ULSAB BODY STRUCTURE COST MODEL Camanoe Associates

in association with:
IBIS Associates &
The MIT Materials Systems Laboratory
(see contact information sheet for details)

OVERALL COST ANALYSIS

BODY STRUCTURE DESIGN SPECIFICATIONS

Total Weight (kg) 203.18
Engineering Scrap 52%
Production Scrap 2%

TOTAL BODY STRUCTURE COST WORKSHEET

Manufacturing Cost #N/A
Quality Assurance Costs 0.00
Cost of Engineering Changes 0.00
Start Up and Production Launch Costs 0.00
Marketing Costs 0.00
Transportation Costs 0.00
Departmental Costs 0.00
Preparation for Paint 0.00
Other BIW Related Costs 0.00

TOTAL BODY STRUCTURE COST #N/A

MANUFACTURING COST BREAKDOWN

Cost of Stamped Parts #N/A
Cost of Tubular & Purchased Parts 81.81
Assembly Cost 281.48

BODY STRUCTURE MANUFACTURING COST #N/A

COST BREAKDOWN: STAMPED PARTS

Material Cost #N/A
 Labor Cost 35.83
Energy Cost 5.63
Total Variable Costs #N/A

Equipment Cost 88.17

Tooling Cost 51.21
Overhead Labor Cost 26.48
Building Cost 7.33
Maintenance Cost 14.67
Working Capital Cost #N/A
Total Fixed Costs #N/A

TOTAL COST OF STAMPED PARTS #N/A

COST BREAKDOWN: ASSEMBLY

Material Cost 0.49
Labor Cost 45.06
Energy Cost 9.87
Total Variable Costs 55.41

Equipment Cost 49.88

Tooling Cost 23.40
Overhead Labor Cost 125.31
Building Cost 17.74
Maintenance Cost 9.10
Working Capital Cost 0.63
Total Fixed Costs 226.07

TOTAL COST OF ASSEMBLY 281.48

 ls Systems Laboratory
rmation sheet for details)
COST SUMMARY CALCULATION SHEET

TOTAL COST FOR ASSEMBLED BODY STRUCTURE: #N/A

PARTS FABRICATION

<======================GENERAL OUTPUT COSTS=========== ==========>

STAMPING
Total
Part ID Part Name Parts Cost
Units $ / parts
001 Reinf Radiator Support Upper 7.22
002/003 Reinf Front Rail Extension 4.86
008/009 Rail Front Outer RH/LH 19.43
010/011 Rail Front Inner RH/LH #N/A
012/013 Rail Front Extension 9.89
014/015 Bracket Roof Rail Mount Lower 3.53
021 Panel Dash 13.89
022 Panel Dash Insert (laminate) #N/A
026 Member Dash Front 7.07
028 Panel Cowl Lower 4.94
032 Panel Cowl Upper 6.21
034 Member Front Floor Support 6.92
038 Reinf Floor Front Seat Rear Outer 0.91
040 Pan Front Floor 25.43
042/043 Panel Rocker Inner #N/A
045 Member Rear Suspension 4.44
046/047 Rail Rear Inner #N/A
048/049 Rail Rear Outer #N/A
050 Panel Spare Tire Tub (laminate) #N/A
055 Member Panel Back 5.72
057 Panel Back 7.58
060 Panel Body Side Outer RH #N/A
061 Panel Body Side Outer LH #N/A
062/063 Panel A-Pillar Inner Lower 9.32
064/065 Panel B-Pillar Inner 19.69
066 Reinf B-Pillar Lower 5.96
068/069 Panel Wheelhouse Inner 10.05
070/071 Panel Wheelhouse Outer 17.94
074/075 Panel A-Pillar Inner Upper 7.06
080 Panel Package Tray Upper 6.69
081 Panel Package Tray Lower 6.84
082/083 Support Package Tray RH 0.71
085 Panel Roof - Hydromechanical Forming Step 18.38
085 Panel Roof - Trimming & Flanging Steps 3.31
086 Panel Front Header 4.59
087 Panel Rear Header 3.78
091 Member Kick Up 6.17
094/095 Reinf Radiator Rail Closeout 5.97
096/097 Panel Skirt #N/A
098/099 Panel Gutter Deck Lid 4.82
102/103 Support Panel Rear Header 0.69
104/105 Rail Fender Support Inner 13.27
106/107 Rail Fender Support Outer 9.22
108/109 Reinf Front Rail 5.32
110 Plate Rear Spring Upper 1.17
115 Reinf Panel Dash Brake Booster 1.50
116/117 Bracket Rear Shock Absorber Mount 1.71
120 Reinf Floor Front Seat Rear Center 0.78
122 Reinf Rear Seat Inner Belt Mount 0.98
128 Bracket Member Pass Through Lower 0.65
130/152 Bracket Member Pass Through Up Fr & R 0.82
136 Reinf Panel Dash Upper 0.43
140 Pan Rear Floor 13.25
142 Reinf Hinge Decklid 0.85
144/145 Reinf A-Pillar 1.14
164/165 Closeout Fender Support Rail 0.86
170/171 Reinf Rail Dash 3.61
172 Assy Reinf Cowl Lower 0.54
180/181 Bracket Trailing Arm Mount Inner 1.48
190 Reinf Seat Belt Retractor Rear 0.85
n/a none 0.00
n/a none 0.00
n/a none 0.00
n/a none 0.00
n/a none 0.00
n/a none 0.00
n/a none 0.00
n/a none 0.00
 n/a none 0.00
n/a none 0.00
n/a none 0.00
n/a none 0.00
n/a none 0.00
n/a none 0.00
n/a none 0.00
n/a none 0.00
n/a none 0.00
n/a none 0.00
n/a none 0.00
n/a none 0.00
n/a none 0.00
n/a none 0.00

STAMPING TOTALS #N/A

<=============
===========GENERAL OUTPUT COSTS=========== =========>

TUBULAR & PURCHASED PARTS

Total
Part ID Part Name Part Cost
Units $ / part
072 Rail Side Roof RH 20.42
073 Rail Side Roof LH 20.44
090 Member Pass Through 0.75
188 Brace Radiator 0.20
XXX Hinges 24.00
XXX Small Brackets 15.00
XXX Weld Studs 1.00
n/a none 0.00
n/a none 0.00
n/a none 0.00
n/a none 0.00
n/a none 0.00
n/a none 0.00

TUBULAR & PURCHASED PARTS TOTALS 81.81

PARTS FABRICATION TOTALS #N/A

 ASSEMBLY

<=======================GENERAL OUTPUT COSTS=========== ==========>

COST/
VEHICLE
AREA # AREA NAME $ / vehicle $ / vehicle
410 Final 55.12
411/412 Body Side Outer 26.92
414 Framing 38.92
415 Underbody Complete 15.08
416/417 Body Side Inner 35.28
421 Front End 15.12
422 Front Ladder Complete 32.57
428 Underbody Floor 27.10
431 Underbody Inner 13.91
439 Dash 7.56
XXX Hinge Assembly 5.06
XXX Miscellaneous Brackets 8.83
n/a none 0.00
n/a none 0.00
n/a none 0.00
n/a none 0.00
n/a none 0.00

ASSEMBLY TOTALS 281.48

TOTAL BODY STRUCTURE COST #N/A

<======= ======== ======== COST BREAKDOWN================ ======== ======>

Overhead Working
Material 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 0.02
2.10 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 0.05
#N/A 1.18 0.19 3.15 1.63 1.06 0.38 0.52 #N/A
6.58 0.42 0.14 1.06 0.99 0.34 0.10 0.22 0.03
0.75 0.55 0.10 0.96 0.58 0.35 0.07 0.16 0.01
8.92 0.25 0.09 2.17 1.74 0.22 0.07 0.40 0.03
#N/A 0.21 0.04 0.21 0.25 0.26 0.03 0.05 0.00
4.10 0.56 0.13 1.03 0.60 0.36 0.09 0.17 0.02
2.11 0.56 0.10 0.80 0.75 0.36 0.07 0.16 0.01
3.34 0.56 0.10 0.80 0.78 0.36 0.07 0.17 0.02
2.39 1.11 0.20 1.56 0.59 0.69 0.14 0.23 0.02
0.36 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 0.07
#N/A 0.89 0.10 3.53 1.76 0.71 0.26 0.56 #N/A
1.93 0.61 0.11 0.81 0.38 0.39 0.08 0.13 0.01
#N/A 1.08 0.11 4.07 2.04 0.96 0.36 0.65 #N/A
#N/A 0.58 0.10 3.17 2.12 0.62 0.25 0.55 #N/A
#N/A 1.23 0.24 1.62 0.76 0.75 0.15 0.25 #N/A
2.35 0.61 0.11 1.24 0.72 0.39 0.08 0.20 0.01
4.14 0.24 0.06 1.68 0.92 0.21 0.05 0.27 0.02
#N/A 3.45 0.37 8.46 4.93 2.64 1.04 1.44 #N/A
#N/A 3.45 0.37 8.46 4.93 2.64 1.04 1.44 #N/A
5.88 0.24 0.07 1.62 0.96 0.21 0.06 0.26 0.02
15.14 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 0.01
6.20 0.24 0.07 1.62 1.33 0.21 0.06 0.30 0.02
9.13 0.87 0.10 4.07 1.68 0.99 0.44 0.62 0.04
3.89 0.24 0.07 1.62 0.72 0.21 0.06 0.24 0.02
3.52 0.56 0.13 1.03 0.78 0.36 0.09 0.19 0.02
3.48 0.61 0.14 1.12 0.78 0.39 0.10 0.20 0.02
0.27 0.06 0.01 0.06 0.20 0.08 0.01 0.03 0.00
9.15 2.34 0.16 4.24 0.45 1.40 0.11 0.48 0.05
0.00 0.84 0.08 1.10 0.65 0.42 0.05 0.18 0.01
1.81 0.67 0.12 0.89 0.43 0.42 0.09 0.14 0.01
1.41 0.56 0.07 0.74 0.45 0.36 0.05 0.12 0.01
3.10 0.56 0.13 1.03 0.70 0.36 0.09 0.18 0.01
2.62 0.61 0.14 1.06 0.84 0.39 0.10 0.20 0.01
#N/A 0.51 0.10 2.97 0.96 0.54 0.22 0.41 #N/A
1.68 0.61 0.14 1.06 0.65 0.39 0.10 0.18 0.01
0.25 0.06 0.01 0.06 0.20 0.08 0.01 0.03 0.00
9.67 0.24 0.06 1.68 1.06 0.21 0.05 0.28 0.03
5.73 0.24 0.06 1.68 0.97 0.21 0.05 0.27 0.02
2.67 0.61 0.11 0.81 0.50 0.39 0.08 0.14 0.01
0.61 0.12 0.02 0.12 0.10 0.15 0.01 0.02 0.00
1.11 0.06 0.01 0.06 0.15 0.08 0.01 0.02 0.00
1.23 0.10 0.02 0.10 0.10 0.12 0.01 0.02 0.00
0.47 0.06 0.01 0.06 0.09 0.08 0.01 0.02 0.00
0.44 0.12 0.02 0.12 0.09 0.15 0.01 0.02 0.00
0.10 0.12 0.02 0.12 0.10 0.15 0.01 0.02 0.00
0.49 0.06 0.01 0.06 0.10 0.08 0.01 0.02 0.00
0.13 0.06 0.01 0.06 0.07 0.08 0.01 0.01 0.00
9.14 0.24 0.06 2.13 1.06 0.21 0.05 0.32 0.03
0.35 0.12 0.02 0.12 0.05 0.15 0.01 0.02 0.00
0.80 0.06 0.01 0.06 0.11 0.08 0.01 0.02 0.00
0.40 0.06 0.01 0.06 0.22 0.08 0.01 0.03 0.00
1.00 0.61 0.11 0.81 0.47 0.39 0.08 0.14 0.01
0.18 0.06 0.01 0.06 0.12 0.08 0.01 0.02 0.00
1.07 0.10 0.02 0.10 0.05 0.12 0.01 0.02 0.00
0.33 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 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

#N/A 35.83 5.63 88.17 51.21 26.48 7.33 14.67 #N/A

<======= ======== ======== COST BREAKDOWN================ ======== ======>

Overhead Working
Material Labor Energy Equip. Tooling Labor Building Maint. Capital
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 0.05
11.09 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 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 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

#N/A 38.88 5.86 97.91 52.85 28.95 7.64 15.84 #N/A

<======= ======== ======== COST BREAKDOWN================ ======== ======>

Overhead Working
Material Labor Energy Equip. Tooling Labor Building Maint. Capital
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 0.12
0.00 3.52 0.31 4.49 1.60 13.38 2.69 0.88 0.06
0.08 4.93 1.51 9.61 3.70 15.49 2.00 1.53 0.08
0.01 2.11 0.39 2.42 1.37 6.34 1.86 0.56 0.03
0.04 5.63 0.64 6.04 4.30 13.38 3.77 1.41 0.07
0.02 2.82 0.42 3.06 0.71 7.04 0.58 0.44 0.04
0.01 8.45 0.64 3.27 2.18 16.19 1.10 0.65 0.09
0.03 4.22 1.86 4.40 0.99 13.38 1.46 0.69 0.07
0.00 2.11 0.13 2.96 0.99 5.63 1.52 0.55 0.03
0.18 2.82 0.01 0.06 0.12 4.22 0.10 0.03 0.02
0.01 1.41 0.02 0.74 0.62 2.11 0.00 0.14 0.01
0.00 2.11 0.34 0.92 1.23 3.52 0.42 0.26 0.02
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

0.49 45.06 9.87 49.88 23.40 125.31 17.74 9.10 0.63

<============INVESTMENT COSTS & MACHINE RENTS=====================>

Effective Machine RENT

Total Machine Tooling Building Model ASSUMPTIONS ONLY
Investment Investment Investment Investment Blanking Stamping
$ $ $ $ $/hr $/hr
2,411,629 1,774,832 456,590 180,208 138 484
2,185,617 1,629,428 426,590 129,600 138 459
6,335,219 4,637,498 1,072,349 625,372 138 484
7,292,414 5,289,144 1,326,074 677,196 159 526
2,761,629 1,774,832 806,590 180,208 138 484
2,206,220 1,608,961 471,590 125,670 138 459
5,182,818 3,641,327 1,413,179 128,312 265 1,446
592,173 347,671 200,000 44,502 74 133
2,387,902 1,731,768 489,884 166,250 201 484
2,089,479 1,349,995 609,884 129,600 201 374
2,114,479 1,349,995 634,884 129,600 201 374
3,344,226 2,618,118 474,768 251,339 201 374
310,796 204,607 80,000 26,190 74 133
6,404,400 3,845,133 2,313,179 246,089 265 807
7,822,293 5,933,449 1,424,799 464,045 265 1,446
1,803,367 1,356,708 306,590 140,069 138 374
9,137,447 6,839,233 1,654,799 643,415 180 1,446
7,490,753 5,332,250 1,722,349 436,154 138 1,446
3,607,384 2,719,863 616,590 270,931 138 374
2,811,185 2,086,232 584,884 140,069 201 502
3,655,376 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 1,841,237 189 942
3,600,689 2,720,664 776,590 103,436 138 1,166
4,846,538 3,579,924 1,163,179 103,436 265 1,421
3,238,894 2,454,376 533,179 251,339 138 374
3,905,689 2,720,664 1,081,590 103,436 138 1,166
8,977,335 6,837,524 1,364,900 774,911 138 1,190
3,405,689 2,720,664 581,590 103,436 138 1,166
2,532,902 1,731,768 634,884 166,250 201 484
2,692,263 1,877,171 634,884 180,208 201 484
275,398 102,303 160,000 13,095 74 133
7,679,061 7,130,024 363,179 185,857 265 410
2,468,250 1,854,246 525,000 89,004 74 434
1,997,768 1,493,024 351,590 153,155 138 374
1,702,195 1,247,656 361,590 92,949 138 349
2,462,902 1,731,768 564,884 166,250 201 484
2,636,629 1,774,832 681,590 180,208 138 484
6,151,086 4,986,563 782,161 382,362 138 1,446
2,481,629 1,774,832 526,590 180,208 138 484
275,398 102,303 160,000 13,095 74 133
3,765,376 2,823,003 859,884 82,489 201 1,141
3,690,376 2,823,003 784,884 82,489 201 1,141
1,903,367 1,356,708 406,590 140,069 138 374
315,796 204,607 85,000 26,190 74 133
235,398 102,303 120,000 13,095 74 133
269,592 163,645 85,000 20,947 74 133
185,398 102,303 70,000 13,095 74 133
300,796 204,607 70,000 26,190 74 133
310,796 204,607 80,000 26,190 74 133
195,398 102,303 80,000 13,095 74 133
175,398 102,303 60,000 13,095 74 133
4,525,591 3,579,924 863,179 82,489 265 1,397
267,796 204,607 37,000 26,190 74 133
205,398 102,303 90,000 13,095 74 133
295,398 102,303 180,000 13,095 74 133
1,878,367 1,356,708 381,590 140,069 138 374
215,398 102,303 100,000 13,095 74 133
226,592 163,645 42,000 20,947 74 133
290,796 204,607 60,000 26,190 74 133
0 0 0 0 74 44
0 0 0 0 74 44
0 0 0 0 74 44
0 0 0 0 74 44
0 0 0 0 74 44
0 0 0 0 74 44
0 0 0 0 74 44
0 0 0 0 74 44
 0 0 0 0 74 44
0 0 0 0 74 44
0 0 0 0 74 44
0 0 0 0 74 44
0 0 0 0 74 44
0 0 0 0 74 44
0 0 0 0 74 44
0 0 0 0 74 44
0 0 0 0 74 44
0 0 0 0 74 44
0 0 0 0 74 44
0 0 0 0 74 44
0 0 0 0 74 44
0 0 0 0 74 44

202,657,837 ### 41,537,958 12,934,522

<============INVESTMENT COSTS===========>

Total Machine Tooling Building

Investment Investment Investment Investment
$ $ $ $
9,119,695 8,183,784 665,000 270,911
9,119,695 8,183,784 665,000 270,911
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0

18,239,390 16,367,567 1,330,000 541,823

220,897,227 ### 42,867,958 13,476,345

<=====INVESTMENT COSTS==================>

Total Machine Tooling Building

Investment Investment Investment Investment
$ $ $ $
18,145,000 9,655,000 4,539,000 3,951,000
9,681,500 3,640,000 1,300,000 4,741,500
14,324,100 7,794,600 3,000,000 3,529,500
6,351,000 1,965,000 1,110,000 3,276,000
15,035,300 4,900,800 3,485,000 6,649,500
4,081,500 2,485,000 575,000 1,021,500
6,358,000 2,650,000 1,770,000 1,938,000
6,954,500 3,570,000 800,000 2,584,500
5,876,000 2,400,000 800,000 2,676,000
330,000 50,000 100,000 180,000
1,100,000 600,000 500,000 0
2,500,000 750,000 1,000,000 750,000
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0

90,736,900 40,460,400 18,979,000 31,297,500

 COST BREAKDOWN BY PROCESS STEP

STAMPED PARTS

===========TOTAL
<====== COST PER PROCESS STEP===========
======== ======== =======>

Material Blanking Welding Stamping

Part 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 2.48
008/009 Rail Front Outer RH/LH 11.96 0.75 2.75 3.97
010/011 Rail Front Inner RH/LH #N/A #N/A 3.02 4.16
012/013 Rail Front Extension 6.58 0.29 0.00 3.01
014/015 Bracket Roof Rail Mount Lower 0.75 0.23 0.00 2.54
021 Panel Dash 8.92 0.58 0.00 4.39
022 Panel Dash Insert (laminate) #N/A 0.00 0.00 1.04
026 Member Dash Front 4.10 0.39 0.00 2.58
028 Panel Cowl Lower 2.11 0.38 0.00 2.44
032 Panel Cowl Upper 3.34 0.39 0.00 2.47
034 Member Front Floor Support 2.39 0.65 0.00 3.87
038 Reinf Floor Front Seat Rear Outer 0.36 0.00 0.00 0.55
040 Pan Front Floor 17.19 0.61 0.00 7.63
042/043 Panel Rocker Inner #N/A #N/A 2.20 4.63
045 Member Rear Suspension 1.93 0.28 0.00 2.23
046/047 Rail Rear Inner #N/A #N/A 3.30 4.94
048/049 Rail Rear Outer #N/A #N/A 1.95 4.74
050 Panel Spare Tire Tub (laminate) #N/A #N/A 0.00 4.73
055 Member Panel Back 2.35 0.38 0.00 2.98
057 Panel Back 4.14 0.39 0.00 3.05
060 Panel Body Side Outer RH #N/A #N/A 9.53 11.06
061 Panel Body Side Outer LH #N/A #N/A 9.53 11.06
062/063 Panel A-Pillar Inner Lower 5.88 0.29 0.00 3.15
064/065 Panel B-Pillar Inner 15.14 0.53 0.00 4.02
066 Reinf B-Pillar Lower 1.46 0.47 0.00 4.03
068/069 Panel Wheelhouse Inner 6.20 0.29 0.00 3.56
070/071 Panel Wheelhouse Outer 9.13 0.50 4.40 3.91
074/075 Panel A-Pillar Inner Upper 3.89 0.28 0.00 2.88
 080 Panel Package Tray Upper 3.52 0.39 0.00 2.78
081 Panel Package Tray Lower 3.48 0.39 0.00 2.97
082/083 Support Package Tray RH 0.27 0.00 0.00 0.44
085 Panel Roof - Hydromechanical Formin 9.15 0.58 0.00 8.65
085 Panel Roof - Trimming & Flanging Ste 0.00 0.00 0.00 3.31
086 Panel Front Header 1.81 0.28 0.00 2.50
087 Panel Rear Header 1.41 0.28 0.00 2.09
091 Member Kick Up 3.10 0.39 0.00 2.68
094/095 Reinf Radiator Rail Closeout 2.62 0.28 0.00 3.07
096/097 Panel Skirt #N/A #N/A 1.64 3.61
098/099 Panel Gutter Deck Lid 1.68 0.28 0.00 2.86
102/103 Support Panel Rear Header 0.25 0.00 0.00 0.44
104/105 Rail Fender Support Inner 9.67 0.41 0.00 3.19
106/107 Rail Fender Support Outer 5.73 0.40 0.00 3.09
108/109 Reinf Front Rail 2.67 0.28 0.00 2.37
110 Plate Rear Spring Upper 0.61 0.00 0.00 0.56
115 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 0.47
120 Reinf Floor Front Seat Rear Center 0.47 0.00 0.00 0.32
122 Reinf Rear Seat Inner Belt Mount 0.44 0.00 0.00 0.54
128 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 0.33
136 Reinf Panel Dash Upper 0.13 0.00 0.00 0.30
140 Pan Rear Floor 9.14 0.51 0.00 3.59
142 Reinf Hinge Decklid 0.35 0.00 0.00 0.49
144/145 Reinf A-Pillar 0.80 0.00 0.00 0.34
164/165 Closeout Fender Support Rail 0.40 0.00 0.00 0.47
170/171 Reinf Rail Dash 1.00 0.27 0.00 2.34
172 Assy Reinf Cowl Lower 0.18 0.00 0.00 0.36
180/181 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 0.52
n/a none 0.00 0.00 0.00 0.00
n/a none 0.00 0.00 0.00 0.00
n/a none 0.00 0.00 0.00 0.00
n/a none 0.00 0.00 0.00 0.00
n/a none 0.00 0.00 0.00 0.00
n/a none 0.00 0.00 0.00 0.00
n/a none 0.00 0.00 0.00 0.00
n/a none 0.00 0.00 0.00 0.00
n/a none 0.00 0.00 0.00 0.00
n/a none 0.00 0.00 0.00 0.00
n/a none 0.00 0.00 0.00 0.00
n/a none 0.00 0.00 0.00 0.00
n/a none 0.00 0.00 0.00 0.00
n/a none 0.00 0.00 0.00 0.00
n/a none 0.00 0.00 0.00 0.00
n/a none 0.00 0.00 0.00 0.00
n/a none 0.00 0.00 0.00 0.00
n/a none 0.00 0.00 0.00 0.00
n/a none 0.00 0.00 0.00 0.00
n/a none 0.00 0.00 0.00 0.00
n/a none 0.00 0.00 0.00 0.00
n/a none 0.00 0.00 0.00 0.00

STAMPED PARTS TOTALS #N/A #N/A 38.33 170.92

<======= ======== BLANKING COST BREAKDOWN=============== ======== ======>

Overhead Working
Material Labor Energy Equip. Tooling Labor Building Maint. Capital
Cost Cost Cost Cost Cost Cost Cost Cost Cost
$ / part $ / part $ / part $ / part $ / part $ / part $ / part $ / part $ / part
4.48 0.05 0.01 0.06 0.07 0.06 0.01 0.01 0.02
2.24 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 0.04
#N/A 0.14 0.03 0.25 0.25 0.18 0.03 0.05 #N/A
6.90 0.05 0.01 0.06 0.07 0.06 0.01 0.01 0.02
0.81 0.04 0.01 0.05 0.07 0.05 0.01 0.01 0.00
9.41 0.06 0.01 0.22 0.14 0.07 0.01 0.04 0.03
#N/A 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
4.26 0.05 0.01 0.12 0.10 0.06 0.01 0.02 0.01
2.24 0.05 0.01 0.12 0.10 0.06 0.01 0.02 0.01
3.62 0.05 0.01 0.12 0.10 0.06 0.01 0.02 0.01
2.47 0.07 0.02 0.19 0.21 0.09 0.02 0.04 0.01
0.39 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 0.06
#N/A 0.09 0.02 0.37 0.28 0.12 0.02 0.07 #N/A
2.01 0.05 0.01 0.06 0.07 0.06 0.01 0.01 0.01
#N/A 0.14 0.03 0.31 0.28 0.18 0.03 0.06 #N/A
#N/A 0.11 0.02 0.15 0.21 0.14 0.03 0.04 #N/A
#N/A 0.05 0.01 0.06 0.07 0.06 0.01 0.01 #N/A
2.51 0.05 0.01 0.12 0.10 0.06 0.01 0.02 0.01
4.46 0.05 0.01 0.12 0.10 0.06 0.01 0.02 0.02
#N/A 0.24 0.05 0.57 0.43 0.30 0.06 0.11 #N/A
#N/A 0.24 0.05 0.57 0.43 0.30 0.06 0.11 #N/A
6.27 0.05 0.01 0.06 0.07 0.06 0.01 0.01 0.02
16.12 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 0.01
6.56 0.05 0.01 0.06 0.07 0.06 0.01 0.01 0.02
9.89 0.07 0.02 0.10 0.14 0.09 0.02 0.03 0.03
4.03 0.05 0.01 0.06 0.07 0.06 0.01 0.01 0.01
 3.76 0.05 0.01 0.12 0.10 0.06 0.01 0.02 0.01
3.76 0.05 0.01 0.12 0.10 0.06 0.01 0.02 0.01
0.29 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
9.35 0.06 0.01 0.22 0.14 0.07 0.01 0.04 0.03
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
1.95 0.05 0.01 0.06 0.07 0.06 0.01 0.01 0.01
1.53 0.05 0.01 0.06 0.07 0.06 0.01 0.01 0.01
3.23 0.05 0.01 0.12 0.10 0.06 0.01 0.02 0.01
2.80 0.05 0.01 0.06 0.07 0.06 0.01 0.01 0.01
#N/A 0.09 0.02 0.12 0.07 0.12 0.02 0.02 #N/A
1.83 0.05 0.01 0.06 0.07 0.06 0.01 0.01 0.01
0.26 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 0.02
2.80 0.05 0.01 0.06 0.07 0.06 0.01 0.01 0.01
0.62 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
1.19 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
1.31 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.49 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.46 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.11 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.52 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.13 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
9.85 0.05 0.01 0.18 0.14 0.06 0.01 0.03 0.03
0.37 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.84 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.42 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
1.05 0.05 0.01 0.06 0.07 0.06 0.01 0.01 0.00
0.19 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
1.12 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.36 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

#N/A 2.80 0.61 6.02 5.45 3.50 0.68 1.22 #N/A

<======= ======== WELDING COST BREAKDOWN================ ======= ======>

Overhead Working
Material Labor Energy Equip. Tooling Labor Building Maint. Capital
Cost Cost Cost Cost Cost Cost Cost Cost Cost
$ / part $ / part $ / part $ / part $ / part $ / part $ / part $ / part $ / part
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 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 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 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 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 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 0.01
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 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 0.01
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 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 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

-0.35 5.22 0.04 20.94 0.00 6.52 3.15 2.41 0.05

<======= ======== STAMPING COST BREAKDOWN=============== ======= ======>

Overhead Working
Material Labor Energy Equip. Tooling Labor Building Maint. Capital
Cost Cost Cost Cost Cost Cost Cost Cost Cost
$ / part $ / part $ / part $ / part $ / part $ / part $ / part $ / part $ / part
-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 0.01
0.00 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
-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 0.00
0.00 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 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

-20.31 27.82 4.99 61.21 45.76 16.47 3.50 11.05 0.13

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

STAMPED PARTS

<====== =========TOTAL INVESTMENT PER PROCESS STEP========= ==========>

Blanking Welding Stamping

Total Total Total
Part ID Part Name Investment Investment Investment
Units $ $ $
001 Reinf Radiator Support Upper 178,578 0 2,233,052
002/003 Reinf Front Rail Extension 178,578 0 2,007,040
008/009 Rail Front Outer RH/LH 469,572 2,922,753 2,942,894
010/011 Rail Front Inner RH/LH 676,497 3,215,029 3,400,888
012/013 Rail Front Extension 178,578 0 2,583,052
014/015 Bracket Roof Rail Mount Lower 154,180 0 2,052,040
021 Panel Dash 505,179 0 4,677,639
022 Panel Dash Insert (laminate) 0 0 592,173
026 Member Dash Front 309,212 0 2,078,690
028 Panel Cowl Lower 309,212 0 1,780,267
032 Panel Cowl Upper 309,212 0 1,805,267
034 Member Front Floor Support 528,691 0 2,815,535
038 Reinf Floor Front Seat Rear Outer 0 0 310,796
040 Pan Front Floor 505,179 0 5,899,221
042/043 Panel Rocker Inner 893,064 2,338,203 4,591,026
045 Member Rear Suspension 178,578 0 1,624,789
046/047 Rail Rear Inner 809,117 3,507,304 4,821,026
048/049 Rail Rear Outer 469,572 2,075,155 4,946,026
050 Panel Spare Tire Tub (laminate) 178,578 0 3,428,806
055 Member Panel Back 309,212 0 2,501,973
057 Panel Back 309,212 0 3,346,164
060 Panel Body Side Outer RH 1,411,434 10,139,224 8,513,185
061 Panel Body Side Outer LH 1,411,434 10,139,224 8,513,185
062/063 Panel A-Pillar Inner Lower 178,578 0 3,422,111
064/065 Panel B-Pillar Inner 439,846 0 4,406,692
066 Reinf B-Pillar Lower 308,360 0 2,930,535
068/069 Panel Wheelhouse Inner 178,578 0 3,727,111
070/071 Panel Wheelhouse Outer 313,048 4,676,406 3,987,881
074/075 Panel A-Pillar Inner Upper 178,578 0 3,227,111
080 Panel Package Tray Upper 309,212 0 2,223,690
081 Panel Package Tray Lower 309,212 0 2,383,052
082/083 Support Package Tray RH 0 0 275,398
085 Panel Roof - Hydromechanical Formin 505,179 0 7,173,881
085 Panel Roof - Trimming & Flanging Ste 0 0 2,468,250
086 Panel Front Header 178,578 0 1,819,190
087 Panel Rear Header 178,578 0 1,523,617
091 Member Kick Up 309,212 0 2,153,690
094/095 Reinf Radiator Rail Closeout 178,578 0 2,458,052
096/097 Panel Skirt 303,603 1,744,844 4,102,639
098/099 Panel Gutter Deck Lid 178,578 0 2,303,052
102/103 Support Panel Rear Header 0 0 275,398
104/105 Rail Fender Support Inner 309,212 0 3,456,164
106/107 Rail Fender Support Outer 309,212 0 3,381,164
108/109 Reinf Front Rail 178,578 0 1,724,789
110 Plate Rear Spring Upper 0 0 315,796
115 Reinf Panel Dash Brake Booster 0 0 235,398
116/117 Bracket Rear Shock Absorber Mount 0 0 269,592
120 Reinf Floor Front Seat Rear Center 0 0 185,398
122 Reinf Rear Seat Inner Belt Mount 0 0 300,796
128 Bracket Member Pass Through Lower 0 0 310,796
130/152 Bracket Member Pass Through Up Fr 0 0 195,398
136 Reinf Panel Dash Upper 0 0 175,398
140 Pan Rear Floor 439,846 0 4,085,746
142 Reinf Hinge Decklid 0 0 267,796
144/145 Reinf A-Pillar 0 0 205,398
164/165 Closeout Fender Support Rail 0 0 295,398
170/171 Reinf Rail Dash 178,578 0 1,699,789
172 Assy Reinf Cowl Lower 0 0 215,398
180/181 Bracket Trailing Arm Mount Inner 0 0 226,592
190 Reinf Seat Belt Retractor Rear 0 0 290,796
n/a none 0 0 0
n/a none 0 0 0
n/a none 0 0 0
n/a none 0 0 0
n/a none 0 0 0
n/a none 0 0 0
n/a none 0 0 0
n/a none 0 0 0
n/a none 0 0 0
n/a none 0 0 0
 n/a none 0 0 0
n/a none 0 0 0
n/a none 0 0 0
n/a none 0 0 0
n/a none 0 0 0
n/a none 0 0 0
n/a none 0 0 0
n/a none 0 0 0
n/a none 0 0 0
n/a none 0 0 0
n/a none 0 0 0
n/a none 0 0 0

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

TUBULAR & PURCHASED PARTS

<====== =========TOTAL INVESTMENT PER PROCESS STEP=========

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

Hydroforming Hydroforming Hydroforming

Line Tooling Building
Part ID Part Name Invest. Invest. Invest.
Units $ $ $
072 Rail Side Roof RH 8,183,784 665,000 270,911
073 Rail Side Roof LH 8,183,784 665,000 270,911
090 Member Pass Through 0 0 0
188 Brace Radiator 0 0 0
XXX Hinges 0 0 0
XXX Small Brackets 0 0 0
XXX Weld Studs 0 0 0
n/a none 0 0 0
n/a none 0 0 0
n/a none 0 0 0
n/a none 0 0 0
n/a none 0 0 0
n/a none 0 0 0

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

ASSEMBLY
<====== ========= INVESTMENT BREAKDOWN=====================
============>

Equipment Tooling Building

Investment 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 4,741,500
414 Framing 7,794,600 3,000,000 3,529,500
415 Underbody Complete 1,965,000 1,110,000 3,276,000
416/417 Body Side Inner 4,900,800 3,485,000 6,649,500
421 Front End 2,485,000 575,000 1,021,500
422 Front Ladder Complete 2,650,000 1,770,000 1,938,000
428 Underbody Floor 3,570,000 800,000 2,584,500
431 Underbody Inner 2,400,000 800,000 2,676,000
439 Dash 50,000 100,000 180,000
XXX Hinge Assembly 600,000 500,000 0
XXX Miscellaneous Brackets 750,000 1,000,000 750,000
n/a none 0 0 0
n/a none 0 0 0
n/a none 0 0 0
n/a none 0 0 0
n/a none 0 0 0

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

<======== ========= INVESTMENT BREAKDOWN=============== ==========

Blanking Blanking Blanking Welding Welding Stamping Stamping

Press Tooling Building Line Building Press Tooling
Invest. Invest. Invest. Invest. Invest. Invest. Invest.
$ $ $ $ $ $ $
102,339 56,590 19,649 0 0 1,672,492 400,000
102,339 56,590 19,649 0 0 1,527,089 370,000
249,348 172,349 47,875 2,524,196 398,557 1,863,954 900,000
415,580 201,074 59,843 2,776,616 438,413 2,096,948 1,125,000
102,339 56,590 19,649 0 0 1,672,492 750,000
81,871 56,590 15,719 0 0 1,527,089 415,000
368,421 113,179 23,579 0 0 3,272,906 1,300,000
0 0 0 0 0 347,671 200,000
204,678 84,884 19,649 0 0 1,527,089 405,000
204,678 84,884 19,649 0 0 1,145,317 525,000
204,678 84,884 19,649 0 0 1,145,317 550,000
327,485 169,768 31,439 0 0 2,290,634 305,000
0 0 0 0 0 204,607 80,000
368,421 113,179 23,579 0 0 3,476,712 2,200,000
623,370 229,799 39,896 2,019,357 318,846 3,290,723 1,195,000
102,339 56,590 19,649 0 0 1,254,369 250,000
519,475 229,799 59,843 3,029,035 478,269 3,290,723 1,425,000
249,348 172,349 47,875 1,792,179 282,976 3,290,723 1,550,000
102,339 56,590 19,649 0 0 2,617,524 560,000
204,678 84,884 19,649 0 0 1,881,554 500,000
204,678 84,884 19,649 0 0 2,618,325 665,000
959,127 350,000 102,307 8,756,603 1,382,621 4,506,876 3,650,000
959,127 350,000 102,307 8,756,603 1,382,621 4,506,876 3,650,000
102,339 56,590 19,649 0 0 2,618,325 720,000
307,018 113,179 19,649 0 0 3,272,906 1,050,000
163,742 113,179 31,439 0 0 2,290,634 420,000
102,339 56,590 19,649 0 0 2,618,325 1,025,000
166,232 114,900 31,917 4,038,714 637,692 2,632,578 1,250,000
102,339 56,590 19,649 0 0 2,618,325 525,000
204,678 84,884 19,649 0 0 1,527,089 550,000
204,678 84,884 19,649 0 0 1,672,492 550,000
0 0 0 0 0 102,303 160,000
368,421 113,179 23,579 0 0 6,761,603 250,000
0 0 0 0 0 1,854,246 525,000
102,339 56,590 19,649 0 0 1,390,685 295,000
102,339 56,590 19,649 0 0 1,145,317 305,000
204,678 84,884 19,649 0 0 1,527,089 480,000
102,339 56,590 19,649 0 0 1,672,492 625,000
206,746 57,161 39,695 1,506,911 237,933 3,272,906 725,000
102,339 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 2,618,325 775,000
204,678 84,884 19,649 0 0 2,618,325 700,000
102,339 56,590 19,649 0 0 1,254,369 350,000
0 0 0 0 0 204,607 85,000
0 0 0 0 0 102,303 120,000
0 0 0 0 0 163,645 85,000
0 0 0 0 0 102,303 70,000
0 0 0 0 0 204,607 70,000
0 0 0 0 0 204,607 80,000
0 0 0 0 0 102,303 80,000
0 0 0 0 0 102,303 60,000
307,018 113,179 19,649 0 0 3,272,906 750,000
0 0 0 0 0 204,607 37,000
0 0 0 0 0 102,303 90,000
0 0 0 0 0 102,303 180,000
102,339 56,590 19,649 0 0 1,254,369 325,000
0 0 0 0 0 102,303 100,000
0 0 0 0 0 163,645 42,000
0 0 0 0 0 204,607 60,000
0 0 0 0 0 0 0
0 0 0 0 0 0 0
0 0 0 0 0 0 0
0 0 0 0 0 0 0
0 0 0 0 0 0 0
0 0 0 0 0 0 0
0 0 0 0 0 0 0
0 0 0 0 0 0 0
0 0 0 0 0 0 0
0 0 0 0 0 0 0
 0 0 0 0 0 0 0
0 0 0 0 0 0 0
0 0 0 0 0 0 0
0 0 0 0 0 0 0
0 0 0 0 0 0 0
0 0 0 0 0 0 0
0 0 0 0 0 0 0
0 0 0 0 0 0 0
0 0 0 0 0 0 0
0 0 0 0 0 0 0
0 0 0 0 0 0 0
0 0 0 0 0 0 0

### 4,423,958 1,191,768 35,200,214 5,557,929 ### 37,114,000

=======>

Stamping
Building
Invest.
$
160,559
109,950
178,940
178,940
160,559
109,950
104,733
44,502
146,601
109,950
109,950
219,901
26,190
222,510
105,303
120,419
105,303
105,303
251,282
120,419
62,840
356,308
356,308
83,786
83,786
219,901
83,786
105,303
 83,786
146,601
160,559
13,095
162,278
89,004
133,506
73,300
146,601
160,559
104,733
160,559
13,095
62,840
62,840
120,419
26,190
13,095
20,947
13,095
26,190
26,190
13,095
13,095
62,840
26,190
13,095
13,095
120,419
13,095
20,947
26,190
0
0
0
0
0
0
0
0
0
0
 0
0
0
0
0
0
0
0
0
0
0
0

6,184,825
GENERAL INPUTS
These parameters are global for all parts and processes

ANNUAL PRODUCTION VOLUME 225000 parts/yr

Important Note: The production is determined by the line rate for which the ULSAB

assembly line is designed. Changing the production volume requires using a

different assembly line rate (see cell B104). However, the equipment and tooling
costs in the model were explicitly determined for the current line rate (72 vehicles/hr).
Changing the line rate therefore REQUIRES the user to also change all of the
equipment and tooling investment inputs.

Exogenous Parameters
Days 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 0.25
Indirect workers/ Press Shop Line 1.00
Indirect workers/ Direct Assembly Worker 1.00
Indirect Workers/Assembly Station 1.00
Building Unit Cost 1500 $/sqm
Production Life 5 yrs
Building Life 25 yrs
Idle Space 100%
Working Capital Period 2 months
Downtimes:
No shifts 8.375 hrs/day
Worker unpaid breaks 0.625 hrs/day
Worker paid breaks 1 hrs/day
Use Part Groups? (1=yes,0=no) 0

STAMPED PARTS
Global Blanking Parameters For Part Specific Process Parameter, Go to Part Input
Blanking Energy Consumption Rate 150 kW
Blanking Line Space Requirement 100 sqm/line
Workers / Blank Line 1 #/line
Blanking Unplanned Downtime 2 hr/day
Average Blanking Lot Size 3000
Average Blanking Die Change Time 0.5 hrs
Blanking Installation Percent 25%
Blanking Aux. Equipment Percent 25%
Blanking Maintenance Percent 10%
Blanking Cutting Tool Life 1,000,000 hits

Global Welding Parameters For Part Specific Process Parameter, Go to Part Input
Filler Wire Unit Cost 2.00 $/kg
Welding Space Requirement 250 sqm/line
Workers / Welding Line 1 #/line
Welding Unplanned Downtime 4 hrs/day
Welding Installation Percent 25%
Welding Maintenance Percent 10%

Global Press Line Parameters For Part Specific Process Parameter, Go to Part Input
Press Energy Consumption Rate 150 kW
Press Station Space Requirement 50 sqm
Press Line Unplanned Downtime 5 hrs/day
Average Stamping Lot Size 1500
Average Stamping Die Change Time 0.5 hrs
Press Line Installation Percent 25%
Press Line Aux. Equipment Percent 25%
Press Line Maintenance Percent 10%

TUBULAR PARTS
Global Parameters For Part Specific Process Parameter, Go to Part Input
Bending Line Unplanned Downtime 2 hrs/day
Average Bending Lot Size 1500
Average Bending Die Change Time 0.5 hrs
Bending Line Energy Consumption Rate 100 kW
Bending Line Space Requirement 100 sqm
Bending Line Installation Percent 25%
Bending Line Maintenance Percent 10%

ASSEMBLY
Global Assembly Parameters
Spot Weld Tip Life (#of welds) 8000
Spot Weld Tip Cost 0.45
Spot 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 m
MIG Electrode Cost 1.50
MIG Filler Metal Needed 0.011 kg/m
MIG Filler Metal Cost 3.94 kg/m
MIG Gas Unit Cost 0.01 $/l
MIG Gas Flow Rate 0.2 l/m
MIG Weld Energy Rate 33 kW
MIG Weld Speed 0.04 m/sec
Laser Energy Rate 115 kW
Laser Welding Rate 0.1 m/sec
Laser Gas Unit Cost 0.02 $/l
Laser Gas Flow Rate 0.33 l/m
Robot Energy Rate 2 kW
Conveyor Energy Rate 5 kW
Robot Transport Time 5 sec
Conveyor 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 Material
Type Price
MPa $/kg
0 0.00
140 0.77
TB96 0.77
80% Mild Steel, 20% HSS Mix Mix 0.80
TB70 0.81
210 0.85
280 0.89
TB60 0.89
350 0.92
TB8 0.92
TB10 0.92
TB42 0.92
 TB46 0.92
TB48 0.92
420 0.99
600 1.07
800 1.16
Tube 1.60
Sandwich 3.60
ULSAB

hicles/hr).

ameter, Go to Part Input

ameter, Go to Part Input

ameter, Go to Part Input

ameter, Go to Part Input

PART SPECIFIC INPUT PARAMETERS:

STAMPED PARTS

<====== ========GENERAL PART INFORMATION============= =======

===========

Part
Weight Number Material
Part ID Part Name (R&L) Req'd Type
Units kg # MPa
001 Reinf Radiator Support Upper 1.613 1 350
002/003 Reinf Front Rail Extension 0.974 1 350
008/009 Rail Front Outer RH/LH 6.050 1 TB8
010/011 Rail Front Inner RH/LH 10.970 1 TB10
012/013 Rail Front Extension 4.157 1 350
014/015 Bracket Roof Rail Mount Lower 0.303 1 350
021 Panel Dash 5.830 1 210
022 Panel Dash Insert (laminate) 0.875 1 Sandwich
026 Member Dash Front 2.280 1 600
028 Panel Cowl Lower 1.272 1 210
032 Panel Cowl Upper 1.374 1 210
034 Member Front Floor Support 0.645 2 800
038 Reinf Floor Front Seat Rear Outer 0.060 2 280
040 Pan Front Floor 14.650 1 210
042/043 Panel Rocker Inner 13.115 1 TB42
045 Member Rear Suspension 1.344 1 350
046/047 Rail Rear Inner 10.490 1 TB46
048/049 Rail Rear Outer 5.092 1 TB48
050 Panel Spare Tire Tub (laminate) 2.107 1 Sandwich
055 Member Panel Back 1.305 1 210
057 Panel Back 2.502 1 140
060 Panel Body Side Outer RH 15.780 1 TB60
061 Panel Body Side Outer LH 15.650 1 TB60
062/063 Panel A-Pillar Inner Lower 2.740 1 350
064/065 Panel B-Pillar Inner 7.172 1 350
066 Reinf B-Pillar Lower 0.415 2 350
068/069 Panel Wheelhouse Inner 3.854 1 210
070/071 Panel Wheelhouse Outer 4.310 1 TB70
074/075 Panel A-Pillar Inner Upper 2.841 1 350
 080 Panel Package Tray Upper 1.876 1 210
081 Panel Package Tray Lower 1.497 1 210
082/083 Support Package Tray RH 0.160 1 280
085 Panel Roof - Hydromechanical Forming Step 8.680 1 210
085 Panel Roof - Trimming & Flanging Steps 0.000 1 210
086 Panel Front Header 0.813 1 280
087 Panel Rear Header 0.773 1 140
091 Member Kick Up 1.397 1 800
094/095 Reinf Radiator Rail Closeout 1.142 1 350
096/097 Panel Skirt 6.925 1 TB96
098/099 Panel Gutter Deck Lid 0.871 1 140
102/103 Support Panel Rear Header 0.196 1 140
104/105 Rail Fender Support Inner 5.411 1 420
106/107 Rail Fender Support Outer 2.594 1 350
108/109 Reinf Front Rail 1.668 1 350
110 Plate Rear Spring Upper 0.263 2 350
115 Reinf Panel Dash Brake Booster 0.454 1 350
116/117 Bracket Rear Shock Absorber Mount 0.674 1 350
120 Reinf Floor Front Seat Rear Center 0.250 1 350
122 Reinf Rear Seat Inner Belt Mount 0.122 2 350
128 Bracket Member Pass Through Lower 0.028 2 350
130/152 Bracket Member Pass Through Up Fr & R 0.274 1 350
136 Reinf Panel Dash Upper 0.100 1 350
140 Pan Rear Floor 4.240 1 210
142 Reinf Hinge Decklid 0.112 2 350
144/145 Reinf A-Pillar 0.459 1 350
164/165 Closeout Fender Support Rail 0.230 1 350
170/171 Reinf Rail Dash 0.621 1 350
172 Assy Reinf Cowl Lower 0.127 1 350
180/181 Bracket Trailing Arm Mount Inner 0.674 1 350
190 Reinf Seat Belt Retractor Rear 0.052 2 350
n/a none 0.000 0 0
n/a none 0.000 0 0
n/a none 0.000 0 0
n/a none 0.000 0 0
n/a none 0.000 0 0
n/a none 0.000 0 0
n/a none 0.000 0 0
n/a none 0.000 0 0
n/a none 0.000 0 0
n/a none 0.000 0 0
n/a none 0.000 0 0
 n/a none 0.000 0 0
n/a none 0.000 0 0
n/a none 0.000 0 0
n/a none 0.000 0 0
n/a none 0.000 0 0
n/a none 0.000 0 0
n/a none 0.000 0 0
n/a none 0.000 0 0
n/a none 0.000 0 0
n/a none 0.000 0 0
n/a none 0.000 0 0

TUBULAR & PURCHASED PARTS

<====== =======================================TUBULAR PART INPUTS====

===========

Part Number Material

Part ID Part Name Weight Req'd Price
kg # $/kg
072 Rail Side Roof RH 4.7 1 Tube
073 Rail Side Roof LH 4.86 1 Tube
090 Member Pass Through 0.331 2 140
188 Brace Radiator 0.125 2 350
XXX Hinges 0.266 8 280
XXX Small Brackets 0.12226 50 140
XXX Weld Studs 0.0032 100 0
n/a none 0 0 0
n/a none 0 0 0
n/a none 0 0 0
n/a none 0 0 0
n/a none 0 0 0
n/a none 0 0 0

ASSEMBLY

<====== ========GENERAL ASSEMBLY INFORMATION ======== =======

===========

# of # of # of
Area # Area Name Workers Robots Stations
# # #
410 Final 7 40 28
411/412 Body Side Outer 5 6 14
414 Framing 7 20 15
415 Underbody Complete 3 6 6
416/417 Body Side Inner 8 8 11
421 Front End 4 8 6
422 Front Ladder Complete 12 11 11
428 Underbody Floor 6 29 13
431 Underbody Inner 3 1 5
439 Dash 4 0 2
XXX Hinge Assembly 2 4 1
XXX Miscellaneous Brackets 3 5 2
n/a none 0 0 0
n/a none 0 0 0
n/a none 0 0 0
n/a none 0 0 0
n/a none 0 0 0
=======> <============================= BLANKING INPUTS===== ==========

Average Purchased Blanking Total Average Non-Ded.

Scrap # of Blank Cost Clean Weight Blanking Shear
Price Blanks (=0 if made Rate of Blanks Press Cost Cost
$ / kg # in house) blanks/hr kg / blank(s) $ / line $ /shear(s)
0.10 1 0.00 1500 4.7100 1,000,000 50,000
0.10 1 0.00 1500 2.3550 1,000,000 50,000
0.10 3 0.00 2000 13.1566 1,000,000 150,000
0.10 3 0.00 1500 19.8527 1,333,333 175,000
0.10 1 0.00 1500 7.2534 1,000,000 50,000
0.10 1 0.00 2000 0.8478 1,000,000 50,000
0.10 1 0.00 1200 10.7153 3,000,000 100,000
0.05 0 0.00 0 1.5390 0 0
0.10 1 0.00 1500 3.8465 2,000,000 75,000
0.10 1 0.00 1500 2.5513 2,000,000 75,000
0.10 1 0.00 1500 4.1213 2,000,000 75,000
0.10 1 0.00 2000 1.0303 2,000,000 75,000
0.10 0 0.00 0 0.2120 0 0
0.10 1 0.00 1200 20.2216 3,000,000 100,000
0.10 2 0.00 1500 27.8832 3,000,000 200,000
0.10 1 0.00 1500 2.1156 1,000,000 50,000
0.10 3 0.00 1500 20.8810 1,666,667 200,000
0.10 3 0.00 2000 10.1489 1,000,000 150,000
0.05 1 0.00 1500 3.2832 1,000,000 50,000
0.10 1 0.00 1500 2.8574 2,000,000 75,000
0.10 1 0.00 1500 5.6049 2,000,000 75,000
0.10 5 0.00 1500 44.3560 1,800,000 0
0.10 5 0.00 1500 44.3600 1,800,000 0
0.10 1 0.00 1500 6.5940 1,000,000 50,000
0.10 1 0.00 1500 16.9560 3,000,000 100,000
0.10 1 0.00 2000 0.8125 1,000,000 50,000
0.10 1 0.00 1500 7.4701 1,000,000 50,000
0.10 2 0.00 2000 11.7044 1,000,000 100,000
0.10 1 0.00 1500 4.239 1,000,000 50,000
0.10 1 0.00 1500 4.2861 2,000,000 75,000
0.10 1 0.00 1500 4.2861 2,000,000 75,000
0.10 0 0.00 0 0.3140 0 0
0.10 1 0.00 1200 10.6500 3,000,000 100,000
0.00 0 0.00 0 0.0000 0 0
0.10 1 0.00 1500 2.1156 1,000,000 50,000
0.10 1 0.00 1500 1.9232 1,000,000 50,000
0.10 1 0.00 1500 2.6926 2,000,000 75,000
0.10 1 0.00 1500 2.9438 1,000,000 50,000
0.10 2 0.00 1500 8.6700 1,000,000 50,000
0.10 1 0.00 1500 2.2961 1,000,000 50,000
0.10 0 0.00 0 0.3297 0 0
0.10 1 0.00 1500 9.8910 2,000,000 75,000
0.10 1 0.00 1500 6.4292 2,000,000 75,000
0.10 1 0.00 1500 2.9438 1,000,000 50,000
0.10 0 0.00 0 0.3266 0 0
0.10 0 0.00 0 1.2560 0 0
0.10 0 0.00 0 1.3738 0 0
0.10 0 0.00 0 0.5181 0 0
0.10 0 0.00 0 0.2446 0 0
0.10 0 0.00 0 0.0565 0 0
0.10 0 0.00 0 0.5495 0 0
0.10 0 0.00 0 0.1374 0 0
0.10 1 0.00 1500 11.2098 3,000,000 100,000
0.10 0 0.00 0 0.1943 0 0
0.10 0 0.00 0 0.8831 0 0
0.10 0 0.00 0 0.4416 0 0
0.10 1 0.00 1500 1.1052 1,000,000 50,000
0.10 0 0.00 0 0.2014 0 0
0.10 0 0.00 0 1.1775 0 0
0.10 0 0.00 0 0.1884 0 0
0.00 1 0.00 1 0.0000 0 0
0.00 1 0.00 1 0.0000 0 0
0.00 1 0.00 1 0.0000 0 0
0.00 1 0.00 1 0.0000 0 0
0.00 1 0.00 1 0.0000 0 0
0.00 1 0.00 1 0.0000 0 0
0.00 1 0.00 1 0.0000 0 0
0.00 1 0.00 1 0.0000 0 0
0.00 1 0.00 1 0.0000 0 0
0.00 1 0.00 1 0.0000 0 0
0.00 1 0.00 1 0.0000 0 0
 0.00 1 0.00 1 0.0000 0 0
0.00 1 0.00 1 0.0000 0 0
0.00 1 0.00 1 0.0000 0 0
0.00 1 0.00 1 0.0000 0 0
0.00 1 0.00 1 0.0000 0 0
0.00 1 0.00 1 0.0000 0 0
0.00 1 0.00 1 0.0000 0 0
0.00 1 0.00 1 0.0000 0 0
0.00 1 0.00 1 0.0000 0 0
0.00 1 0.00 1 0.0000 0 0
0.00 1 0.00 1 0.0000 0 0

===========
===========
==============================> <===========BENDING============

Purchased Overall
Scrap Part Input Reject # of Line Tooling
Price Cost Material Rate Workers Investment Investment
$/kg $ kg % # $ $
0.10 0.00 7 1.0% 0.5 1,250,000 50,000
0.10 0.00 7 1.0% 0.5 1,250,000 50,000
0.10 0.75 0 0.0% 0.0 0 0
0.10 0.20 0 0.0% 0.0 0 0
0.05 24.00 0 0.0% 0.0 0 0
0.10 15.00 0 0.0% 0.0 0 0
0.00 1.00 0 0.0% 0.0 0 0
0.00 0.00 0 0.0% 0.0 0 0
0.00 0.00 0 0.0% 0.0 0 0
0.00 0.00 0 0.0% 0.0 0 0
0.00 0.00 0 0.0% 0.0 0 0
0.00 0.00 0 0.0% 0.0 0 0
0.00 0.00 0 0.0% 0.0 0 0

=======> <=================== ASSEMBLY METHOD INPUTS===============>

# of Length of Length of Length of

Space Spot Adhesive MIG Laser Equipment Tooling
Req'd Welds Bonding Welds Welds Investment Investment
sqm # 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 1,300,000
2353 317 0.000 0.562 5.162 7,794,600 3,000,000
2184 92 0.000 0.000 0.000 1,965,000 1,110,000
4433 128 0.000 0.314 3.078 4,900,800 3,485,000
681 96 0.000 0.250 0.150 2,485,000 575,000
1292 150 0.000 0.000 0.090 2,650,000 1,770,000
1723 437 0.000 0.000 0.850 3,570,000 800,000
1784 32 0.000 0.000 0.000 2,400,000 800,000
120 0 4.400 0.000 0.000 50,000 100,000
0 0 0.000 0.292 0.000 600,000 500,000
500 80 0.000 0.000 0.000 750,000 1,000,000
0 0 0.000 0.000 0.000 0 0
0 0 0.000 0.000 0.000 0 0
0 0 0.000 0.000 0.000 0 0
0 0 0.000 0.000 0.000 0 0
0 0 0.000 0.000 0.000 0 0
===========================> <=================== ========= WELDING INPUTS=======

Dedicated Blanking Coil Welding Weld

Blank Die Reject Material Line Laser Parts Setup
Cost Rate Loss Cost Power Per Run Time
$ /die(s) % % $ / line kW # sec
0 0.1% 3% NA 0 0 NA
0 0.1% 3% NA 0 0 NA
0 0.1% 3% 3,800,000 6 1 15
0 0.1% 3% 3,800,000 6 1 15
0 0.1% 3% NA 0 0 NA
0 0.1% 3% NA 0 0 NA
0 0.1% 3% NA 0 0 NA
0 0.0% 3% NA 0 0 NA
0 0.1% 3% NA 0 0 NA
0 0.1% 3% NA 0 0 NA
0 0.1% 3% NA 0 0 NA
0 0.1% 3% NA 0 0 NA
0 0.0% 3% NA 0 0 NA
0 0.1% 3% NA 0 0 NA
0 0.1% 3% 3,800,000 6 1 15
0 0.1% 3% NA 0 0 NA
0 0.1% 3% 3,800,000 6 1 15
0 0.1% 3% 3,800,000 6 1 10
0 0.1% 3% NA 0 0 NA
0 0.1% 3% NA 0 0 NA
0 0.1% 3% NA 0 0 NA
350,000 0.1% 3% 3,800,000 6 1 30
350,000 0.1% 3% 3,800,000 6 1 30
0 0.1% 3% NA 0 0 NA
0 0.1% 3% NA 0 0 NA
0 0.1% 3% NA 0 0 NA
0 0.1% 3% NA 0 0 NA
0 0.1% 3% 3,800,000 6 1 15
0 0.1% 3% NA 0 0 NA
0 0.1% 3% NA 0 0 NA
0 0.1% 3% NA 0 0 NA
0 0.0% 3% NA 0 0 NA
0 0.1% 3% NA 0 0 NA
0 0.0% 0% NA 0 0 NA
0 0.1% 3% NA 0 0 NA
0 0.1% 3% NA 0 0 NA
0 0.1% 3% NA 0 0 NA
0 0.1% 3% NA 0 0 NA
0 0.1% 3% 3,800,000 6 1 10
0 0.1% 3% NA 0 0 NA
0 0.0% 3% NA 0 0 NA
0 0.1% 3% NA 0 0 NA
0 0.1% 3% NA 0 0 NA
0 0.1% 3% NA 0 0 NA
0 0.0% 3% NA 0 0 NA
0 0.0% 3% NA 0 0 NA
0 0.0% 3% NA 0 0 NA
0 0.0% 3% NA 0 0 NA
0 0.0% 3% NA 0 0 NA
0 0.0% 3% NA 0 0 NA
0 0.0% 3% NA 0 0 NA
0 0.0% 3% NA 0 0 NA
0 0.1% 3% NA 0 0 NA
0 0.0% 3% NA 0 0 NA
0 0.0% 3% NA 0 0 NA
0 0.0% 3% NA 0 0 NA
0 0.1% 3% NA 0 0 NA
0 0.0% 3% NA 0 0 NA
0 0.0% 3% NA 0 0 NA
0 0.0% 3% NA 0 0 NA
0 0.0% 0% 0 0 0 0
0 0.0% 0% 0 0 0 0
0 0.0% 0% 0 0 0 0
0 0.0% 0% 0 0 0 0
0 0.0% 0% 0 0 0 0
0 0.0% 0% 0 0 0 0
0 0.0% 0% 0 0 0 0
0 0.0% 0% 0 0 0 0
0 0.0% 0% 0 0 0 0
0 0.0% 0% 0 0 0 0
0 0.0% 0% 0 0 0 0
 0 0.0% 0% 0 0 0 0
0 0.0% 0% 0 0 0 0
0 0.0% 0% 0 0 0 0
0 0.0% 0% 0 0 0 0
0 0.0% 0% 0 0 0 0
0 0.0% 0% 0 0 0 0
0 0.0% 0% 0 0 0 0
0 0.0% 0% 0 0 0 0
0 0.0% 0% 0 0 0 0
0 0.0% 0% 0 0 0 0
0 0.0% 0% 0 0 0 0

=========> <======== PRE-FORMING===================> <======== HYDROFORMING========

Cycle # of Line Tooling Cycle # of Line

Time Workers Investment Investment Time Workers Investment
sec/part # $ $ sec/part # $
40 1.0 2,400,000 235,000 40 1.0 3,300,000
40 1.0 2,400,000 235,000 40 1.0 3,300,000
0 0.0 0 0 0 0.0 0
0 0.0 0 0 0 0.0 0
0 0.0 0 0 0 0.0 0
0 0.0 0 0 0 0.0 0
0 0.0 0 0 0 0.0 0
0 0.0 0 0 0 0.0 0
0 0.0 0 0 0 0.0 0
0 0.0 0 0 0 0.0 0
0 0.0 0 0 0 0.0 0
0 0.0 0 0 0 0.0 0
0 0.0 0 0 0 0.0 0
NG INPUTS======= ========= ======== ========== ===================> <===========

Time Filler Welding

Weld Weld # of Between Metal Reject Press
Speed Length Welds Welds Rate Rate Line Cost
mm/sec mm # sec g/sec % $ / Line
0 0 0 0 NA 0.0% 4,000,000
0 0 0 0 NA 0.0% 4,000,000
100 1600 2 2 0.000 1.0% 4,000,000
100 1800 2 2 0.000 1.0% 4,500,000
0 0 0 0 NA 0.0% 4,000,000
0 0 0 0 NA 0.0% 4,000,000
0 0 0 0 NA 0.0% 15,000,000
0 0 0 0 NA 0.0% 750,000
0 0 0 0 NA 0.0% 4,000,000
0 0 0 0 NA 0.0% 3,000,000
0 0 0 0 NA 0.0% 3,000,000
0 0 0 0 NA 0.0% 3,000,000
0 0 0 0 NA 0.0% 750,000
0 0 0 0 NA 0.0% 7,500,000
100 1200 2 2 0.000 1.0% 15,000,000
0 0 0 0 NA 0.0% 3,000,000
100 2000 2 2 0.000 1.0% 15,000,000
100 1020 2 2 0.000 1.0% 15,000,000
0 0 0 0 NA 0.0% 3,000,000
0 0 0 0 NA 0.0% 4,500,000
0 0 0 0 NA 0.0% 12,000,000
100 5764 5 2 0.000 2.5% 8,500,000
100 5764 5 2 0.000 2.5% 8,500,000
0 0 0 0 NA 0.0% 12,000,000
0 0 0 0 NA 0.0% 15,000,000
0 0 0 0 NA 0.0% 3,000,000
0 0 0 0 NA 0.0% 12,000,000
100 2800 2 2 0.000 1.0% 12,000,000
0 0 0 0 NA 0.0% 12,000,000
 0 0 0 0 NA 0.0% 4,000,000
0 0 0 0 NA 0.0% 4,000,000
0 0 0 0 NA 0.0% 750,000
0 0 0 0 NA 0.0% 4,000,000
0 0 0 0 NA 0.0% 4,000,000
0 0 0 0 NA 0.0% 3,000,000
0 0 0 0 NA 0.0% 3,000,000
0 0 0 0 NA 0.0% 4,000,000
0 0 0 0 NA 0.0% 4,000,000
100 800 2 2 0.000 1.0% 15,000,000
0 0 0 0 NA 0.0% 4,000,000
0 0 0 0 NA 0.0% 750,000
0 0 0 0 NA 0.0% 12,000,000
0 0 0 0 NA 0.0% 12,000,000
0 0 0 0 NA 0.0% 3,000,000
0 0 0 0 NA 0.0% 750,000
0 0 0 0 NA 0.0% 750,000
0 0 0 0 NA 0.0% 750,000
0 0 0 0 NA 0.0% 750,000
0 0 0 0 NA 0.0% 750,000
0 0 0 0 NA 0.0% 750,000
0 0 0 0 NA 0.0% 750,000
0 0 0 0 NA 0.0% 750,000
0 0 0 0 NA 0.0% 15,000,000
0 0 0 0 NA 0.0% 750,000
0 0 0 0 NA 0.0% 750,000
0 0 0 0 NA 0.0% 750,000
0 0 0 0 NA 0.0% 3,000,000
0 0 0 0 NA 0.0% 750,000
0 0 0 0 NA 0.0% 750,000
0 0 0 0 NA 0.0% 750,000
0 0 0 0 0.000 0.0% 0
0 0 0 0 0.000 0.0% 0
0 0 0 0 0.000 0.0% 0
0 0 0 0 0.000 0.0% 0
0 0 0 0 0.000 0.0% 0
0 0 0 0 0.000 0.0% 0
0 0 0 0 0.000 0.0% 0
0 0 0 0 0.000 0.0% 0
0 0 0 0 0.000 0.0% 0
0 0 0 0 0.000 0.0% 0
0 0 0 0 0.000 0.0% 0
 0 0 0 0 0.000 0.0% 0
0 0 0 0 0.000 0.0% 0
0 0 0 0 0.000 0.0% 0
0 0 0 0 0.000 0.0% 0
0 0 0 0 0.000 0.0% 0
0 0 0 0 0.000 0.0% 0
0 0 0 0 0.000 0.0% 0
0 0 0 0 0.000 0.0% 0
0 0 0 0 0.000 0.0% 0
0 0 0 0 0.000 0.0% 0
0 0 0 0 0.000 0.0% 0

OFORMING================> <==========TRIMMING ===================>

Tooling Cycle # of Line Tooling Cycle

Investment Time Workers Investment Investment Time
$ sec/part # $ $ sec/part
355,000 40 0.5 300,000 25,000 22
355,000 40 0.5 300,000 25,000 22
0 0 0.0 0 0 0
0 0 0.0 0 0 0
0 0 0.0 0 0 0
0 0 0.0 0 0 0
0 0 0.0 0 0 0
0 0 0.0 0 0 0
0 0 0.0 0 0 0
0 0 0.0 0 0 0
0 0 0.0 0 0 0
0 0 0.0 0 0 0
0 0 0.0 0 0 0
==============STAMPING INPUTS==== =======================>

Stamping Total Stamping

Press Tool Clean Workers Number Reject
Cost Run Rate per Line of Hits Rate
$ / die set parts / hr # / line # %
400,000 450 3 4 0.5%
370,000 500 3 3 0.5%
900,000 400 4 4 1.0%
1,125,000 400 3 4 1.0%
750,000 450 2 4 0.5%
415,000 500 3 3 0.5%
1,300,000 1000 2 5 0.5%
200,000 400 1 1 0.5%
405,000 500 3 4 0.5%
525,000 500 3 3 0.5%
550,000 500 3 3 0.5%
305,000 500 3 3 0.5%
80,000 2000 1 1 0.5%
2,200,000 400 7 5 0.5%
1,195,000 1000 5 5 1.0%
250,000 450 3 3 0.5%
1,425,000 1000 5 5 1.0%
1,550,000 1000 2 5 1.0%
560,000 200 3 3 0.5%
500,000 450 3 3 0.5%
665,000 1000 2 3 0.5%
3,650,000 350 8 7 2.0%
3,650,000 350 8 7 2.0%
720,000 1000 2 4 0.5%
1,050,000 1000 2 4 0.5%
420,000 500 3 3 0.5%
1,025,000 1000 2 4 0.5%
1,250,000 1000 2 5 1.0%
525,000 1000 2 4 0.5%
550,000 500 3 4 0.5%
550,000 450 3 4 0.5%
160,000 2000 1 1 0.5%
250,000 100 3 1 0.5%
525,000 400 4 2 0.5%
295,000 400 3 3 0.5%
305,000 500 3 2 0.5%
480,000 500 3 4 0.5%
625,000 450 3 4 0.5%
725,000 1000 2 5 0.5%
470,000 450 3 4 0.5%
160,000 2000 1 1 0.5%
775,000 1000 2 3 0.5%
700,000 1000 2 3 0.5%
350,000 450 3 3 0.5%
85,000 2000 1 1 0.5%
120,000 2000 1 1 0.5%
85,000 1000 1 1 0.5%
70,000 2000 1 1 0.5%
70,000 2000 1 1 0.5%
80,000 2000 1 1 0.5%
80,000 2000 1 1 0.5%
60,000 2000 1 1 0.5%
750,000 1000 2 3 0.5%
37,000 2000 1 1 0.5%
90,000 2000 1 1 0.5%
180,000 2000 1 1 0.5%
325,000 450 3 3 0.5%
100,000 2000 1 1 0.5%
42,000 1000 1 1 0.5%
60,000 2000 1 1 0.5%
0 1 0 0 0.0%
0 1 0 0 0.0%
0 1 0 0 0.0%
0 1 0 0 0.0%
0 1 0 0 0.0%
0 1 0 0 0.0%
0 1 0 0 0.0%
0 1 0 0 0.0%
0 1 0 0 0.0%
0 1 0 0 0.0%
0 1 0 0 0.0%
0 1 0 0 0.0%
0 1 0 0 0.0%
0 1 0 0 0.0%
0 1 0 0 0.0%
0 1 0 0 0.0%
0 1 0 0 0.0%
0 1 0 0 0.0%
0 1 0 0 0.0%
0 1 0 0 0.0%
0 1 0 0 0.0%
0 1 0 0 0.0%
INTERMEDIATE CALCULATIONS

STAMPED PARTS

<===================GENERAL CALCULATIONS============================

Annual Total
Paid Input
Part ID Part Name Time Steel
Units hr/yr kg/yr
001 Reinf Radiator Support Upper 3600 1099120
002/003 Reinf Front Rail Extension 3600 549560
008/009 Rail Front Outer RH/LH 3600 3116880
010/011 Rail Front Inner RH/LH 3600 4703227
012/013 Rail Front Extension 3600 1692644
014/015 Bracket Roof Rail Mount Lower 3600 197842
021 Panel Dash 3600 2500509
022 Panel Dash Insert (laminate) 3600 358779
026 Member Dash Front 3600 897614
028 Panel Cowl Lower 3600 595368
032 Panel Cowl Upper 3600 961741
034 Member Front Floor Support 3600 480858
038 Reinf Floor Front Seat Rear Outer 3600 98845
040 Pan Front Floor 3600 4718888
042/043 Panel Rocker Inner 3600 6605703
045 Member Rear Suspension 3600 493694
046/047 Rail Rear Inner 3600 4946838
048/049 Rail Rear Outer 3600 2404337
050 Panel Spare Tire Tub (laminate) 3600 766163
055 Member Panel Back 3600 666799
057 Panel Back 3600 1307953
060 Panel Body Side Outer RH 3600 10778737
061 Panel Body Side Outer LH 3600 10779709
062/063 Panel A-Pillar Inner Lower 3600 1538768
064/065 Panel B-Pillar Inner 3600 3956831
066 Reinf B-Pillar Lower 3600 379207
068/069 Panel Wheelhouse Inner 3600 1743213
070/071 Panel Wheelhouse Outer 3600 2772845
074/075 Panel A-Pillar Inner Upper 3600 989208
 080 Panel Package Tray Upper 3600 1000199
081 Panel Package Tray Lower 3600 1000199
082/083 Support Package Tray RH 3600 73201
085 Panel Roof - Hydromechanical Forming Step 3600 2485271
085 Panel Roof - Trimming & Flanging Steps 3600 0
086 Panel Front Header 3600 493694
087 Panel Rear Header 3600 448796
091 Member Kick Up 3600 628342
094/095 Reinf Radiator Rail Closeout 3600 686962
096/097 Panel Skirt 3600 2043662
098/099 Panel Gutter Deck Lid 3600 535815
102/103 Support Panel Rear Header 3600 76861
104/105 Rail Fender Support Inner 3600 2308152
106/107 Rail Fender Support Outer 3600 1500310
108/109 Reinf Front Rail 3600 686962
110 Plate Rear Spring Upper 3600 152277
115 Reinf Panel Dash Brake Booster 3600 292805
116/117 Bracket Rear Shock Absorber Mount 3600 320267
120 Reinf Floor Front Seat Rear Center 3600 120782
122 Reinf Rear Seat Inner Belt Mount 3600 114045
128 Bracket Member Pass Through Lower 3600 26343
130/152 Bracket Member Pass Through Up Fr & R 3600 128102
136 Reinf Panel Dash Upper 3600 32031
140 Pan Rear Floor 3600 2615905
142 Reinf Hinge Decklid 3600 90592
144/145 Reinf A-Pillar 3600 205872
164/165 Closeout Fender Support Rail 3600 102948
170/171 Reinf Rail Dash 3600 257908
172 Assy Reinf Cowl Lower 3600 46951
180/181 Bracket Trailing Arm Mount Inner 3600 274504
190 Reinf Seat Belt Retractor Rear 3600 87841
n/a none 3600 0
n/a none 3600 0
n/a none 3600 0
n/a none 3600 0
n/a none 3600 0
n/a none 3600 0
n/a none 3600 0
n/a none 3600 0
n/a none 3600 0
n/a none 3600 0
n/a none 3600 0
 n/a none 3600 0
n/a none 3600 0
n/a none 3600 0
n/a none 3600 0
n/a none 3600 0
n/a none 3600 0
n/a none 3600 0
n/a none 3600 0
n/a none 3600 0
n/a none 3600 0
n/a none 3600 0

TUBULAR & PURCHASED PARTS

<========== =========GENERAL CALCULATIONS============================

Annual
Paid Tube
Part ID Part Name Time Weight
Units hr/yr kg
072 Rail Side Roof RH 3600 7.00
073 Rail Side Roof LH 3600 7.00
090 Member Pass Through 0 0.00
188 Brace Radiator 0 0.00
XXX Hinges 0 0.00
XXX Small Brackets 0 0.00
XXX Weld Studs 0 0.00
n/a none 0 0.00
n/a none 0 0.00
n/a none 0 0.00
n/a none 0 0.00
n/a none 0 0.00
n/a none 0 0.00

ASSEMBLY

<==========
===========GENERAL OUTPUT COSTS===========
====================
 Production Production
Volume Time
AREA # AREA NAME # hr
410 Final 225000 3120
411/412 Body Side Outer 225000 3120
414 Framing 225000 3120
415 Underbody Complete 225000 3120
416/417 Body Side Inner 225000 3120
421 Front End 225000 3120
422 Front Ladder Complete 225000 3120
428 Underbody Floor 225000 3120
431 Underbody Inner 225000 3120
439 Dash 225000 3120
XXX Hinge Assembly 225000 3120
XXX Miscellaneous Brackets 225000 3120
n/a none 225000 3120
n/a none 225000 3120
n/a none 225000 3120
n/a none 225000 3120
n/a none 225000 3120

Material Utilization Calculations

Total Weight of Input Blanks 90939478.5 kg
Total Weight of Input Tubes 3150000 kg
Weight of Purchased Parts 9.47 kg
Weight of Blanks & Tubes per Body Structure 399.74 kg
TS

========= ========= =================> <================== BLANKING CALCULATIONS

Unit Weight Weight Blanking Blanking Blanking

Material of All of All Material Effective Recovered Production
Cost Parts Blanks Ulitization Prod. Vol. Scrap Time
$/kg kg kg % #/yr kg/yr hr/yr
0.92 1.613 4.71 34% 226358 34043 151
0.92 0.974 2.355 41% 226358 17021 151
0.92 6.05 13.1566 46% 689397 96532 345
#N/A 10.97 19.8527 55% 689397 145663 460
0.92 4.157 7.2534 57% 226358 52426 151
0.92 0.303 0.8478 36% 226358 6128 113
0.85 5.83 10.7153 54% 226358 77448 189
#N/A 0.875 1.539 57% 226131 10763 #N/A
1.07 2.28 3.8465 59% 226358 27802 151
0.85 1.272 2.5513 50% 226358 18440 151
0.85 1.374 4.1213 33% 226358 29788 151
1.16 1.29 2.0606 63% 452715 14892 226
0.89 0.12 0.424 28% 452262 2965 #N/A
0.85 14.65 20.2216 72% 226358 146157 189
#N/A 13.115 27.8832 47% 459598 204584 306
0.92 1.344 2.1156 64% 226358 15291 151
#N/A 10.49 20.881 50% 689397 153208 460
#N/A 5.092 10.1489 50% 689397 74464 345
#N/A 2.107 3.2832 64% 226358 23730 151
0.85 1.305 2.8574 46% 226358 20653 151
0.77 2.502 5.6049 45% 226358 40511 151
#N/A 15.78 44.356 36% 1178575 333830 786
#N/A 15.65 44.36 35% 1178575 333860 786
0.92 2.74 6.594 42% 226358 47660 151
0.92 7.172 16.956 42% 226358 122554 151
0.92 0.83 1.625 51% 452715 11744 226
0.85 3.854 7.4701 52% 226358 53992 151
0.81 4.31 11.7044 37% 459598 85877 230
0.92 2.841 4.239 67% 226358 30638 151
0.85 1.876 4.2861 44% 226358 30979 151
0.85 1.497 4.2861 35% 226358 30979 151
0.89 0.16 0.314 51% 226131 2196 #N/A
0.85 8.68 10.65 82% 226358 76976 189
0.85 0 0 0% 226131 0 #N/A
0.89 0.813 2.1156 38% 226358 15291 151
0.77 0.773 1.9232 40% 226358 13900 151
1.16 1.397 2.6926 52% 226358 19461 151
0.92 1.142 2.9438 39% 226358 21277 151
#N/A 6.925 8.67 80% 457290 63295 305
0.77 0.871 2.2961 38% 226358 16596 151
0.77 0.196 0.3297 59% 226131 2306 #N/A
0.99 5.411 9.891 55% 226358 71490 151
0.92 2.594 6.4292 40% 226358 46469 151
0.92 1.668 2.9438 57% 226358 21277 151
0.92 0.526 0.6532 81% 452262 4568 #N/A
0.92 0.454 1.256 36% 226131 8784 #N/A
0.92 0.674 1.3738 49% 226131 9608 #N/A
0.92 0.25 0.5181 48% 226131 3623 #N/A
0.92 0.244 0.4892 50% 452262 3421 #N/A
0.92 0.056 0.113 50% 452262 790 #N/A
0.92 0.274 0.5495 50% 226131 3843 #N/A
0.92 0.1 0.1374 73% 226131 961 #N/A
0.85 4.24 11.2098 38% 226358 81022 151
0.92 0.224 0.3886 58% 452262 2718 #N/A
0.92 0.459 0.8831 52% 226131 6176 #N/A
0.92 0.23 0.4416 52% 226131 3088 #N/A
0.92 0.621 1.1052 56% 226358 7988 151
0.92 0.127 0.2014 63% 226131 1409 #N/A
0.92 0.674 1.1775 57% 226131 8235 #N/A
0.92 0.104 0.3768 28% 452262 2635 #N/A
0.00 0 0 0% 0 0 0
0.00 0 0 0% 0 0 0
0.00 0 0 0% 0 0 0
0.00 0 0 0% 0 0 0
0.00 0 0 0% 0 0 0
0.00 0 0 0% 0 0 0
0.00 0 0 0% 0 0 0
0.00 0 0 0% 0 0 0
0.00 0 0 0% 0 0 0
0.00 0 0 0% 0 0 0
0.00 0 0 0% 0 0 0
 0.00 0 0 0% 0 0 0
0.00 0 0 0% 0 0 0
0.00 0 0 0% 0 0 0
0.00 0 0 0% 0 0 0
0.00 0 0 0% 0 0 0
0.00 0 0 0% 0 0 0
0.00 0 0 0% 0 0 0
0.00 0 0 0% 0 0 0
0.00 0 0 0% 0 0 0
0.00 0 0 0% 0 0 0
0.00 0 0 0% 0 0 0

========= ========= =================> <===================PROCESS CALCULATIONS=

Unit Weight Hydroform Hydroform Hydroform

Material of All Materials Effective Production Available
Cost Parts Utilization Prod. Vol. Time Time
$/kg kg % #/yr hr/yr hr/yr
1.60 4.7 67% 227250 2525 2880
1.60 4.86 69% 227250 2525 2880
0.77 0.662 0% 0 0 0
0.92 0.25 0% 0 0 0
0.89 2.128 0% 0 0 0
0.77 6.113 0% 0 0 0
0.00 0.32 0% 0 0 0
0.00 0 0% 0 0 0
0.00 0 0% 0 0 0
0.00 0 0% 0 0 0
0.00 0 0% 0 0 0
0.00 0 0% 0 0 0
0.00 0 0% 0 0 0

========= ========= =================> <================== ENERGY CALCULATIONS==

Spot Adhesive
 Total Welding Bonding
Energy Energy Energy
kWhr kWhr kWhr
36.18 32.08 0.00
3.06 2.88 0.00
15.07 12.68 0.00
3.86 3.68 0.00
6.42 5.12 0.00
4.19 3.84 0.00
6.36 6.00 0.00
18.64 17.48 0.00
1.31 1.28 0.00
0.06 0.00 0.06
0.19 0.00 0.00
3.35 3.20 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
NKING CALCULATIONS================== ========> <======== ========= WELDING CALCULATION

Blanking Blanking Blanking Blanking Welding Welding Welding

Available Time % of Line Indirect Effective Scrap Labor
Time Required Required Workers Prod. Vol. Recovered Time
hr/yr hr/yr % # #/yr kg/yr hr/yr
2880 189 7% 0.08 226131 #N/A #N/A
2880 189 7% 0.08 226131 #N/A #N/A
2880 460 16% 0.20 229569 30208 1913
2880 574 20% 0.25 229569 45582 2104
2880 189 7% 0.08 226131 #N/A #N/A
2880 151 5% 0.07 226131 #N/A #N/A
2880 226 8% 0.10 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
2880 189 7% 0.08 226131 #N/A #N/A
2880 189 7% 0.08 226131 #N/A #N/A
2880 302 10% 0.13 452262 #N/A #N/A
#N/A #N/A #N/A #N/A 452262 #N/A #N/A
2880 226 8% 0.10 226131 #N/A #N/A
2880 383 13% 0.17 229569 64020 1530
2880 189 7% 0.08 226131 #N/A #N/A
2880 574 20% 0.25 229569 47943 2296
2880 460 16% 0.20 229569 23302 1358
2880 189 7% 0.08 226131 #N/A #N/A
2880 189 7% 0.08 226131 #N/A #N/A
2880 189 7% 0.08 226131 #N/A #N/A
2880 982 34% 0.43 235479 261124 6637
2880 982 34% 0.43 235479 261147 6637
2880 189 7% 0.08 226131 #N/A #N/A
2880 189 7% 0.08 226131 #N/A #N/A
2880 302 10% 0.13 452262 #N/A #N/A
2880 189 7% 0.08 226131 #N/A #N/A
2880 306 11% 0.13 229569 26873 3061
2880 189 7% 0.08 226131 #N/A #N/A
2880 189 7% 0.08 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
2880 226 8% 0.10 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
2880 189 7% 0.08 226131 #N/A #N/A
2880 189 7% 0.08 226131 #N/A #N/A
2880 189 7% 0.08 226131 #N/A #N/A
2880 381 13% 0.17 228416 19811 1142
2880 189 7% 0.08 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
2880 189 7% 0.08 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
#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/A
2880 0 0% 0.00 0 #N/A #N/A
2880 0 0% 0.00 0 #N/A #N/A
2880 0 0% 0.00 0 #N/A #N/A
2880 0 0% 0.00 0 #N/A #N/A
2880 0 0% 0.00 0 #N/A #N/A
2880 0 0% 0.00 0 #N/A #N/A
2880 0 0% 0.00 0 #N/A #N/A
2880 0 0% 0.00 0 #N/A #N/A
2880 0 0% 0.00 0 #N/A #N/A
2880 0 0% 0.00 0 #N/A #N/A
 2880 0 0% 0.00 0 #N/A #N/A
2880 0 0% 0.00 0 #N/A #N/A
2880 0 0% 0.00 0 #N/A #N/A
2880 0 0% 0.00 0 #N/A #N/A
2880 0 0% 0.00 0 #N/A #N/A
2880 0 0% 0.00 0 #N/A #N/A
2880 0 0% 0.00 0 #N/A #N/A
2880 0 0% 0.00 0 #N/A #N/A
2880 0 0% 0.00 0 #N/A #N/A
2880 0 0% 0.00 0 #N/A #N/A
2880 0 0% 0.00 0 #N/A #N/A

CESS CALCULATIONS===========================> <=======PROCESS SUMMATIONS========>

Hydroform Hydroform Hydroform Purchased

Time % of Line Indirect Part # of Line Tooling
Required Required Workers Weight Workers Investment Investment
hr/yr % # kg # $ $
2600.75 0.90303819 1.75 0.00 3 7,250,000 665,000
2600.75 0.90303819 1.75 0.00 3 7,250,000 665,000
0 0 0 0.66 0 0 0
0 0 0 0.25 0 0 0
0 0 0 2.13 0 0 0
0 0 0 6.11 0 0 0
0 0 0 0.32 0 0 0
0 0 0 0.00 0 0 0
0 0 0 0.00 0 0 0
0 0 0 0.00 0 0 0
0 0 0 0.00 0 0 0
0 0 0 0.00 0 0 0
0 0 0 0.00 0 0 0

RGY CALCULATIONS========= ===================> <======== MATERIAL & LABOR CALCULATIONS

MIG Laser Spot

Welding Welding Robot Worker Overhead Welding
Energy Energy Energy Paid Time Workers Material
kWhr kWhr kWhr hr/yr # $
0.02 2.86 1.22 3600 35 0.05
0.00 0.00 0.18 3600 19 0.00
0.13 1.65 0.61 3600 22 0.02
0.00 0.00 0.18 3600 9 0.01
0.07 0.98 0.24 3600 19 0.01
0.06 0.05 0.24 3600 10 0.01
0.00 0.03 0.34 3600 23 0.01
0.00 0.27 0.89 3600 19 0.02
0.00 0.00 0.03 3600 8 0.00
0.00 0.00 0.00 3600 6 0.00
0.07 0.00 0.12 3600 3 0.00
0.00 0.00 0.15 3600 5 0.00
0.00 0.00 0.00 3600 0 0.00
0.00 0.00 0.00 3600 0 0.00
0.00 0.00 0.00 3600 0 0.00
0.00 0.00 0.00 3600 0 0.00
0.00 0.00 0.00 3600 0 0.00
DING CALCULATIONS=============== ========= =======> <======================

Welding Welding Welding Actual Welding Stamping Stamping

Lines Cycle Required Welding Indirect Effective Scrap
Required Time Time Time Workers Prod. Vol. Recovered
# sec/part hr/yr hr/yr # #/yr kg/yr
#N/A #N/A #N/A #N/A #N/A 226131 702152
#N/A #N/A #N/A #N/A #N/A 226131 313389
0.53 20.00 1275 1020 0.66 227273 1628890
0.58 22.00 1403 1148 0.73 227273 2043733
#N/A #N/A #N/A #N/A #N/A 226131 704894
#N/A #N/A #N/A #N/A #N/A 226131 123539
#N/A #N/A #N/A #N/A #N/A 226131 1111312
#N/A #N/A #N/A #N/A #N/A 226131 151141
#N/A #N/A #N/A #N/A #N/A 226131 356813
#N/A #N/A #N/A #N/A #N/A 226131 290728
#N/A #N/A #N/A #N/A #N/A 226131 622804
#N/A #N/A #N/A #N/A #N/A 452262 175716
#N/A #N/A #N/A #N/A #N/A 452262 68880
#N/A #N/A #N/A #N/A #N/A 226131 1276481
0.43 16.00 1020 765 0.53 227273 3386224
#N/A #N/A #N/A #N/A #N/A 226131 176003
0.64 24.00 1530 1275 0.80 227273 2385438
0.38 14.20 906 650 0.47 227273 1160871
#N/A #N/A #N/A #N/A #N/A 226131 268358
#N/A #N/A #N/A #N/A #N/A 226131 352522
#N/A #N/A #N/A #N/A #N/A 226131 704492
1.84 67.64 4424 3770 2.30 229592 6633283
1.84 67.64 4424 3770 2.30 229592 6663451
#N/A #N/A #N/A #N/A #N/A 226131 874608
#N/A #N/A #N/A #N/A #N/A 226131 2220577
#N/A #N/A #N/A #N/A #N/A 452262 180713
#N/A #N/A #N/A #N/A #N/A 226131 822071
0.85 32.00 2041 1786 1.06 227273 1690344
#N/A #N/A #N/A #N/A #N/A 226131 319344
#N/A #N/A #N/A #N/A #N/A 226131 547120
#N/A #N/A #N/A #N/A #N/A 226131 632395
#N/A #N/A #N/A #N/A #N/A 226131 35005
#N/A #N/A #N/A #N/A #N/A 226131 455295
#N/A #N/A #N/A #N/A #N/A 226131 0
#N/A #N/A #N/A #N/A #N/A 226131 295478
#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

TIONS========>

Cycle
Time
sec/part
40
40
0
0
0
0
0
0
0
0
0
0
0

OR CALCULATIONS=======
=========>

Adhesive MIG Laser

Bonding Welding Welding
Material Material Material
$ $ $
0.00 0.00 0.06
0.00 0.00 0.00
0.00 0.03 0.03
0.00 0.00 0.00
0.00 0.01 0.02
0.00 0.01 0.00
0.00 0.00 0.00
0.00 0.00 0.01
0.00 0.00 0.00
0.18 0.00 0.00
0.00 0.01 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
STAMPING CALCULATIONS ========== =========> <===================

Press Stamping Percent Stamping

Time Production of Press Line Indirect Blanking Blanking
Required Time Required Workers Energy Equipment
hr/yr hr/yr % # $/hr $/hr
578 503 27% 0.47 15.00 58.11
528 452 24% 0.43 15.00 58.11
644 568 30% 0.60 15.00 58.11
644 568 30% 0.52 15.00 77.48
578 503 27% 0.40 15.00 58.11
528 452 24% 0.43 15.00 58.11
302 226 14% 0.21 15.00 174.32
641 565 30% 0.37 15.00 0.00
528 452 24% 0.43 15.00 116.21
528 452 24% 0.43 15.00 116.21
528 452 24% 0.43 15.00 116.21
1056 905 49% 0.86 15.00 116.21
377 226 17% 0.22 15.00 0.00
641 565 30% 0.82 15.00 174.32
303 227 14% 0.32 15.00 174.32
578 503 27% 0.47 15.00 58.11
303 227 14% 0.32 15.00 96.85
303 227 14% 0.21 15.00 58.11
1206 1131 56% 0.98 15.00 58.11
578 503 27% 0.47 15.00 116.21
302 226 14% 0.21 15.00 116.21
733 656 34% 1.02 15.00 104.59
733 656 34% 1.02 15.00 104.59
302 226 14% 0.21 15.00 58.11
302 226 14% 0.21 15.00 174.32
1056 905 49% 0.86 15.00 58.11
302 226 14% 0.21 15.00 58.11
303 227 14% 0.21 15.00 58.11
302 226 14% 0.21 15.00 58.11
 528 452 24% 0.43 15.00 116.21
578 503 27% 0.47 15.00 116.21
189 113 9% 0.11 15.00 0.00
2337 2261 108% 1.89 15.00 174.32
641 565 30% 0.59 15.00 0.00
641 565 30% 0.52 15.00 58.11
528 452 24% 0.43 15.00 58.11
528 452 24% 0.43 15.00 116.21
578 503 27% 0.47 15.00 58.11
302 226 14% 0.21 15.00 58.11
578 503 27% 0.47 15.00 58.11
189 113 9% 0.11 15.00 0.00
302 226 14% 0.21 15.00 116.21
302 226 14% 0.21 15.00 116.21
578 503 27% 0.47 15.00 58.11
377 226 17% 0.22 15.00 0.00
189 113 9% 0.11 15.00 0.00
302 226 14% 0.17 15.00 0.00
189 113 9% 0.11 15.00 0.00
377 226 17% 0.22 15.00 0.00
377 226 17% 0.22 15.00 0.00
189 113 9% 0.11 15.00 0.00
189 113 9% 0.11 15.00 0.00
302 226 14% 0.21 15.00 174.32
377 226 17% 0.22 15.00 0.00
189 113 9% 0.11 15.00 0.00
189 113 9% 0.11 15.00 0.00
578 503 27% 0.47 15.00 58.11
189 113 9% 0.11 15.00 0.00
302 226 14% 0.17 15.00 0.00
377 226 17% 0.22 15.00 0.00
0 0 0% 0.00 15.00 0.00
0 0 0% 0.00 15.00 0.00
0 0 0% 0.00 15.00 0.00
0 0 0% 0.00 15.00 0.00
0 0 0% 0.00 15.00 0.00
0 0 0% 0.00 15.00 0.00
0 0 0% 0.00 15.00 0.00
0 0 0% 0.00 15.00 0.00
0 0 0% 0.00 15.00 0.00
0 0 0% 0.00 15.00 0.00
0 0 0% 0.00 15.00 0.00
0 0 0% 0.00 15.00 0.00
0 0 0% 0.00 15.00 0.00
0 0 0% 0.00 15.00 0.00
0 0 0% 0.00 15.00 0.00
0 0 0% 0.00 15.00 0.00
0 0 0% 0.00 15.00 0.00
0 0 0% 0.00 15.00 0.00
0 0 0% 0.00 15.00 0.00
0 0 0% 0.00 15.00 0.00
0 0 0% 0.00 15.00 0.00
0 0 0% 0.00 15.00 0.00
==========MACHINE RENT CALCULATIONS===================================

Blanking Blanking Blanking Blanking Stamping Stamping Stamping

Overhead 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 44.00
44.00 13.28 7.14 0.00 45.00 309.90 44.00
44.00 13.28 7.14 0.00 60.00 309.90 44.00
44.00 13.28 9.08 0.00 60.00 348.64 44.00
44.00 13.28 7.14 0.00 60.00 309.90 44.00
44.00 13.28 7.14 0.00 45.00 309.90 44.00
44.00 13.28 18.76 0.00 75.00 1162.14 44.00
44.00 13.28 1.33 0.00 15.00 58.11 44.00
44.00 13.28 12.95 0.00 60.00 309.90 44.00
44.00 13.28 12.95 0.00 45.00 232.43 44.00
44.00 13.28 12.95 0.00 45.00 232.43 44.00
44.00 13.28 12.95 0.00 45.00 232.43 44.00
44.00 13.28 1.33 0.00 15.00 58.11 44.00
44.00 13.28 18.76 0.00 75.00 581.07 44.00
44.00 13.28 18.76 0.00 75.00 1162.14 44.00
44.00 13.28 7.14 0.00 45.00 232.43 44.00
44.00 13.28 11.01 0.00 75.00 1162.14 44.00
44.00 13.28 7.14 0.00 75.00 1162.14 44.00
44.00 13.28 7.14 0.00 45.00 232.43 44.00
44.00 13.28 12.95 0.00 45.00 348.64 44.00
44.00 13.28 12.95 0.00 45.00 929.71 44.00
44.00 13.28 11.79 0.00 105.00 658.55 44.00
44.00 13.28 11.79 0.00 105.00 658.55 44.00
44.00 13.28 7.14 0.00 60.00 929.71 44.00
44.00 13.28 18.76 0.00 60.00 1162.14 44.00
44.00 13.28 7.14 0.00 45.00 232.43 44.00
44.00 13.28 7.14 0.00 60.00 929.71 44.00
44.00 13.28 7.14 0.00 75.00 929.71 44.00
44.00 13.28 7.14 0.00 60.00 929.71 44.00
44.00 13.28 12.95 0.00 60.00 309.90 44.00
44.00 13.28 12.95 0.00 60.00 309.90 44.00
44.00 13.28 1.33 0.00 15.00 58.11 44.00
44.00 13.28 18.76 0.00 15.00 309.90 44.00
44.00 13.28 1.33 0.00 30.00 309.90 44.00
44.00 13.28 7.14 0.00 45.00 232.43 44.00
44.00 13.28 7.14 0.00 30.00 232.43 44.00
44.00 13.28 12.95 0.00 60.00 309.90 44.00
44.00 13.28 7.14 0.00 60.00 309.90 44.00
44.00 13.28 7.14 0.00 75.00 1162.14 44.00
44.00 13.28 7.14 0.00 60.00 309.90 44.00
44.00 13.28 1.33 0.00 15.00 58.11 44.00
44.00 13.28 12.95 0.00 45.00 929.71 44.00
44.00 13.28 12.95 0.00 45.00 929.71 44.00
44.00 13.28 7.14 0.00 45.00 232.43 44.00
44.00 13.28 1.33 0.00 15.00 58.11 44.00
44.00 13.28 1.33 0.00 15.00 58.11 44.00
44.00 13.28 1.33 0.00 15.00 58.11 44.00
44.00 13.28 1.33 0.00 15.00 58.11 44.00
44.00 13.28 1.33 0.00 15.00 58.11 44.00
44.00 13.28 1.33 0.00 15.00 58.11 44.00
44.00 13.28 1.33 0.00 15.00 58.11 44.00
44.00 13.28 1.33 0.00 15.00 58.11 44.00
44.00 13.28 18.76 0.00 45.00 1162.14 44.00
44.00 13.28 1.33 0.00 15.00 58.11 44.00
44.00 13.28 1.33 0.00 15.00 58.11 44.00
44.00 13.28 1.33 0.00 15.00 58.11 44.00
44.00 13.28 7.14 0.00 45.00 232.43 44.00
44.00 13.28 1.33 0.00 15.00 58.11 44.00
44.00 13.28 1.33 0.00 15.00 58.11 44.00
44.00 13.28 1.33 0.00 15.00 58.11 44.00
44.00 13.28 1.33 0.00 0.00 0.00 44.00
44.00 13.28 1.33 0.00 0.00 0.00 44.00
44.00 13.28 1.33 0.00 0.00 0.00 44.00
44.00 13.28 1.33 0.00 0.00 0.00 44.00
44.00 13.28 1.33 0.00 0.00 0.00 44.00
44.00 13.28 1.33 0.00 0.00 0.00 44.00
44.00 13.28 1.33 0.00 0.00 0.00 44.00
44.00 13.28 1.33 0.00 0.00 0.00 44.00
44.00 13.28 1.33 0.00 0.00 0.00 44.00
44.00 13.28 1.33 0.00 0.00 0.00 44.00
44.00 13.28 1.33 0.00 0.00 0.00 44.00
44.00 13.28 1.33 0.00 0.00 0.00 44.00
44.00 13.28 1.33 0.00 0.00 0.00 44.00
44.00 13.28 1.33 0.00 0.00 0.00 44.00
44.00 13.28 1.33 0.00 0.00 0.00 44.00
44.00 13.28 1.33 0.00 0.00 0.00 44.00
44.00 13.28 1.33 0.00 0.00 0.00 44.00
44.00 13.28 1.33 0.00 0.00 0.00 44.00
44.00 13.28 1.33 0.00 0.00 0.00 44.00
44.00 13.28 1.33 0.00 0.00 0.00 44.00
44.00 13.28 1.33 0.00 0.00 0.00 44.00
44.00 13.28 1.33 0.00 0.00 0.00 44.00
==============================>

Stamping Stamping Stamping

Building Maintenance W. Cap.
$/hr $/hr $/hr
35.42 34.53 0.01
26.56 33.65 0.01
35.42 34.53 0.01
35.42 38.41 0.01
35.42 34.53 0.01
26.56 33.65 0.01
44.27 120.64 0.02
8.85 6.70 0.00
35.42 34.53 0.01
26.56 25.90 0.01
26.56 25.90 0.01
26.56 25.90 0.01
8.85 6.70 0.00
44.27 62.53 0.01
44.27 120.64 0.02
26.56 25.90 0.01
44.27 120.64 0.02
44.27 120.64 0.02
26.56 25.90 0.01
26.56 37.52 0.01
26.56 95.63 0.02
61.98 72.05 0.01
61.98 72.05 0.01
35.42 96.51 0.02
35.42 119.76 0.02
26.56 25.90 0.01
35.42 96.51 0.02
44.27 97.40 0.02
35.42 96.51 0.02
35.42 34.53 0.01
35.42 34.53 0.01
8.85 6.70 0.00
8.85 31.88 0.01
17.71 32.76 0.01
26.56 25.90 0.01
17.71 25.01 0.00
35.42 34.53 0.01
35.42 34.53 0.01
44.27 120.64 0.02
35.42 34.53 0.01
8.85 6.70 0.00
26.56 95.63 0.02
26.56 95.63 0.02
26.56 25.90 0.01
8.85 6.70 0.00
8.85 6.70 0.00
8.85 6.70 0.00
8.85 6.70 0.00
8.85 6.70 0.00
8.85 6.70 0.00
8.85 6.70 0.00
8.85 6.70 0.00
26.56 118.87 0.02
8.85 6.70 0.00
8.85 6.70 0.00
8.85 6.70 0.00
26.56 25.90 0.01
8.85 6.70 0.00
8.85 6.70 0.00
8.85 6.70 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
0.00 0.00 0.00
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 model
does not use the calculated machine rents to arrive at the final costs. This is provided
strictly 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. To
ensure consistency of results, the user MUST be certain that their own machine
rent 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 gives
the user the ability to test a single part at a time). The "Test Part Number" must be
entered 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 and
stamping lines. The user is invited to use the adjacent "test values" column to see
the effects of changes in the inputs on the machine rents. If the user would like the
overall model to reflect these machine rents he should use the test values column
to 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 and
parts inputs) and will then result in the same final part costs.

Test Part Number 001

Current
Model Test
Inputs Values Values
Blanking Line Energy Consumption Rate 150 150
Press Energy Consumption Rate 150 150
Number of Presses 4 4
Unit Energy Cost 0.10 0.10
Blanking Press Cost 1000000 1000000
Stamping Press Line Cost 4000000 4000000
Blanking Auxiliary Equipment Percent 25% 25%
Stamping Auxiliary Equipment Percent 25% 25%
Interest Rate 12% 12%
Equipment Life 20 20
Days per Year 240 240
No shifts 8.375 8.375
Worker unpaid breaks 0.625 0.625
Worker paid breaks 1 1
Blanking Line Unplanned Downtime 2 2
Stamping Line Unplanned Downtime 5 5
Indirect workers/Line 1 1
Wage (including benefits) 44 44
Blanking Line Space Requirement 100 100
Press Space Requirement 50 50
Idle Space Percent 100% 100%
Building Unit Cost 1500 1500
Building Life 25 25
Blanking Line Maintenance Percent 10% 10%
Press Line Maintenance Percent 10% 10%
Working Capital Period 2 2

BLANKING RENTS ($/hr)

Contribution from Energy 15.00 15.00
Contribution from Equipment 58.11 58.11
Contribution from Overhead Labor 44.00 44.00
Contribution from Building 13.28 13.28
Contribution from Maintenance 7.14 7.14
Contribution from Working Capital 0.00 0.00

BLANKING MACHINE RENT 137.53 137.53

STAMPING RENTS ($/hr)

Contribution from Energy 60.00 60.00
Contribution from Equipment 309.90 309.90
Contribution from Overhead Labor 44.00 44.00
Contribution from Building 35.42 35.42
Contribution from Maintenance 34.53 34.53
Contribution from Working Capital 0.01 0.01

STAMPING MACHINE RENT 483.86 483.86

INFORMATION SHEET: BLANK SIZES

* Note: For parts made from progr

the blank length is the advance of
needed to produce the part.

Blank Length
Part ID Part Name Blank # mm
001 Reinf Radiator Support Upper 1 1500
002/003 Reinf Front Rail Extension 1 1200
008/009 Rail Front Outer RH/LH 1 800
2 800
3 800
010/011 Rail Front Inner RH/LH 1 500
2 500
3 700
012/013 Rail Front Extension 1 600
014/015 Bracket Roof Rail Mount Lower 1 300
021 Panel Dash 1 1300
022 Panel Dash Insert (laminate) Laminate 450
026 Member Dash Front 1 350
028 Panel Cowl Lower 1 650
032 Panel Cowl Upper 1 500
034 Member Front Floor Support 1 250
038 Reinf Floor Front Seat Rear Outer Progressive 200
040 Pan Front Floor 1 1600
042/043 Panel Rocker Inner 1 1200
2 1200
045 Member Rear Suspension 1 350
046/047 Rail Rear Inner 1 1000
2 1000
3 1000
048/049 Rail Rear Outer 1 650
2 650
3 650
050 Panel Spare Tire Tub (laminate) Laminate 1000
055 Member Panel Back 1 400
057 Panel Back 1 600
060 Panel Body Side Outer RH The five blanks making upper the bod
 061 Panel Body Side Outer LH are NOT rectangular. See blank drawin
062/063 Panel A-Pillar Inner Lower 1 700
064/065 Panel B-Pillar Inner 1 1200
066 Reinf B-Pillar Lower 1 460
068/069 Panel Wheelhouse Inner 1 1220
070/071 Panel Wheelhouse Outer 1 1400
2 1400
3 1400
074/075 Panel A-Pillar Inner Upper 1 400
080 Panel Package Tray Upper 1 600
081 Panel Package Tray Lower 1 600
082/083 Support Package Tray RH Progressive 350
085 Panel Roof 1 1250
086 Panel Front Header 1 350
087 Panel Rear Header 1 350
091 Member Kick Up 1 350
094/095 Reinf Radiator Rail Closeout 1 500
096/097 Panel Skirt 1 800
2 800
098/099 Panel Gutter Deck Lid 1 500
102/103 Support Panel Rear Header Progressive 300
104/105 Rail Fender Support Inner 1 1000
106/107 Rail Fender Support Outer 1 700
108/109 Reinf Front Rail 1 500
110 Plate Rear Spring Upper Progressive 160
115 Reinf Panel Dash Brake Booster Progressive 500
116/117 Bracket Rear Shock Absorber Mount Progressive 300
120 Reinf Floor Front Seat Rear Center Progressive 550
122 Reinf Rear Seat Inner Belt Mount Progressive 205
128 Bracket Member Pass Through Lower Progressive 120
130/152 Bracket Member Pass Through Up Fr & R Progressive 350
136 Reinf Panel Dash Upper Progressive 175
140 Pan Rear Floor 1 1200
142 Reinf Hinge Decklid Progressive 220
144/145 Reinf A-Pillar Progressive 500
164/165 Closeout Fender Support Rail Progressive 450
170/171 Reinf Rail Dash 1 190
172 Assy Reinf Cowl Lower Progressive 190
180/181 Bracket Trailing Arm Mount Inner Progressive 300
190 Reinf Seat Belt Retractor Rear Progressive 200
For parts made from progressive dies,
k length is the advance of the coil
to produce the part.

Blank Width Thickness Density Weight Mat. Type

mm mm g/cc kg MPa
400 1.00 7.85 4.71 350
250 1.00 7.85 2.36 350
450 1.50 7.85 4.24 350
450 1.60 7.85 4.52 350
350 2.00 7.85 4.40 350
900 1.50 7.85 5.30 350
900 1.60 7.85 5.65 350
900 1.80 7.85 8.90 350
1100 1.40 7.85 7.25 350
300 1.20 7.85 0.85 350
1500 0.70 7.85 10.72 210
1000 1.00 3.42 1.54 Sandwich
1400 1.00 7.85 3.85 600
500 1.00 7.85 2.55 210
1500 0.70 7.85 4.12 210
750 0.70 7.85 1.03 800
150 0.90 7.85 0.21 280
2300 0.70 7.85 20.22 210
1100 1.30 7.85 13.47 350
900 1.70 7.85 14.41 350
1100 0.70 7.85 2.12 350
600 1.00 7.85 4.71 350
600 1.30 7.85 6.12 350
800 1.60 7.85 10.05 350
510 1.00 7.85 2.60 350
510 1.30 7.85 3.38 350
510 1.60 7.85 4.16 350
1000 0.96 3.42 3.28 Sandwich
1400 0.65 7.85 2.86 210
1700 0.70 7.85 5.60 140
ks making upper the body side outers TB60
ngular. See blank drawings for details TB60
1200 1.00 7.85 6.59 350
1200 1.50 7.85 16.96 350
250 0.90 7.85 0.81 350
1200 0.65 7.85 7.47 210
300 0.80 7.85 2.64 210
900 0.65 7.85 6.43 140
300 0.80 7.85 2.64 210
900 1.50 7.85 4.24 350
1400 0.65 7.85 4.29 210
1400 0.65 7.85 4.29 210
200 0.80 7.85 0.44 280
1550 0.70 7.85 10.65 210
1100 0.70 7.85 2.12 280
1000 0.70 7.85 1.92 140
1400 0.70 7.85 2.69 800
750 1.00 7.85 2.94 350
450 2.00 7.85 5.65 140
300 1.60 7.85 3.01 140
900 0.65 7.85 2.30 140
200 0.70 7.85 0.33 140
1500 0.90 7.85 10.60 420
1300 0.90 7.85 6.43 350
750 1.00 7.85 2.94 350
130 2.00 7.85 0.33 350
320 1.00 7.85 1.26 350
250 2.00 7.85 1.18 350
100 1.20 7.85 0.52 350
76 2.00 7.85 0.24 350
60 1.00 7.85 0.06 350
200 1.00 7.85 0.55 350
100 1.00 7.85 0.14 350
1700 0.70 7.85 11.21 210
75 1.50 7.85 0.19 350
150 1.50 7.85 0.88 350
125 1.00 7.85 0.44 350
570 1.30 7.85 1.11 350
135 1.00 7.85 0.20 350
250 2.00 7.85 1.18 350
100 1.20 7.85 0.19 350
ULSAB BODY STRUCTURE COST MODEL

Camanoe Associates IBIS Associates

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

contact person: contact person:

Dr. Richard Roth Jeff Dieffenbach
tel: 1-617-253-6487 tel: 1-781-239-0666
fax: 1-617-258-7471 fax: 1-781-239-0852
e-mail: rroth@mit.edu e-mail: JRDibis@aol.com
Camanoe Associates
in association with:
IBIS Associates &
The MIT Materials Systems Laboratory

MIT Materials Systems Laboratory

77 Massachusetts Avenue, Rm E40-202
Cambridge, MA 02139
USA

contact person:
Dr. Frank Field
tel: 1-617-253-2146
fax: 1-617-258-7471
e-mail: furd@mit.edu