel B-Pillar Inner 439,846 0 4,406,692

066 Reinf B-Pillar Lower 308,360 0 2,930,535068/069 Panel Wheelhouse Inner 178,578 0 3,727,111070/071 Panel Wheelhouse Outer 313,048 4,676,406 3,987,881074/075 Panel A-Pillar Inner Upper 178,578 0 3,227,111

080 Panel Package Tray Upper 309,212 0 2,223,690081 Panel Package Tray Lower 309,212 0 2,383,052

082/083 Support Package Tray RH 0 0 275,398085 Panel Roof - Hydromechanical Formin 505,179 0 7,173,881085 Panel Roof - Trimming & Flanging Ste 0 0 2,468,250


29/81

086 Panel Front Header 178,578 0 1,819,190087 Panel Rear Header 178,578 0 1,523,617091 Member Kick Up 309,212 0 2,153,690

094/095 Reinf Radiator Rail Closeout 178,578 0 2,458,052096/097 Panel Skirt 303,603 1,744,844 4,102,639098/099 Panel Gutter Deck Lid 178,578 0 2,303,052102/103 Support Panel Rear Header 0 0 275,398

104/105 Rail Fender Support Inner 309,212 0 3,456,164106/107 Rail Fender Support Outer 309,212 0 3,381,164108/109 Reinf Front Rail 178,578 0 1,724,789

110 Plate Rear Spring Upper 0 0 315,796115 Reinf Panel Dash Brake Booster 0 0 235,398

116/117 Bracket Rear Shock Absorber Mount 0 0 269,592120 Reinf Floor Front Seat Rear Center 0 0 185,398122 Reinf Rear Seat Inner Belt Mount 0 0 300,796128 Bracket Member Pass Through Lower 0 0 310,796

130/152 Bracket Member Pass Through Up Fr 0 0 195,398136 Reinf Panel Dash Upper 0 0 175,398140 Pan Rear Floor 439,846 0 4,085,746142 Reinf Hinge Decklid 0 0 267,796

144/145 Reinf A-Pillar 0 0 205,398164/165 Closeout Fender Support Rail 0 0 295,398170/171 Reinf Rail Dash 178,578 0 1,699,789

172 Assy Reinf Cowl Lower 0 0 215,398180/181 Bracket Trailing Arm Mount Inner 0 0 226,592

190 Reinf Seat Belt Retractor Rear 0 0 290,796n/a none 0 0 0n/a none 0 0 0

n/a none 0 0 0n/a none 0 0 0n/a none 0 0 0n/a none 0 0 0n/a none 0 0 0n/a none 0 0 0n/a none 0 0 0n/a none 0 0 0n/a none 0 0 0n/a none 0 0 0

n/a none 0 0 0n/a none 0 0 0n/a none 0 0 0n/a none 0 0 0n/a none 0 0 0n/a none 0 0 0n/a none 0 0 0n/a none 0 0 0n/a none 0 0 0n/a none 0 0 0


30/81

STAMPED PART INVESTMENTS 15,736,010 40,758,143 146,163,684

TUBULAR & PURCHASED PARTS

Hydroforming Hydroforming HydroformingLine Tooling Building

Part ID Part Name Invest. Invest. Invest.Units $ $ $

072 Rail Side Roof RH 8,183,784 665,000 270,911073 Rail Side Roof LH 8,183,784 665,000 270,911090 Member Pass Through 0 0 0188 Brace Radiator 0 0 0XXX Hinges 0 0 0

XXX Small Brackets 0 0 0XXX Weld Studs 0 0 0n/a none 0 0 0n/a none 0 0 0n/a none 0 0 0n/a none 0 0 0n/a none 0 0 0n/a none 0 0 0

TUBULAR PART INVESTMENTS 16,367,567 1,330,000 541,823

ASSEMBLY

Equipment Tooling BuildingInvestment Investment Investment

AREA # AREA NAME $ $ $410 Final 9,655,000 4,539,000 3,951,000

411/412 Body Side Outer 3,640,000 1,300,000 4,741,500414 Framing 7,794,600 3,000,000 3,529,500415 Underbody Complete 1,965,000 1,110,000 3,276,000

416/417 Body Side Inner 4,900,800 3,485,000 6,649,500421 Front End 2,485,000 575,000 1,021,500422 Front Ladder Complete 2,650,000 1,770,000 1,938,000428 Underbody Floor 3,570,000 800,000 2,584,500431 Underbody Inner 2,400,000 800,000 2,676,000439 Dash 50,000 100,000 180,000XXX Hinge Assembly 600,000 500,000 0


31/81

XXX Miscellaneous Brackets 750,000 1,000,000 750,000n/a none 0 0 0n/a none 0 0 0n/a none 0 0 0n/a none 0 0 0n/a none 0 0 0

ASSEMBLY INVESTMENT TOTALS 40,460,400 18,979,000 31,297,500


32/81


33/81

102,339 56,590 19,649 0 0 1,390,685 295,000102,339 56,590 19,649 0 0 1,145,317 305,000204,678 84,884 19,649 0 0 1,527,089 480,000102,339 56,590 19,649 0 0 1,672,492 625,000206,746 57,161 39,695 1,506,911 237,933 3,272,906 725,000102,339 56,590 19,649 0 0 1,672,492 470,000

0 0 0 0 0 102,303 160,000

204,678 84,884 19,649 0 0 2,618,325 775,000204,678 84,884 19,649 0 0 2,618,325 700,000102,339 56,590 19,649 0 0 1,254,369 350,000

0 0 0 0 0 204,607 85,0000 0 0 0 0 102,303 120,0000 0 0 0 0 163,645 85,0000 0 0 0 0 102,303 70,0000 0 0 0 0 204,607 70,0000 0 0 0 0 204,607 80,0000 0 0 0 0 102,303 80,0000 0 0 0 0 102,303 60,000

307,018 113,179 19,649 0 0 3,272,906 750,0000 0 0 0 0 204,607 37,0000 0 0 0 0 102,303 90,0000 0 0 0 0 102,303 180,000

102,339 56,590 19,649 0 0 1,254,369 325,0000 0 0 0 0 102,303 100,0000 0 0 0 0 163,645 42,0000 0 0 0 0 204,607 60,0000 0 0 0 0 0 00 0 0 0 0 0 0

0 0 0 0 0 0 00 0 0 0 0 0 00 0 0 0 0 0 00 0 0 0 0 0 00 0 0 0 0 0 00 0 0 0 0 0 00 0 0 0 0 0 00 0 0 0 0 0 00 0 0 0 0 0 00 0 0 0 0 0 0

0 0 0 0 0 0 00 0 0 0 0 0 00 0 0 0 0 0 00 0 0 0 0 0 00 0 0 0 0 0 00 0 0 0 0 0 00 0 0 0 0 0 00 0 0 0 0 0 00 0 0 0 0 0 00 0 0 0 0 0 0


34/81


35/81


36/81

=======>

StampingBuildingInvest.

$ 160,559109,950178,940178,940160,559109,950104,733

44,502146,601109,950109,950219,901

26,190222,510

105,303120,419105,303105,303251,282120,419

62,840356,308356,308

83,78683,786

219,90183,786

105,30383,786

146,601160,559

13,095162,278

89,004


37/81

133,50673,300

146,601160,559104,733160,559

13,095

62,84062,840120,419

26,19013,09520,94713,09526,19026,19013,09513,09562,84026,19013,09513,095

120,41913,09520,94726,190

00

0000000000

0000000000


38/81

6,184,825


39/81

GENERAL INPUTSThese parameters are g lob al for a l l par ts and processes

ANNUAL PRODUCTION VOLUME 225000 parts/yr

Important Note: The production is determined by the line rate for which the ULSABassembly line is designed. Changing the production volume requires using adifferent assembly line rate (see cell B104). However, the equipment and toolingcosts in the model were explicitly determined for the current line rate (72 vehicles/hChanging the line rate therefore REQUIRES the user to also change all of theequipment and tooling investment inputs.

Exogenous ParametersDays per Year 240 days/yr Wage (including benefits) 44.00 $/hr Unit Energy Cost 0.10 $/kWhr Interest 12%Equipment Life 20 yr Indirect workers/ Direct Press Shop Worker 0.25Indirect workers/ Press Shop Line 1.00Indirect workers/ Direct Assembly Worker 1.00Indirect Workers/Assembly Station 1.00Building Unit Cost 1500 $/sqmProduction Life 5 yrsBuilding Life 25 yrs

Idle Space 100%Working Capital Period 2 monthsDowntimes:

No shifts 8.375 hrs/dayWorker unpaid breaks 0.625 hrs/day

Worker paid breaks 1 hrs/dayUse Part Groups? (1=yes,0=no) 0

STAMPED PARTSGlobal Blanking Parameters For Part Specific Process Parameter,

Blanking Energy Consumption Rate 150 kWBlanking Line Space Requirement 100 sqm/lineWorkers / Blank Line 1 #/lineBlanking Unplanned Downtime 2 hr/day

Average Blanking Lot Size 3000 Average Blanking Die Change Time 0.5 hrsBlanking Installation Percent 25%Blanking Aux. Equipment Percent 25%Blanking Maintenance Percent 10%Blanking Cutting Tool Life 1,000,000 hits


40/81

Global Welding Parameters For Part Specific Process Parameter,Filler Wire Unit Cost 2.00 $/kgWelding Space Requirement 250 sqm/lineWorkers / Welding Line 1 #/lineWelding Unplanned Downtime 4 hrs/dayWelding Installation Percent 25%

Welding Maintenance Percent 10%

Global Press Line Parameters For Part Specific Process Parameter,Press Energy Consumption Rate 150 kWPress Station Space Requirement 50 sqmPress Line Unplanned Downtime 5 hrs/day

Average Stamping Lot Size 1500 Average Stamping Die Change Time 0.5 hrsPress Line Installation Percent 25%Press Line Aux. Equipment Percent 25%Press Line Maintenance Percent 10%

TUBULAR PARTSGlobal Parameters For Part Specific Process Parameter,Bending Line Unplanned Downtime 2 hrs/day

Average Bending Lot Size 1500 Average Bending Die Change Time 0.5 hrsBending Line Energy Consumption Rate 100 kWBending Line Space Requirement 100 sqmBending Line Installation Percent 25%Bending Line Maintenance Percent 10%

ASSEMBLYGlobal Assembly ParametersSpot Weld Tip Life (#of welds) 8000Spot Weld Tip Cost 0.45Spot Weld Energy Consumption 0.04 kWhr/weld

Adhesive Application 0.01 kg/m Adhesive Unit Cost 4.00 $/kg Adhesive Bonding Energy Rate 30 kW Adhesive Bonding Rate 0.6 m/sec

MIG Electrode Life 10000 mMIG Electrode Cost 1.50MIG Filler Metal Needed 0.011 kg/mMIG Filler Metal Cost 3.94 kg/mMIG Gas Unit Cost 0.01 $/lMIG Gas Flow Rate 0.2 l/mMIG Weld Energy Rate 33 kWMIG Weld Speed 0.04 m/secLaser Energy Rate 115 kWLaser Welding Rate 0.1 m/sec


41/81

Laser Gas Unit Cost 0.02 $/lLaser Gas Flow Rate 0.33 l/mRobot Energy Rate 2 kWConveyor Energy Rate 5 kWRobot Transport Time 5 secConveyor Transport Time 10 sec

Ass'y Unplanned Downtime 1 hrs/day

Assembly Maintenance Cost 10% Assembly Line Running Rate 72 vehicles/hr

MATERIAL PRICE TABLE

Material MaterialType Price

MPa $/kg 0 0.00140 0.77

TB96 0.7780% Mild Steel, 20% HSS Mix Mix 0.80

TB70 0.81210 0.85280 0.89

TB60 0.89350 0.92TB8 0.92

TB10 0.92TB42 0.92TB46 0.92TB48 0.92420 0.99600 1.07800 1.16

Tube 1.60Sandwich 3.60


42/81


43/81

Go to Part Input

Go to Part Input

Go to Part Input


44/81


45/81

=======>

# of Length of Length of Length of Space Spot Adhesive MIG Laser Equipment ToolingReq'd Welds Bonding Welds Welds Investment Investmentsqm # m m m $ $

2634 802 0.000 0.072 8.956 9,655,000 4,539,000

3161 72 0.000 0.000 0.000 3,640,000 1,300,0002353 317 0.000 0.562 5.162 7,794,600 3,000,0002184 92 0.000 0.000 0.000 1,965,000 1,110,0004433 128 0.000 0.314 3.078 4,900,800 3,485,000

681 96 0.000 0.250 0.150 2,485,000 575,0001292 150 0.000 0.000 0.090 2,650,000 1,770,0001723 437 0.000 0.000 0.850 3,570,000 800,0001784 32 0.000 0.000 0.000 2,400,000 800,000

120 0 4.400 0.000 0.000 50,000 100,000


46/81

INTERMEDIATE CALCULATIONS

STAMPED PARTS


47/81

087 Panel Rear Header 3600 448796091 Member Kick Up 3600 628342

094/095 Reinf Radiator Rail Closeout 3600 686962096/097 Panel Skirt 3600 2043662098/099 Panel Gutter Deck Lid 3600 535815102/103 Support Panel Rear Header 3600 76861104/105 Rail Fender Support Inner 3600 2308152

106/107 Rail Fender Support Outer 3600 1500310108/109 Reinf Front Rail 3600 686962110 Plate Rear Spring Upper 3600 152277115 Reinf Panel Dash Brake Booster 3600 292805

116/117 Bracket Rear Shock Absorber Mount 3600 320267120 Reinf Floor Front Seat Rear Center 3600 120782122 Reinf Rear Seat Inner Belt Mount 3600 114045128 Bracket Member Pass Through Lower 3600 26343

130/152 Bracket Member Pass Through Up Fr & R 3600 128102136 Reinf Panel Dash Upper 3600 32031140 Pan Rear Floor 3600 2615905142 Reinf Hinge Decklid 3600 90592

144/145 Reinf A-Pillar 3600 205872164/165 Closeout Fender Support Rail 3600 102948170/171 Reinf Rail Dash 3600 257908

172 Assy Reinf Cowl Lower 3600 46951180/181 Bracket Trailing Arm Mount Inner 3600 274504

190 Reinf Seat Belt Retractor Rear 3600 87841n/a none 3600 0n/a none 3600 0n/a none 3600 0

n/a none 3600 0n/a none 3600 0n/a none 3600 0n/a none 3600 0n/a none 3600 0n/a none 3600 0n/a none 3600 0n/a none 3600 0n/a none 3600 0n/a none 3600 0

n/a none 3600 0n/a none 3600 0n/a none 3600 0n/a none 3600 0n/a none 3600 0n/a none 3600 0n/a none 3600 0n/a none 3600 0n/a none 3600 0


48/81

TUBULAR & PURCHASED PARTS


49/81


50/81

========= ========= ========= ========>


51/81

0.77 0.773 1.9232 40% 226358 13900 1511.16 1.397 2.6926 52% 226358 19461 1510.92 1.142 2.9438 39% 226358 21277 1510.77 6.925 8.67 80% 457290 63295 3050.77 0.871 2.2961 38% 226358 16596 1510.77 0.196 0.3297 59% 226131 2306 #N/A0.99 5.411 9.891 55% 226358 71490 151

0.92 2.594 6.4292 40% 226358 46469 1510.92 1.668 2.9438 57% 226358 21277 1510.92 0.526 0.6532 81% 452262 4568 #N/A0.92 0.454 1.256 36% 226131 8784 #N/A0.92 0.674 1.3738 49% 226131 9608 #N/A0.92 0.25 0.5181 48% 226131 3623 #N/A0.92 0.244 0.4892 50% 452262 3421 #N/A0.92 0.056 0.113 50% 452262 790 #N/A0.92 0.274 0.5495 50% 226131 3843 #N/A0.92 0.1 0.1374 73% 226131 961 #N/A0.85 4.24 11.2098 38% 226358 81022 1510.92 0.224 0.3886 58% 452262 2718 #N/A0.92 0.459 0.8831 52% 226131 6176 #N/A0.92 0.23 0.4416 52% 226131 3088 #N/A0.92 0.621 1.1052 56% 226358 7988 1510.92 0.127 0.2014 63% 226131 1409 #N/A0.92 0.674 1.1775 57% 226131 8235 #N/A0.92 0.104 0.3768 28% 452262 2635 #N/A0.00 0 0 0% 0 0 00.00 0 0 0% 0 0 00.00 0 0 0% 0 0 0

0.00 0 0 0% 0 0 00.00 0 0 0% 0 0 00.00 0 0 0% 0 0 00.00 0 0 0% 0 0 00.00 0 0 0% 0 0 00.00 0 0 0% 0 0 00.00 0 0 0% 0 0 00.00 0 0 0% 0 0 00.00 0 0 0% 0 0 00.00 0 0 0% 0 0 0

0.00 0 0 0% 0 0 00.00 0 0 0% 0 0 00.00 0 0 0% 0 0 00.00 0 0 0% 0 0 00.00 0 0 0% 0 0 00.00 0 0 0% 0 0 00.00 0 0 0% 0 0 00.00 0 0 0% 0 0 00.00 0 0 0% 0 0 0


52/81

========= ========= ========= ========>


53/81

0.00 0.00 0.000.00 0.00 0.00


54/81

ALCULATIONS======== ========== ========>


55/81

2880 189 7% 0.08 226131 #N/A #N/A2880 189 7% 0.08 226131 #N/A #N/A2880 189 7% 0.08 226131 #N/A #N/A2880 381 13% 0.17 228416 19811 11422880 189 7% 0.08 226131 #N/A #N/A

#N/A #N/A #N/A #N/A 226131 #N/A #N/A2880 189 7% 0.08 226131 #N/A #N/A

2880 189 7% 0.08 226131 #N/A #N/A2880 189 7% 0.08 226131 #N/A #N/A#N/A #N/A #N/A #N/A 452262 #N/A #N/A#N/A #N/A #N/A #N/A 226131 #N/A #N/A#N/A #N/A #N/A #N/A 226131 #N/A #N/A#N/A #N/A #N/A #N/A 226131 #N/A #N/A#N/A #N/A #N/A #N/A 452262 #N/A #N/A#N/A #N/A #N/A #N/A 452262 #N/A #N/A#N/A #N/A #N/A #N/A 226131 #N/A #N/A#N/A #N/A #N/A #N/A 226131 #N/A #N/A

2880 189 7% 0.08 226131 #N/A #N/A#N/A #N/A #N/A #N/A 452262 #N/A #N/A#N/A #N/A #N/A #N/A 226131 #N/A #N/A#N/A #N/A #N/A #N/A 226131 #N/A #N/A

2880 189 7% 0.08 226131 #N/A #N/A#N/A #N/A #N/A #N/A 226131 #N/A #N/A#N/A #N/A #N/A #N/A 226131 #N/A #N/A#N/A #N/A #N/A #N/A 452262 #N/A #N/A

2880 0 0% 0.00 0 #N/A #N/A2880 0 0% 0.00 0 #N/A #N/A2880 0 0% 0.00 0 #N/A #N/A

2880 0 0% 0.00 0 #N/A #N/A2880 0 0% 0.00 0 #N/A #N/A2880 0 0% 0.00 0 #N/A #N/A2880 0 0% 0.00 0 #N/A #N/A2880 0 0% 0.00 0 #N/A #N/A2880 0 0% 0.00 0 #N/A #N/A2880 0 0% 0.00 0 #N/A #N/A2880 0 0% 0.00 0 #N/A #N/A2880 0 0% 0.00 0 #N/A #N/A2880 0 0% 0.00 0 #N/A #N/A

2880 0 0% 0.00 0 #N/A #N/A2880 0 0% 0.00 0 #N/A #N/A2880 0 0% 0.00 0 #N/A #N/A2880 0 0% 0.00 0 #N/A #N/A2880 0 0% 0.00 0 #N/A #N/A2880 0 0% 0.00 0 #N/A #N/A2880 0 0% 0.00 0 #N/A #N/A2880 0 0% 0.00 0 #N/A #N/A2880 0 0% 0.00 0 #N/A #N/A


56/81

ALCULATIONS======== ===================>


57/81

0.00 0.00 0.00 3600 0 0.000.00 0.00 0.00 3600 0 0.00


58/81

LCULATIONS====== ========= ========= =======>


59/81

#N/A #N/A #N/A #N/A #N/A 226131 260970#N/A #N/A #N/A #N/A #N/A 226131 294555#N/A #N/A #N/A #N/A #N/A 226131 408734

0.32 12.00 761 508 0.40 226131 402431#N/A #N/A #N/A #N/A #N/A 226131 323244#N/A #N/A #N/A #N/A #N/A 226131 30455#N/A #N/A #N/A #N/A #N/A 226131 1019187

#N/A #N/A #N/A #N/A #N/A 226131 870191#N/A #N/A #N/A #N/A #N/A 226131 290384#N/A #N/A #N/A #N/A #N/A 452262 29359#N/A #N/A #N/A #N/A #N/A 226131 181871#N/A #N/A #N/A #N/A #N/A 226131 159009#N/A #N/A #N/A #N/A #N/A 226131 60908#N/A #N/A #N/A #N/A #N/A 452262 55723#N/A #N/A #N/A #N/A #N/A 452262 12953#N/A #N/A #N/A #N/A #N/A 226131 62609#N/A #N/A #N/A #N/A #N/A 226131 8570#N/A #N/A #N/A #N/A #N/A 226131 1580883#N/A #N/A #N/A #N/A #N/A 452262 37475#N/A #N/A #N/A #N/A #N/A 226131 96421#N/A #N/A #N/A #N/A #N/A 226131 48109#N/A #N/A #N/A #N/A #N/A 226131 110195#N/A #N/A #N/A #N/A #N/A 226131 16968#N/A #N/A #N/A #N/A #N/A 226131 114619#N/A #N/A #N/A #N/A #N/A 452262 61806#N/A #N/A #N/A #N/A #N/A 0 0#N/A #N/A #N/A #N/A #N/A 0 0#N/A #N/A #N/A #N/A #N/A 0 0

#N/A #N/A #N/A #N/A #N/A 0 0#N/A #N/A #N/A #N/A #N/A 0 0#N/A #N/A #N/A #N/A #N/A 0 0#N/A #N/A #N/A #N/A #N/A 0 0#N/A #N/A #N/A #N/A #N/A 0 0#N/A #N/A #N/A #N/A #N/A 0 0#N/A #N/A #N/A #N/A #N/A 0 0#N/A #N/A #N/A #N/A #N/A 0 0#N/A #N/A #N/A #N/A #N/A 0 0#N/A #N/A #N/A #N/A #N/A 0 0

#N/A #N/A #N/A #N/A #N/A 0 0#N/A #N/A #N/A #N/A #N/A 0 0#N/A #N/A #N/A #N/A #N/A 0 0#N/A #N/A #N/A #N/A #N/A 0 0#N/A #N/A #N/A #N/A #N/A 0 0#N/A #N/A #N/A #N/A #N/A 0 0#N/A #N/A #N/A #N/A #N/A 0 0#N/A #N/A #N/A #N/A #N/A 0 0#N/A #N/A #N/A #N/A #N/A 0 0


60/81

======>

Cycle

Timesec/part

4040

000000

00000

CULATIONS================>

Adhesive MIG Laser Bonding Welding WeldingMaterial Material Material

$ $ $ 0.00 0.00 0.060.00 0.00 0.000.00 0.03 0.030.00 0.00 0.000.00 0.01 0.020.00 0.01 0.000.00 0.00 0.000.00 0.00 0.010.00 0.00 0.000.18 0.00 0.000.00 0.01 0.000.00 0.00 0.000.00 0.00 0.000.00 0.00 0.000.00 0.00 0.00


61/81

0.00 0.00 0.000.00 0.00 0.00


62/81

STAMPING CALCULATIONS =========== =========>


63/81

528 452 24% 0.43 15.00 58.11528 452 24% 0.43 15.00 116.21578 503 27% 0.47 15.00 58.11302 226 14% 0.21 15.00 58.11578 503 27% 0.47 15.00 58.11189 113 9% 0.11 15.00 0.00302 226 14% 0.21 15.00 116.21

302 226 14% 0.21 15.00 116.21578 503 27% 0.47 15.00 58.11377 226 17% 0.22 15.00 0.00189 113 9% 0.11 15.00 0.00302 226 14% 0.17 15.00 0.00189 113 9% 0.11 15.00 0.00377 226 17% 0.22 15.00 0.00377 226 17% 0.22 15.00 0.00189 113 9% 0.11 15.00 0.00189 113 9% 0.11 15.00 0.00302 226 14% 0.21 15.00 174.32377 226 17% 0.22 15.00 0.00189 113 9% 0.11 15.00 0.00189 113 9% 0.11 15.00 0.00578 503 27% 0.47 15.00 58.11189 113 9% 0.11 15.00 0.00302 226 14% 0.17 15.00 0.00377 226 17% 0.22 15.00 0.00

0 0 0% 0.00 15.00 0.000 0 0% 0.00 15.00 0.000 0 0% 0.00 15.00 0.00

0 0 0% 0.00 15.00 0.000 0 0% 0.00 15.00 0.000 0 0% 0.00 15.00 0.000 0 0% 0.00 15.00 0.000 0 0% 0.00 15.00 0.000 0 0% 0.00 15.00 0.000 0 0% 0.00 15.00 0.000 0 0% 0.00 15.00 0.000 0 0% 0.00 15.00 0.000 0 0% 0.00 15.00 0.00

0 0 0% 0.00 15.00 0.000 0 0% 0.00 15.00 0.000 0 0% 0.00 15.00 0.000 0 0% 0.00 15.00 0.000 0 0% 0.00 15.00 0.000 0 0% 0.00 15.00 0.000 0 0% 0.00 15.00 0.000 0 0% 0.00 15.00 0.000 0 0% 0.00 15.00 0.00


64/81


65/81


66/81

========== MACHINE RENT CALCULATIONS==== ========== ========== ==========

Blanking Blanking Blanking Blanking Stamping Stamping StampingOverhead Building Maintenance W. Cap. Energy Equipment Overhead

$/hr $/hr $/hr $/hr $/hr $/hr $/hr 44.00 13.28 7.14 0.00 60.00 309.90 44.0044.00 13.28 7.14 0.00 45.00 309.90 44.0044.00 13.28 7.14 0.00 60.00 309.90 44.0044.00 13.28 9.08 0.00 60.00 348.64 44.0044.00 13.28 7.14 0.00 60.00 309.90 44.0044.00 13.28 7.14 0.00 45.00 309.90 44.0044.00 13.28 18.76 0.00 75.00 1162.14 44.0044.00 13.28 1.33 0.00 15.00 58.11 44.0044.00 13.28 12.95 0.00 60.00 309.90 44.0044.00 13.28 12.95 0.00 45.00 232.43 44.0044.00 13.28 12.95 0.00 45.00 232.43 44.0044.00 13.28 12.95 0.00 45.00 232.43 44.0044.00 13.28 1.33 0.00 15.00 58.11 44.0044.00 13.28 18.76 0.00 75.00 581.07 44.0044.00 13.28 18.76 0.00 75.00 1162.14 44.00

44.00 13.28 7.14 0.00 45.00 232.43 44.0044.00 13.28 11.01 0.00 75.00 1162.14 44.0044.00 13.28 7.14 0.00 75.00 1162.14 44.0044.00 13.28 7.14 0.00 45.00 232.43 44.0044.00 13.28 12.95 0.00 45.00 348.64 44.0044.00 13.28 12.95 0.00 45.00 929.71 44.0044.00 13.28 11.79 0.00 105.00 658.55 44.0044.00 13.28 11.79 0.00 105.00 658.55 44.0044.00 13.28 7.14 0.00 60.00 929.71 44.0044.00 13.28 18.76 0.00 60.00 1162.14 44.0044.00 13.28 7.14 0.00 45.00 232.43 44.0044.00 13.28 7.14 0.00 60.00 929.71 44.0044.00 13.28 7.14 0.00 75.00 929.71 44.0044.00 13.28 7.14 0.00 60.00 929.71 44.0044.00 13.28 12.95 0.00 60.00 309.90 44.0044.00 13.28 12.95 0.00 60.00 309.90 44.0044.00 13.28 1.33 0.00 15.00 58.11 44.0044.00 13.28 18.76 0.00 15.00 309.90 44.0044.00 13.28 1.33 0.00 30.00 309.90 44.0044.00 13.28 7.14 0.00 45.00 232.43 44.00


67/81

44.00 13.28 7.14 0.00 30.00 232.43 44.0044.00 13.28 12.95 0.00 60.00 309.90 44.0044.00 13.28 7.14 0.00 60.00 309.90 44.0044.00 13.28 7.14 0.00 75.00 1162.14 44.0044.00 13.28 7.14 0.00 60.00 309.90 44.0044.00 13.28 1.33 0.00 15.00 58.11 44.0044.00 13.28 12.95 0.00 45.00 929.71 44.00

44.00 13.28 12.95 0.00 45.00 929.71 44.0044.00 13.28 7.14 0.00 45.00 232.43 44.0044.00 13.28 1.33 0.00 15.00 58.11 44.0044.00 13.28 1.33 0.00 15.00 58.11 44.0044.00 13.28 1.33 0.00 15.00 58.11 44.0044.00 13.28 1.33 0.00 15.00 58.11 44.0044.00 13.28 1.33 0.00 15.00 58.11 44.0044.00 13.28 1.33 0.00 15.00 58.11 44.0044.00 13.28 1.33 0.00 15.00 58.11 44.0044.00 13.28 1.33 0.00 15.00 58.11 44.0044.00 13.28 18.76 0.00 45.00 1162.14 44.0044.00 13.28 1.33 0.00 15.00 58.11 44.0044.00 13.28 1.33 0.00 15.00 58.11 44.0044.00 13.28 1.33 0.00 15.00 58.11 44.0044.00 13.28 7.14 0.00 45.00 232.43 44.0044.00 13.28 1.33 0.00 15.00 58.11 44.0044.00 13.28 1.33 0.00 15.00 58.11 44.0044.00 13.28 1.33 0.00 15.00 58.11 44.0044.00 13.28 1.33 0.00 0.00 0.00 44.0044.00 13.28 1.33 0.00 0.00 0.00 44.0044.00 13.28 1.33 0.00 0.00 0.00 44.00

44.00 13.28 1.33 0.00 0.00 0.00 44.0044.00 13.28 1.33 0.00 0.00 0.00 44.0044.00 13.28 1.33 0.00 0.00 0.00 44.0044.00 13.28 1.33 0.00 0.00 0.00 44.0044.00 13.28 1.33 0.00 0.00 0.00 44.0044.00 13.28 1.33 0.00 0.00 0.00 44.0044.00 13.28 1.33 0.00 0.00 0.00 44.0044.00 13.28 1.33 0.00 0.00 0.00 44.0044.00 13.28 1.33 0.00 0.00 0.00 44.0044.00 13.28 1.33 0.00 0.00 0.00 44.00

44.00 13.28 1.33 0.00 0.00 0.00 44.0044.00 13.28 1.33 0.00 0.00 0.00 44.0044.00 13.28 1.33 0.00 0.00 0.00 44.0044.00 13.28 1.33 0.00 0.00 0.00 44.0044.00 13.28 1.33 0.00 0.00 0.00 44.0044.00 13.28 1.33 0.00 0.00 0.00 44.0044.00 13.28 1.33 0.00 0.00 0.00 44.0044.00 13.28 1.33 0.00 0.00 0.00 44.0044.00 13.28 1.33 0.00 0.00 0.00 44.00


68/81


69/81


70/81


71/81

17.71 25.01 0.0035.42 34.53 0.0135.42 34.53 0.0144.27 120.64 0.0235.42 34.53 0.01

8.85 6.70 0.0026.56 95.63 0.02

26.56 95.63 0.0226.56 25.90 0.018.85 6.70 0.008.85 6.70 0.008.85 6.70 0.008.85 6.70 0.008.85 6.70 0.008.85 6.70 0.008.85 6.70 0.008.85 6.70 0.00

26.56 118.87 0.028.85 6.70 0.008.85 6.70 0.008.85 6.70 0.00

26.56 25.90 0.018.85 6.70 0.008.85 6.70 0.008.85 6.70 0.000.00 0.00 0.000.00 0.00 0.000.00 0.00 0.00

0.00 0.00 0.000.00 0.00 0.000.00 0.00 0.000.00 0.00 0.000.00 0.00 0.000.00 0.00 0.000.00 0.00 0.000.00 0.00 0.000.00 0.00 0.000.00 0.00 0.00

0.00 0.00 0.000.00 0.00 0.000.00 0.00 0.000.00 0.00 0.000.00 0.00 0.000.00 0.00 0.000.00 0.00 0.000.00 0.00 0.000.00 0.00 0.00


72/81


73/81

MACHINE RENT ESTIMATION

This page is provided for those users who prefer to analyze cost from machine rents.This is NOT an approach advocated by the model designers, and thus the modeldoes not use the calculated machine rents to arrive at the final costs. This is providedstrictly as a basis for comparison for those users who prefer this approach.

This model considers only the items listed below to be part of the machine rent. Toensure consistency of results, the user MUST be certain that their own machinerent values contain the EXACT same cost elements. To use this sheet, the user should first enter the number of the part to be examined. (Note, this sheet only givesthe user the ability to test a single part at a time). The "Test Part Number" must beentered as TEXT and must appear exactly as it does in the Part Inputs sheet.

A test table is provided below. The first column contains the relevant model data for

the specified part. This is used to calculate the machine rents for the blanking andstamping lines. The user is invited to use the adjacent "test values" column to seethe effects of changes in the inputs on the machine rents. If the user would like theoverall model to reflect these machine rents he should use the test values columnto determine the set of inputs which will result in the desired machine rent value.These inputs can then be copied to the actual model input pages (general andparts inputs) and will then result in the same final part costs.

Test Part Number 001

CurrentModel Test

Inputs Values ValuesBlanking Line Energy Consumption Rate 150 150Press Energy Consumption Rate 150 150Number of Presses 4 4Unit Energy Cost 0.10 0.10Blanking Press Cost 1000000 1000000Stamping Press Line Cost 4000000 4000000Blanking Auxiliary Equipment Percent 25% 25%Stamping Auxiliary Equipment Percent 25% 25%Interest Rate 12% 12%Equipment Life 20 20Days per Year 240 240No shifts 8.375 8.375Worker unpaid breaks 0.625 0.625Worker paid breaks 1 1Blanking Line Unplanned Downtime 2 2


74/81

Stamping Line Unplanned Downtime 5 5Indirect workers/Line 1 1Wage (including benefits) 44 44Blanking Line Space Requirement 100 100Press Space Requirement 50 50Idle Space Percent 100% 100%Building Unit Cost 1500 1500

Building Life 25 25Blanking Line Maintenance Percent 10% 10%Press Line Maintenance Percent 10% 10%Working Capital Period 2 2

BLANKING RENTS ($/hr)Contribution from Energy 15.00 15.00Contribution from Equipment 58.11 58.11Contribution from Overhead Labor 44.00 44.00Contribution from Building 13.28 13.28Contribution from Maintenance 7.14 7.14Contribution from Working Capital 0.00 0.00

BLANKING MACHINE RENT 137.53 137.53

STAMPING RENTS ($/hr)Contribution from Energy 60.00 60.00Contribution from Equipment 309.90 309.90Contribution from Overhead Labor 44.00 44.00

Contribution from Building 35.42 35.42Contribution from Maintenance 34.53 34.53Contribution from Working Capital 0.01 0.01

STAMPING MACHINE RENT 483.86 483.86


75/81


76/81

INFORMATION SHEET: BLANK SIZES

* Note: For partthe blank lengthneeded to prod

Blank LengthPart ID Part Name Blank # mm

001 Reinf Radiator Support Upper 1 1500002/003 Reinf Front Rail Extension 1 1200008/009 Rail Front Outer RH/LH 1 800

2 8003 800

010/011 Rail Front Inner RH/LH 1 5002 5003 700

012/013 Rail Front Extension 1 600014/015 Bracket Roof Rail Mount Lower 1 300

021 Panel Dash 1 1300022 Panel Dash Insert (laminate) Laminate 450026 Member Dash Front 1 350028 Panel Cowl Lower 1 650032 Panel Cowl Upper 1 500034 Member Front Floor Support 1 250038 Reinf Floor Front Seat Rear Outer Progressive 200

040 Pan Front Floor 1 1600042/043 Panel Rocker Inner 1 1200

2 1200045 Member Rear Suspension 1 350

046/047 Rail Rear Inner 1 10002 10003 1000

048/049 Rail Rear Outer 1 6502 6503 650

050 Panel Spare Tire Tub (laminate) Laminate 1000055 Member Panel Back 1 400057 Panel Back 1 600060 Panel Body Side Outer RH The five blanks mak061 Panel Body Side Outer LH are NOT rectangular.

062/063 Panel A-Pillar Inner Lower 1 700064/065 Panel B-Pillar Inner 1 1200

066 Reinf B-Pillar Lower 1 460068/069 Panel Wheelhouse Inner 1 1220070/071 Panel Wheelhouse Outer 1 1400


77/81

2 14003 1400

074/075 Panel A-Pillar Inner Upper 1 400080 Panel Package Tray Upper 1 600081 Panel Package Tray Lower 1 600

082/083 Support Package Tray RH Progressive 350085 Panel Roof 1 1250

086 Panel Front Header 1 350087 Panel Rear Header 1 350091 Member Kick Up 1 350

094/095 Reinf Radiator Rail Closeout 1 500096/097 Panel Skirt 1 800

2 800098/099 Panel Gutter Deck Lid 1 500102/103 Support Panel Rear Header Progressive 300104/105 Rail Fender Support Inner 1 1000106/107 Rail Fender Support Outer 1 700108/109 Reinf Front Rail 1 500

110 Plate Rear Spring Upper Progressive 160115 Reinf Panel Dash Brake Booster Progressive 500

116/117 Bracket Rear Shock Absorber Mount Progressive 300120 Reinf Floor Front Seat Rear Center Progressive 550122 Reinf Rear Seat Inner Belt Mount Progressive 205128 Bracket Member Pass Through Lower Progressive 120

130/152 Bracket Member Pass Through Up Fr & R Progressive 350136 Reinf Panel Dash Upper Progressive 175140 Pan Rear Floor 1 1200142 Reinf Hinge Decklid Progressive 220

144/145 Reinf A-Pillar Progressive 500164/165 Closeout Fender Support Rail Progressive 450170/171 Reinf Rail Dash 1 190

172 Assy Reinf Cowl Lower Progressive 190180/181 Bracket Trailing Arm Mount Inner Progressive 300

190 Reinf Seat Belt Retractor Rear Progressive 200


78/81


79/81

900 0.65 7.85 6.43 140300 0.80 7.85 2.64 210900 1.50 7.85 4.24 350

1400 0.65 7.85 4.29 2101400 0.65 7.85 4.29 210

200 0.80 7.85 0.44 2801550 0.70 7.85 10.65 210

1100 0.70 7.85 2.12 2801000 0.70 7.85 1.92 1401400 0.70 7.85 2.69 800

750 1.00 7.85 2.94 350450 2.00 7.85 5.65 140300 1.60 7.85 3.01 140900 0.65 7.85 2.30 140200 0.70 7.85 0.33 140

1500 0.90 7.85 10.60 4201300 0.90 7.85 6.43 350

750 1.00 7.85 2.94 350130 2.00 7.85 0.33 350320 1.00 7.85 1.26 350250 2.00 7.85 1.18 350100 1.20 7.85 0.52 350

76 2.00 7.85 0.24 35060 1.00 7.85 0.06 350

200 1.00 7.85 0.55 350100 1.00 7.85 0.14 350

1700 0.70 7.85 11.21 21075 1.50 7.85 0.19 350

150 1.50 7.85 0.88 350125 1.00 7.85 0.44 350570 1.30 7.85 1.11 350135 1.00 7.85 0.20 350250 2.00 7.85 1.18 350100 1.20 7.85 0.19 350


80/81

ULSAB BODY STRUCTURE COST MODEL

Camanoe Associates IBIS AssociatesKendall Square P.O. Box 842 55 Williams Street, Suite 220Cambridge, MA 02142 Wellesley, MA 02181-4003USA USA

contact person: contact person:Dr. Richard Roth Jeff Dieffenbachtel: 1-617-253-6487 tel: 1-781-239-0666fax: 1-617-258-7471 fax: 1-781-239-0852

e-mail: [email protected] e-mail: [email protected]


81/81

Date post:	04-Jun-2018
Category:	Documents
Upload:	prasadkcp
View:	215 times
Download:	0 times

Ulsab Model 9

Documents