K&B Brake Status Report II

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Brake System Status Report

2014-04-29 WEEK 18

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Topics1. Project Update2. Risk Assessment & Management

• Brake System • Schedule & Tasks• Budget

3. Interface Audits & Conflict Resolution4. Project Documentation & Resource Allocation5. Conclusions

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Project Update

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Events Since March Status Report (WEEK 14)• Received & Evaluated Prototype Testing Data

CAD Geometry – Soft Lines needed to be adjusted for new ROM in caliper fittings position Torque vs Time Plots revealed that pad material was operating below spec It is prototype data so take it with a grain of salt

• Fasterthnu Deliver Prototype ahead of Schedule Received Increased Size of Decal on Car Resulted in .5% lost sponsorship revenue for K&B Racing Increased decal size from 2.5” x 8” on L&R RW Endplate to 5” X 16” on Bottom of L&R Doors

• Test 1 @ Leguna Seca – April 21-25 Non-Catastrophic failure at 10 laps second session Soft lines failed at full lock due to increased fitting position delta Ackerman change was the culprit Increase length of soft lines was not implemented correctly; resulted in internal conflict At end of sessions 1 & 2 ,Prototype Pads showed significant wear well under spec

• Final Product Delivery Changed to May 13th

Product late by 1 standard week Delivery scheduled for Day 1 of test at Sebring Risk Mitigation Plans drawn up for affected systems

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Clarification of Technical Requirements for 3 Fasterthnu Systems

Brake SystemTotal weight of the vehicle : 2150 lbsTarget weight for the brake system : 130lbsWheel size : 398 x 223 x 36mmPackaging Area : 300 mm^2Operating Temp Range: -50C to 1000C

Dynamic Operating Characteristics : 100mph 0 in 75ft60mph 0 in 50ftProduce a min of 2.3 G’s of Acceleration under Braking

Caliper 6 PistonMaterial: Aluminum Titanium Piston Insert Weight (Kg): 2.35 to 2.5 Fluid Capacity: 116 - 121 mlPiston Size (mm) : 2x28 , 2x30 , 2x38Piston Area (cm2): 49.13 Mounting Offset (mm): 42 Pad Area (cm2): 80 Mounting Hole Dia. (mm): 12.23Pad Thickness (mm): 31,5 C-C Disc Thickness (mm): 35 C-C Disc Diameter (mm): 355 C-C - 390 C-C Mounting Hole Center (mm) 210

RotorMaterial: Carbon Ceramic MatrixMin Weight reduction fromSteel Rotor (10lbs) of 52% - 48% Bolt Pattern : 10 x 110(mm)OD: 210 (mm)Thickness: 35 (mm)

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Brake SystemRisk Assessment & Management

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K&B RacingRisk Identification

CAD Geometry revealed that due to the new position of the caliper, when the car setup called for maximum Ackerman, soft lines were to short, failure at fitting through shear load

Risk Assessment:

Probability: There are not a lot of sharp corners in the race track, therefore the probability of occurrence is considered moderate

Magnitude : It increases the braking distance and hence might result in crash. Therefore the impact of occurrence is high.

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K&B RacingRisk Scoring Matrix

for Quantification

Low Min Mod Sig High

Low

Min

Mod

Sig

High.9.8

.8

.7

.7

Probability ofOccurrence

(Po)

Consequence of Occurrence(Co)

.6

.6

.6

.5 .7.3

.1

.1

.2

.2

.3

.3

.2 .3 .5 .6

.4

.5

.4

.5

HighModLow

Legend

X

K&B RacingRisk Mitigation Plan

• Assess the Steering angle; its maximum limit and the minimum limit. • Assess the Ackerman change after the test run. • Check the CAD data for the validation.• Hence we can precisely know the extra length of soft line required.• Soft lines are fabricated, and spares kept.• Labor is charged to this project• Hence we can reduce the probability of occurrence to low and also the

probability of impact to low.

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K&B RacingRisk Scoring Matrix

for Quantification


Low

Min

Mod

Sig

High.9.8

.8

.7

.7


(Po)


.6

.6

.6

.5 .7.3

.1

.1

.2

.2

.3

.3

.2 .3 .5 .6

.4

.5

.4

.5

HighModLow

LegendX

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April 4 April 5 April 6

Assess the fitting position of soft lines

Assess the steering angle

CAD/CAM models constructed

calculate the range of motion in steering system

Softline lenght calculation Complete

We precisely know the extra lenght of soft line required

0.9

0.8

0.7

0.6

0.5

0.4

0.3

0.2

0.1

K&B Racing Risk management plan

Risk Management - By tracking the plan indicated on the risk waterfall chart, and following the steps outlined in the risk mitigation plan, the risks to the Braking can be monitored, controlled, and modified if necessary, thus minimizing the possibility of failure for the Brakes.

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K&B RacingReliability centered maintenance

• RCM is a process to establish the safe minimum level of maintenance• It leads to increase in cost effectiveness and a greater understanding of

the level of risk that our race team is managing• Routine maintenance program• Determines the type of maintenance appropriate for a given component.

K&B RacingFailure mode sheet

Component Functional Failure Failure mode Source of failure

Brake lines

Brake pads

Large braking distance

Ineffective braking

Brake lines leakage

Brake pads wear

Change in fitting positionAckerman change

High friction(Failure reported to Fasterthnu)

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rFunction Functional Failure Failure effect Maintenance and

Operation

Brake line It carries Brake fluid from master cylinder to the brake calipers

Brake pads Converts Kinetic energy of the car to thermal energy by friction

Insufficient brake fluid flow

Pads wear

Non catastrophic

Non catastrophic

Both

Maintenance

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Will the failure of components have an adverse effect on safety and critical

operation?

Is the item expendable Can redesign solve the problem permanently and cost effectively

Is there a CM technology that will give sufficient warning of the

impending

Is CM cost and priority justified

is there a PM task that will minimize functional

Is establishing redundancy cost and

priority justified

Accept risk of failure.Run to failure

Install redundancy unitProactive maintenance

Define PM task and schedule

Preventive maintenance

Define CM task and schedule

Predictive maintenance

No Yes

Redesign

Yes No No Yes

No yes

No Yes

No yes

No

Yes

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Schedule & TasksRisk Assessment & Management


Final Product being delivered late by 1 standard week, causing Test #2 to be pushed back.

Risk Assessment:

Probability: After contact with Fasterthnu, the probability of occurrence is scored as Moderate.

Magnitude: Although being late will push our scheduled test back slightly, the magnitude is scored as Minimum.

K&B Racing Risk Scoring Matrix

for Quantification


Low

Min

Mod

Sig

High.9.8

.8

.7

.7


(Po)


.6

.6

.6

.5 .7.3

.1

.1

.2

.2

.3

.3

.2 .3 .5 .6

.4

.5

.4

.5

HighModLow

Legend

X


• Reschedule Test #2 as early as possible.• Ensure that resources are allocated for the time crunch in preparation for

Test #2.• Stay in Contact with Fasterthnu to ensure that delivery is not pushed back

further.• Change and Develop Test Plan to maximize test value.


for Quantification


Low

Min

Mod

Sig

High.9.8

.8

.7

.7


(Po)


.6

.6

.6

.5 .7.3

.1

.1

.2

.2

.3

.3

.2 .3 .5 .6

.4

.5

.4

.5

HighModLow

Legend

X


Delivery of Final Product scheduled for Day 1 of Test #2 at Sebring. Due to missing the original deadline a risk exists for missing an early morning delivery at the test.

Risk Assessment:

Probability: Missing the first deadline has created a surplus of time to get the final system completed and delivered, therefore the probability of occurrence is Low.

Magnitude: Because this is a reschedule test and significant effort was involved to ensure that it could take place, another late delivery would be catastrophic. This results in a Consequence score of High.


for Quantification


Low

Min

Mod

Sig

High.9.8

.8

.7

.7


(Po)


.6

.6

.6

.5 .7.3

.1

.1

.2

.2

.3

.3

.2 .3 .5 .6

.4

.5

.4

.5

HighModLow

LegendX


• Ensure that we are setup and ready to go very early for the test day.• Have car prepped for assembly of new system. (Old system Removed)• Have tools and personnel prepared to install system when it arrives.• Ensure that Fasterthnu has an appropriate schedule to ensue early

morning delivery. (Stay in Contact)


for Quantification


Low

Min

Mod

Sig

High.9.8

.8

.7

.7


(Po)


.6

.6

.6

.5 .7.3

.1

.1

.2

.2

.3

.3

.2 .3 .5 .6

.4

.5

.4

.5

HighModLow

LegendX

K&B Racing Risk Management Plan

Risk Management – By following the created risk mitigation plans we can ensure that even though both of these events are for the most part, out of our control, that the impacts and consequences are minimized despite the inevitable, through resource allocation and proper communication.

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BudgetRisk Assessment & Management

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Budget is effected by Event 1: Product late by 1 standard week Event 2: Delivery scheduled for Day 1 of test at Sebring

Event OutcomesEvent 1

Best Case: Product in only late 1 standard week Moderate Case: Product is late 1 – 3 standard weeks lateWorst Case: Product is not shipped by end of season

Event 2Best Case: Product arrives on schedule early morning of day 1 test Moderate Case: Arrives at end of Day 1 testWorst Case: Arrives Day 2 of test

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Event Outcome Analysis :: Event 1Best Case: Product in only late 1 standard week Effect Occurrence : Likely• No increase in Testing Cost• $3600 off Total price as penalty to Fasterthnu• Engineering Labor increases 12.2% pre-test due to Test Plan changes• Costs 9% of Management Reserve for Labor

Moderate Case: Product is late 1 – 3 standard weeks lateEffect Occurrence : Possible• Max of 3 weeks or 21 days of penalty to Fasterthnu Final Payment• Increase labor, travel and testing costs

Worst Case: Product is not shipped by end of seasonEffect Occurrence : Not Likely• No increase in testing cost,• Last Payment to Fasterthnu not made• Litigation or Arbitration pursued

Event 1 Moderate Overall Costs %∆

Labor $69,424.50 19.47%Travel $26,144.10 40.21%Testing $55,000.00 71.88%Overhead $4,186.23 0.00%Long Term $19,592.72 0.00%

Design & Manufacture $127,155.00 -13.50%Total Project Cost $301,502.55 7.86%

Management Reserve Used is $25756.71 or %92.14

Event 1 Worst Overall Costs %∆

Labor $58,110.00 0.00%Travel $18,645.90 0.00%Testing $32,000.00 0.00%Overhead $4,186.23 0.00%Long Term $19,592.72 0.00%Design & Manufacture $98,049.00 -33.30%

Total Project Cost $230,583.85 -17.51%

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Event Outcome Analysis :: Event 2Best Case: Product arrives on schedule early morning of day 1 test Effect Occurrence : Likely• Similarly to Best Case of Event 1

Moderate Case: Arrives at end of Day 1 testEffect Occurrence : Possible• Possible increase in the engineering labor due to change in test plan for future tests

Worst Case: Arrives Day 2 of testEffect Occurrence : Not Likely• Leads to Moderate Case of Event 1

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Man Hours 108 6 6 4.5 30 20 36Labor per Task Total Cost RFP Mgmt (1) RFP Eng. (1) Brake Inst. (4) Brake Remv. (3) Test 1 (1) Test 2 (1) Report (1)Team Manager $14,220.00 $9,720.00 - - - $2,700.00 $1,800.00 -Technical Director $13,430.00 $9,180.00 - - - $2,550.00 $1,700.00 -Race Engineer $8,296.00 - $2,448.00 - - $2,040.00 $1,360.00 $2,448.00Asst. Engineer $4,026.00 - $1,188.00 - - $990.00 $660.00 $1,188.00Asst. Engineer $2,838.00 - - - - $990.00 $660.00 $1,188.00Data Engineer $1,450.00 - - - - $870.00 $580.00 -Damper Engineer $1,500.00 - - - - $900.00 $600.00 -Gearbox Mechanic $1,550.00 - - - - $930.00 $620.00 -Mechanic $1,200.00 - - - - $720.00 $480.00 -Mechanic $1,200.00 - - - - $720.00 $480.00 -Mechanic $1,452.00 - - $144.00 $108.00 $720.00 $480.00 -Mechanic $1,452.00 - - $144.00 $108.00 $720.00 $480.00 -Mechanic $1,452.00 - - $144.00 $108.00 $720.00 $480.00 -Mechanic $1,452.00 - - $144.00 $108.00 $720.00 $480.00 - RFP Mgmt RFP Eng. Brake Inst Brake Remv. Test 1 Test 2 Report Cost Per Task $18,900.00 $3,636.00 $2,304.00 $1,296.00 $16,290.00 $10,860.00 $4,824.00 Cost Per Occurrence $18,900.00 $3,636.00 $576.00 $432.00 $16,290.00 $10,860.00 $4,824.00

Cost Per Day $1,575.00 $909.00 $2,304.00 $1,296.00 $16,290.00 $5,430.00 $1,206.00

• Budget Cost Structure now includes labor and time allotted for brake system installs

• Brake installs on test days are included in testing labor

Overall CostsLabor $58,110.00Travel $18,645.90Testing $32,000.00Overhead $4,186.23Long Term $19,592.72Design & Manufacture $147,000.00

Total Project Cost $279,534.85

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Interface Audits&

Conflict Resolution

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System & Component Interface Managed by : Engineering

Mitigation Tools : CAD, FEA, Suppliers, Process Change, elevate responseResponse Elevation: Technical Director Team Manger Owners SponsorsOutcome: Cancelation, Accepted Risk Feedback to Eng. Mitigation tools

Example:

CAD geometry was received from Fasterthu -> Inspected using CAD -> Engineers Changed Supply channels request longer soft line -> Draws up new spec., Makes Engineering drawings -> Notifies fabrication and chief mechanic via email with work request -> Save plans and new test plan assembly change order to network storage Issue Mitigated

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Labor Force InterfaceManaged by: Team Manager

Mitigation Tools: Shift change, 3rd party labor, Labor Restructuring(Hire & Fire), Contract Renegotiation, Conflict ResolutionResponse elevation: Owner(s) SponsorsOutcome : Cancelation, Accepted Risk Feedback to Management Mitigation tools

Conflict resolution : The Burns Conflict Resolution Method

• All managers are attend Conflict and Confrontation Seminars yearly held by the Burns foundation

• The same foundation also produces the race teams Sexual Harassment and Ethics Training documentation that all New Hires must read and pass a test on.

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Project Documentation&

Resource Allocation

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Project DocumentationTools• Technical Reports completed either by Fasterthnu or internal engineering staff• Excel Based Schedules and Budgets • Test Plans• Internal Emails and Meetings

Documents• RFP • RFP Amendment I• RFP Amendment II• Fasterthnu Technical Proposal• Technical Reports• Cost Reports• Test Plans

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Schedule Monitoring

Project reports• Testing • Fasterthnu Data Analysis• Race Reports

Budget reportsUse excel and are project specific for inter-team operations10% Standard Management ReserveTop-Down Budgeting dictates reports at project start and endpoint only

Weekly Management MeetingAddresses Management specific tasks and sponsor critical Weekly Team Meeting

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Date Session Driver Distance T-Session Lap Time Fuel Mileage Laps13-May-14 Day 1 CRASH 1.658 600min 1.3 0.5

Run Laps Test Plans Tires T-Pit (min) T-Run (min) Miles F-Start F-used F -Left F-Add Tire Set Tire Miles 1 20 Shake down 1008 0 26 33.16 22 10 12 0 0 Inspect Pads/ Tire pressure Adjustments 5 2 10 1st Test Run BRAKE 1008 0 13 16.58 17 5 12 0 0 Change pads/Driver feed back 25 3 10 2nd Test Run BRAKE 1008 0 13 16.58 14.5 5 9.5 0 1008 66.32 Review Pads/Chassis changes 10 4 8 3rd Test Run BRAKE 1010 0 10.4 13.264 9.5 4 5.5 13 Review Pads/Compare Set 1&2 10 5 22 4th Test Run BRAKE 1010 0 28.6 36.476 20 11 9 0 Review Data/ Pull Driver 25 6 10 Brake Pressure Adjust 1010 0 13 16.58 7.5 5 2.5 10 Driver thoughts on car 10 1010 66.32 7 5 Chassis adjustment 1012 0 6.5 8.29 12.5 2.5 10 0 Data/Driver feed back 15 8 5 Feed back on Brake/changes 1012 0 6.5 8.29 8.5 2.5 6 20 Review Pads and changes 5 9 5 presure/ Chassis adjustments 1012 0 6.5 8.29 23.5 2.5 21 0 Review Changes/ Driver Feed back 5 10 22 Minor change Long Test 1012 0 28.6 36.476 19.5 11 8.5 0 Pull Driver Lunch Discuss Results 65 11 10 Shake down 1014 0 13 16.58 8.5 5 3.5 10 1012 61.346 Minor change/ check brakes 5 12 15 New Pads 1014 0 19.5 24.87 13.5 7.5 6 0 analyze pads 10 13 10 Chassis adjustment 1014 0 13 16.58 6 5 1 21

Driver thoughts on car 5 14 3 Make changes to car 1014 0 3.9 4.974 22 1.5 20.5 0 Adjust Chassis 10 1014 63.004

15 5 Test Chassis 1016 6.5 8.29 20.5 2.5 18 Make changes for long run 15

16 35 Race Analysis 1016 0 45.5 58.03 18 17.5 0.5 15 Pull Driver/ Review Data 30

17 13 Chassis adjustment 1018 0 16.9 21.554 15.5 6.5 9 0 minor adjustments 20 1016 66.32

18 15 Chassis adjustment 1018 0 19.5 24.87 10.5 7.5 3 10 Driver Feedback on Changes 20

19 10 Fianl Run 1018 13 16.58 13 5 8 1018 63.004 Total time 592.9 End of test Debreif 60

Sebring Test Plan Day 1

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Sebring Test Plan Day 1Mitigation Plan for Late Delivery of Brake systems


Run Laps Test Plans Tires T-Pit (min) T-Run (min) Miles F-Start F-used F -Left F-Add Tire Set Tire Miles 1 20 Shake down 1008 0 26 33.16 22 10 12 0 0 Inspect Pads/ Tire pressure Adjustments 5 2 10 1st Test Run 1008 0 13 16.58 17 5 12 0 0 Driver feed back 25 3 10 2nd Test Run 1008 0 13 16.58 14.5 5 9.5 0 1008 66.32 Chassis changes 10 4 8 3rd Test Run 1010 0 10.4 13.264 9.5 4 5.5 13 Minor change to Chassis 10 5 22 4th Test Run 1010 0 28.6 36.476 20 11 9 0 Review Data/ Pull Driver 25 6 10 Brake Pressure Adjust 1010 0 13 16.58 7.5 5 2.5 10 Driver thoughts on car 10 1010 66.32 7 5 Chassis adjustment 1012 0 6.5 8.29 12.5 2.5 10 0 Data/Driver feed back 15 8 5 Feed back on Brake/changes 1012 0 6.5 8.29 8.5 2.5 6 20 Review Pads and changes 5 9 5 presure/ Chassis adjustments 1012 0 6.5 8.29 23.5 2.5 21 0 Review Changes/ Driver Feed back 5

10 22 Minor change Long Test 1012 0 28.6 36.476 19.5 11 8.5 0 Pull Driver Lunch Discuss Results 65 Install new Brake system 240 1012 61.346

11 15 Shake down 1014 0 19.5 24.87 8.5 7.5 1 0 Test brakes for test tmrw End of test Debreif 60

Total time 586.6

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Date Session Driver Distance T-Session Lap Time Fuel Mileage Laps14-May-14 Day 2` CRASH 1.658 600min 1.3 0.5

Run Laps Test Plans Tires T-Pit (min) T-Run (min) Miles F-Start F-used F -Left F-Add Tire Set Tire Miles 1 20 Shake down 1008 0 26 33.16 22 10 12 0 0 Inspect Pads/ Tire pressure Adjustments 5 2 10 1st Test Run BRAKE 1008 0 13 16.58 17 5 12 0 0 Change pads/Driver feed back 25 3 10 2nd Test Run BRAKE 1008 0 13 16.58 14.5 5 9.5 0 1014 66.32 Review Pads/Chassis changes 10 4 8 3rd Test Run BRAKE 1010 0 10.4 13.264 9.5 4 5.5 13 Review Pads/Compare Set 1&2 10 5 22 4th Test Run BRAKE 1010 0 28.6 36.476 20 11 9 0 Review Data/ Pull Driver 25 6 10 Brake Pressure Adjust 1010 0 13 16.58 7.5 5 2.5 10 Driver thoughts on car 10 1016 66.32 7 5 Chassis adjustment 1012 0 6.5 8.29 12.5 2.5 10 0 Data/Driver feed back 15 8 5 Feed back on Brake/changes 1012 0 6.5 8.29 8.5 2.5 6 20 Review Pads and changes 5 9 5 presure/ Chassis adjustments 1012 0 6.5 8.29 23.5 2.5 21 0 Review Changes/ Driver Feed back 5

10 22 Minor change Long Test 1012 0 28.6 36.476 19.5 11 8.5 0 Pull Driver Lunch Discuss Results 65

11 10 Shake down 1014 0 13 16.58 8.5 5 3.5 10 1018 61.346 Minor change/ check brakes 5

12 15 New Pads 1014 0 19.5 24.87 13.5 7.5 6 0 analyze pads 10

13 10 Chassis adjustment 1014 0 13 16.58 6 5 1 21 Driver thoughts on car 5

14 3 Make changes to car 1014 0 3.9 4.974 22 1.5 20.5 0 Ajust Chassis 10 1020 63.004

15 5 Test Chassis 1016 6.5 8.29 20.5 2.5 18 Make changes for long run 15

16 35 Race Analysis 1016 0 45.5 58.03 18 17.5 0.5 15 Pull Driver/ Review Data 30

17 13 Chassis adjustment 1018 0 16.9 21.554 15.5 6.5 9 0 minor adjustments 20 1022 66.32

18 15 Chassis adjustment 1018 0 19.5 24.87 10.5 7.5 3 10 Driver Feedback on Changes 20

19 10 Fianl Run 1018 13 16.58 13 5 8 1024 63.004 Total time 592.9 End of test Debreif 60

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Run Laps Test Plans Tires T-Pit (min) T-Run (min) Miles F-Start F-used F -Left F-Add Tire Set Tire Miles 1 20 Install new Brake system 240 0 Shake down 1014 0 19.5 24.87 8.5 7.5 1 0 2 10 Test brakes for test tmrw 0 Lunch 60 3 10 Shake down 1008 0 26 33.16 22 10 12 0 1008 66.32 Inspect Pads/ Tire pressure Adjustments 5 4 8 1st Test Run 1008 0 13 16.58 17 5 12 0 Driver feed back 25 5 22 2nd Test Run 1008 0 13 16.58 14.5 5 9.5 0 Chassis changes 10 6 10 3rd Test Run 1010 0 10.4 13.264 9.5 4 5.5 13 Minor change to Chassis 10 1010 66.32 7 5 4th Test Run 1010 0 28.6 36.476 20 11 9 0 Review Data/ Pull Driver 25 8 5 Brake Pressure Adjust 1010 0 13 16.58 7.5 5 2.5 10 Driver thoughts on car 10 9 5 Chassis adjustment 1012 0 6.5 8.29 12.5 2.5 10 0 Data/Driver feed back 15

10 22 Feed back on Brake/changes 1012 0 6.5 8.29 8.5 2.5 6 20 Review Pads and changes 5 presure/ Chassis adjustments 1012 0 6.5 8.29 23.5 2.5 21 0 1012 61.346 Review Changes/ Driver Feed back 5

11 15 Minor change Long Test 1012 0 28.6 36.476 19.5 11 8.5 0 Pull Driver Discuss Results 65

Total time 586.6

Sebring Test Plan Day 2Mitigation Plan for Late Delivery of Brake systems

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CONTROLSAsset Control Cost/Hr RFP Mgmt RFP Eng. Brake Inst. Brake Remv. Test 1 Test 2 ReportTeam Manager $90.00 Y N N N Y Y NTechnical Director $85.00 Y N N N Y Y NRace Engineer $68.00 N Y N N Y Y YAsst. Engineer $33.00 N Y N N Y Y YAsst. Engineer $33.00 N N N N Y Y YData Engineer $29.00 N N N N Y Y NDamper Engineer $30.00 N N N N Y Y NGearbox Mechanic $31.00 N N N N Y Y NMechanic $24.00 N N N N Y Y NMechanic $24.00 N N N N Y Y NMechanic $24.00 N N Y Y Y Y NMechanic $24.00 N N Y Y Y Y NMechanic $24.00 N N Y Y Y Y NMechanic $24.00 N N Y Y Y Y N

Resource Management• Budgets are generated from using a top down approach with key approval for spending coming from the owners

• This chart was used to assign and allot for human resources on the project

• All employees who were apart on this project are tracked and linked to tasks here

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Man Hours per Day 9 INPUTS CONTROLS Labor Rate & Time $/Hr $/Day Asset Control Cost/Hr RFP Mgmt RFP Eng. Brake Inst. Brake Remv. Test 1 Test 2 Report Team Manager $90.00 $810.00 Team Manager $90.00 Y N N N Y Y N Technical Director $85.00 $765.00 Technical Director $85.00 Y N N N Y Y N Race Engineer $68.00 $612.00 Race Engineer $68.00 N Y N N Y Y Y Asst. Engineer $33.00 $297.00 Asst. Engineer $33.00 N Y N N Y Y Y Data Engineer $29.00 $261.00 Asst. Engineer $33.00 N N N N Y Y Y Damper Engineer $30.00 $270.00 Data Engineer $29.00 N N N N Y Y N Gearbox Mechanic $31.00 $279.00 Damper Engineer $30.00 N N N N Y Y N Mechanic $24.00 $216.00 Gearbox Mechanic $31.00 N N N N Y Y N Per Diem $3.33 $30.00 Mechanic $24.00 N N N N Y Y N

Mechanic $24.00 N N N N Y Y N

Sub Tasks Time Days Man Hours Occurrence Mechanic $24.00 N N Y Y Y Y N RFP Management 12 108 1 Mechanic $24.00 N N Y Y Y Y N RFP Engineering 4 36 1 Mechanic $24.00 N N Y Y Y Y N Brake Install 1 6 4 Mechanic $24.00 N N Y Y Y Y N Brake Removal 1 4.5 3 Test 1 3 30 1 Man Hours 108 6 6 4.5 30 20 36 Test 2 2 20 1 Labor per Task Total Cost RFP Mgmt (1) RFP Eng. (1) Brake Inst. (4) Brake Remv. (3) Test 1 (1) Test 2 (1) Report (1) Report Writing 4 36 1 Team Manager $14,220.00 $9,720.00 - - - $2,700.00 $1,800.00 - Technical Director $13,430.00 $9,180.00 - - - $2,550.00 $1,700.00 - Race Engineer $8,296.00 - $2,448.00 - - $2,040.00 $1,360.00 $2,448.00 Asst. Engineer $4,026.00 - $1,188.00 - - $990.00 $660.00 $1,188.00 Asst. Engineer $2,838.00 - - - - $990.00 $660.00 $1,188.00 Data Engineer $1,450.00 - - - - $870.00 $580.00 - Damper Engineer $1,500.00 - - - - $900.00 $600.00 - Gearbox Mechanic $1,550.00 - - - - $930.00 $620.00 - Facilty Costs Amount Min. Man Hours Mechanic $1,200.00 - - - - $720.00 $480.00 - Laguna seca $9,000.00 10 Mechanic $1,200.00 - - - - $720.00 $480.00 - Kansas $11,500.00 10 Mechanic $1,452.00 - - $144.00 $108.00 $720.00 $480.00 - Mechanic $1,452.00 - - $144.00 $108.00 $720.00 $480.00 - Mechanic $1,452.00 - - $144.00 $108.00 $720.00 $480.00 - Mechanic $1,452.00 - - $144.00 $108.00 $720.00 $480.00 - Road Travel Costs Fuel Cost/Gal. MPG Car $3.50 25 RFP Mgmt RFP Eng. Brake Inst Brake Remv. Test 1 Test 2 Report Van $3.50 15 Cost Per Task $18,900.00 $3,636.00 $2,304.00 $1,296.00 $16,290.00 $10,860.00 $4,824.00

Semi Rig $3.75 5 Cost Per Occurrence $18,900.00 $3,636.00 $576.00 $432.00 $16,290.00 $10,860.00 $4,824.00

Cost Per Day $1,575.00 $909.00 $2,304.00 $1,296.00 $16,290.00 $5,430.00 $1,206.00 Testing Expenses Facilty w/Travel Laguna Seca Seabring Laguna seca $9,000.00 $20,147.70 Test Days Duration Test Days Duration Sebring $23,000.00 $23,000.00 Destination Laguna Seca 3 5 Destination Sebring 2 4 Per Diem Per Diem Total Program Cost Cost Personnel 12 $1,800.00 Personnel 12 $1,440.00 Non- Recurring Labor $54,510.00 Transportation Rental Price Transportation Rental Price Recurring Labor $3,600.00 Est Milage Fuel Cost # of Vech. 78 Est Milage Fuel Cost # of Vech. 78 Testing $32,000.00 Semi Rig 4590 $3,442.50 1 Rental Total Semi Rig 2060 $1,545.00 1 Rental Total Travel $18,645.90 Car 45 $25.20 4 $1,585.20 Car 45 $25.20 4 $1,273.20 Flights Flights Total $108,755.90 Tickets Cost Total Tickets Cost Total 10 $655.00 $6,550.00 10 $655.00 $6,550.00 Hotel Hotel Rooms Nights Cost/Night Total Rooms Nights Cost/Night Total 9 4 $120.00 $4,320.00 9 3 $120.00 $3,240.00 Repeat Repeat Trip Cost $11,147.70 1 Trip Cost $7,498.20 1 Complete Cost $11,147.70 Complete Cost $7,498.20

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53

MONTHLY OVERHEAD COST Monthly Overhead

Type Items Amount Utilities $610.00 Insurance

Utilities

Property $330.00Electricity $100.00 Liability $300.00Heating Gas $150.00 Administrative $7,400.00Water $60.00 Rent $2,000.00Sewerage $50.00 Monthly Total $10,640.0

0Internet Connection $100.00 Phone Service $150.00 Project Overhead Calculation Days 27

Insurance % of Facilty Usage per Month 39% Project Overhead $4,186.23

Property

Machineries and Equipments $100.00 Furnitures $40.00 Computers $40.00 Fixtures $150.00

Liability Accident at job site $150.00 Company vehicle $150.00

Administrative

Accounting $900.00 security $700.00 HR and personal $800.00 Salaries and fringe benefit $5,000.00

Rent office space rent $2,000.00

Long-term Costs

New System Costs Quantity Cost Each Cost

FasterThnU Carbon Ceramic Brake Package 1.00 $147,000 $147,000.00

Parts Needed to Update Car Quantity Cost Each Cost

Brake Fluid 13.00 $58.96 $766.48 Brake Line 100.00 $2.20 $220.00

Brake Pressure Sensors 8.00 $38.28 $306.24

System Upkeep Quantity Cost Each Cost

Lathe Tooling 1.00 $700.00 $700.00laksfdjla;kdjf;alskjf laksfdjla;kdjf;alskjf laksfdjla;kdjf;alskjf

Fasterthu DecalArea Sym? H (in) W (in) $/in^2 TotalRW Endplate Y 2 6 250 $3,000.00Bottom of Door Y 5 16 220 $17,600.00

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54

Conclusions

K&B Racing

K&B RacingFinal Verdict on Fasterthnu Business Relationship

Brake System Positives• Final product met RFP Specifications• Fasterthnu were Professional and Prompt • Fasterthnu Addressed Concerns Immediately• Pad Wear Issues were Fixed Without Issue • Milestone 1 Early• Milestone 2 On Time

Brake System Negatives• Milestone 3 late by one week• Pads Life is not Ideal may be inferior to Competitor• Competitors Pad Life may exceed Fasterthnu Achieved Results

K&B Racing


Lessons Learned• Future outsourcing endeavors will focus on smaller sub-systems or parts only

• Negotiate for Steeper Penalties for Missing Milestones

• Poor Company Interfacing can Lead to Conflict

• Always Have a Contingency Plan

K&B Racing


Fasterthnu Comments on the Project• Happy with Sticker Placement on Door• Will Attend 3 More Events to Assist K&B Racing and Gather

On-Track Data• Have an Interest in Continuing the Business Relationship

with K&B Racing• Have Expressed Sincere Regret in Missing Milestone #3 : Delivery Of 3 Complete Brake Systems

K&B Racing

K&B RacingInternal Project Audit and Assessment

• Poor Communication Between Engineering Staff and Fabricators lead to Soft Line Failure

• External and Internal Conflicts Can Appear at Any Time and Must Be Dealt With Professionally

• Company Interfacing is Important and Must Have Clearly Defined Processes

• Schedule and Budget Planning helped to mitigate Lateness of Milestone #3 at Little Expense

• In Racing Few Events Ever Occur as Planned, Risk Mitigation and Planning is an Important Tool

Overall CostsLabor $58,110.00Travel $18,645.90Testing $32,000.00Overhead $4,186.23Long Term $19,592.72Design & Manufacture $147,000.00

Total Project Cost $279,534.85