K&B Racing

Brake System Status Report

2014-04-29

WEEK 18

K&B Racing
Topics
1. Project Update 2. Risk Assessment & Management
Brake System Schedule & Tasks Budget

3. Interface Audits & Conflict Resolution 4. Project Documentation & Resource Allocation 5. Conclusions
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Project Update

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K&B Racing
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 System
Total weight of the vehicle : 2150 lbs Target weight for the brake system : 130lbs Wheel size : 398 x 223 x 36mm Packaging Area : 300 mm^2 Operating Temp Range: -50C to 1000C

Caliper
6 Piston Material: Aluminum Titanium Piston Insert Weight (Kg): 2.35 to 2.5 Fluid Capacity: 116 - 121 ml Piston Size (mm) : 2x28 , 2x30 , 2x38 Piston Area (cm2): 49.13 Mounting Offset (mm): 42 Pad Area (cm2): 80 Mounting Hole Dia. (mm): 12.23 Pad 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

Dynamic Operating Characteristics :

100mph 0 in 75ft 60mph 0 in 50ft Produce a min of 2.3 Gs of Acceleration under Braking

Rotor
Material: Carbon Ceramic Matrix Min Weight reduction from Steel Rotor (10lbs) of 52% - 48% Bolt Pattern : 10 x 110(mm) OD: 210 (mm) Thickness: 35 (mm)

K&B Racing
Brake System Risk Assessment & Management

K&B Racing

K&B Racing
Risk 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.

K&B Racing
Risk Scoring Matrix for Quantification
.3
High

.5

.7

.8

.9

.2
Sig

.4 .3 .3 .2
Min Mod

.6 .5

.7 .6 .5

.8 .7

Probability of Occurrence Mod (Po)

Min

.2 .1

.4 .3
Sig

.6

.1
Low

.5
High

.6

Legend
High Mod Low Low Consequence of Occurrence (Co)

K&B Racing
Risk 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.

K&B Racing
Risk Scoring Matrix for Quantification
.3
High

.5

.7

.8

.9

.2
Sig

.4 .3 .3 .2
Min Mod

.6 .5

.7 .6 .5

.8 .7

Probability of Occurrence Mod (Po)

Min

.2 .1

.4 .3
Sig

.6

Low

Legend
High Mod Low

X
Low

.1

.5
High

.6

Consequence of Occurrence (Co)

K&B Racing
Assess the steering angle Assess the fitting position of soft lines
0.9 0.8 0.7

CAD/CAM models constructed

0.6

0.5

0.4

calculate the range of motion in steering system

0.3

Softline lenght calculation Complete

We precisely know the extra lenght of soft line required

0.2

0.1 April 4 April 5 April 6

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.

K&B Racing
Reliability 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 Racing
Failure mode sheet
Component
Brake lines

Functional Failure
Large braking distance

Failure mode
Brake lines leakage

Source of failure
Change in fitting position Ackerman change

Brake pads

Ineffective braking

Brake pads wear

High friction(Failure reported to Fasterthnu)

K&B Racing r
Function Functional Failure Failure effect Non catastrophic Maintenance and Operation Both Brake line Insufficient brake It carries Brake fluid fluid flow from master cylinder to the brake calipers Brake pads Converts Kinetic energy of the car to thermal energy by friction

Pads wear

Non catastrophic

Maintenance

K&B Racing
No Is the item expendable Will the failure of components have an adverse effect on safety and critical operation? Yes Can redesign solve the problem permanently and cost effectively Yes No Is there a CM technology that will give sufficient warning of the impending No Yes

Redesign
No yes Is CM cost and priority justified

is there a PM task that will minimize functional No Is establishing redundancy cost and priority justified Yes Accept risk of failure. Run to failure Install redundancy unit Proactive maintenance yes

No

Yes

No

Define PM task and schedule Preventive maintenance

Define CM task and schedule Predictive maintenance

K&B Racing
Schedule & Tasks Risk Assessment & Management

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Risk Identification
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
.3
High

.5

.7

.8

.9

.2
Sig

.4 .3

.6 .5

.7 .6 .5

.8 .7

Probability of Occurrence Mod (Po)

Min

.2

X
.1 .3 .2
Min Mod

.4 .3
Sig

.6

.1
Low

.5
High

.6

Legend
High Mod Low Low Consequence of Occurrence (Co)

K&B Racing
Risk Mitigation Plan
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.

K&B Racing
Risk Scoring Matrix for Quantification
.3
High

.5

.7

.8

.9

.2
Sig

.4 .3 .3 .2
Min Mod

.6 .5

.7 .6 .5

.8 .7

Probability of Occurrence Mod (Po)

Min

.2 .1

.4 .3
Sig

.6

.1
Low

.5
High

.6

Legend
High Mod Low Low Consequence of Occurrence (Co)

K&B Racing
Risk Identification
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.

K&B Racing
Risk Scoring Matrix for Quantification
.3
High

.5

.7

.8

.9

.2
Sig

.4 .3 .3 .2
Min Mod

.6 .5

.7 .6 .5

.8 .7

Probability of Occurrence Mod (Po)

Min

.2 .1

.4 .3
Sig

.6

.1
Low

.5

X
High

.6

Legend
High Mod Low Low Consequence of Occurrence (Co)

K&B Racing
Risk Mitigation Plan
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)

K&B Racing
Risk Scoring Matrix for Quantification
.3
High

.5

.7

.8

.9

.2
Sig

.4 .3 .3 .2
Mod

.6 .5

.7 .6 .5

.8 .7

Probability of Occurrence Mod (Po)

Min

.2 .1

.4 .3
Sig

.6

.1
Low

X
Min

.5
High

.6

Legend
High Mod Low Low Consequence of Occurrence (Co)

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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Budget Risk 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 Outcomes
Event 1 Best Case: Product in only late 1 standard week Moderate Case: Product is late 1 3 standard weeks late Worst Case: Product is not shipped by end of season Event 2 Best Case: Product arrives on schedule early morning of day 1 test Moderate Case: Arrives at end of Day 1 test Worst Case: Arrives Day 2 of test
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Event Outcome Analysis :: Event 1
Best 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 late Effect Occurrence : Possible Max of 3 weeks or 21 days of penalty to Fasterthnu Final Payment Increase labor, travel and testing costs
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

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

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 2 Best 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 test Effect Occurrence : Possible Possible increase in the engineering labor due to change in test plan for future tests Worst Case: Arrives Day 2 of test Effect Occurrence : Not Likely Leads to Moderate Case of Event 1

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K&B Racing
Labor per Task Team Manager Technical Director Race Engineer Asst. Engineer Asst. Engineer Data Engineer Damper Engineer Gearbox Mechanic Mechanic Mechanic Mechanic Mechanic Mechanic Mechanic Man Hours Total Cost $14,220.00 $13,430.00 $8,296.00 $4,026.00 $2,838.00 $1,450.00 $1,500.00 $1,550.00 $1,200.00 $1,200.00 $1,452.00 $1,452.00 $1,452.00 $1,452.00 108 RFP Mgmt (1) $9,720.00 $9,180.00 RFP Mgmt $18,900.00 $18,900.00 $1,575.00 6 RFP Eng. (1) $2,448.00 $1,188.00 RFP Eng. $3,636.00 $3,636.00 $909.00 6 Brake Inst. (4) $144.00 $144.00 $144.00 $144.00 Brake Inst $2,304.00 $576.00 $2,304.00 4.5 Brake Remv. (3) $108.00 $108.00 $108.00 $108.00 Brake Remv. $1,296.00 $432.00 $1,296.00 30 Test 1 (1) $2,700.00 $2,550.00 $2,040.00 $990.00 $990.00 $870.00 $900.00 $930.00 $720.00 $720.00 $720.00 $720.00 $720.00 $720.00 Test 1 $16,290.00 $16,290.00 $16,290.00 20 Test 2 (1) $1,800.00 $1,700.00 $1,360.00 $660.00 $660.00 $580.00 $600.00 $620.00 $480.00 $480.00 $480.00 $480.00 $480.00 $480.00 Test 2 $10,860.00 $10,860.00 $5,430.00 36 Report (1) $2,448.00 $1,188.00 $1,188.00 Report $4,824.00 $4,824.00 $1,206.00

Cost Per Task Cost Per Occurrence Cost Per Day

Budget Cost Structure now includes labor and time allotted for brake system installs Brake installs on test days are included in testing labor

Overall Costs

Labor Travel Testing Overhead Long Term Design & Manufacture Total Project Cost

$58,110.00 $18,645.90 $32,000.00 $4,186.23 $19,592.72 $147,000.00 $279,534.85 35

K&B Racing
Interface Audits & Conflict Resolution
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K&B Racing
System & Component Interface
Managed by : Engineering
Mitigation Tools : CAD, FEA, Suppliers, Process Change, elevate response Response Elevation: Technical Director Team Manger Owners Sponsors Outcome: 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 Interface
Managed by: Team Manager
Mitigation Tools: Shift change, 3rd party labor, Labor Restructuring(Hire & Fire), Contract Renegotiation, Conflict Resolution Response elevation: Owner(s) Sponsors Outcome : 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 Documentation
Tools
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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K&B Racing
Schedule Monitoring
Project reports Testing Fasterthnu Data Analysis Race Reports Budget reports Use excel and are project specific for inter-team operations 10% Standard Management Reserve Top-Down Budgeting dictates reports at project start and endpoint only
Weekly Management Meeting Addresses Management specific tasks and sponsor critical Weekly Team Meeting

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K&B Racing
Date 13-May-14 Run Laps 1 20 0 2 10 0 3 10 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 8 22 10 5 5 5 22 10 15 10 3 5 35 13 15 10 Session Day 1 Driver CRASH Test Plans Shake down Inspect Pads/ Tire pressure Adjustments 1st Test Run BRAKE Change pads/Driver feed back 2nd Test Run BRAKE Review Pads/Chassis changes 3rd Test Run BRAKE Review Pads/Compare Set 1&2 4th Test Run BRAKE Review Data/ Pull Driver Brake Pressure Adjust Driver thoughts on car Chassis adjustment Data/Driver feed back Feed back on Brake/changes Review Pads and changes presure/ Chassis adjustments Review Changes/ Driver Feed back Minor change Long Test Pull Driver Lunch Discuss Results Shake down Minor change/ check brakes New Pads analyze pads Chassis adjustment Driver thoughts on car Make changes to car Adjust Chassis Test Chassis Make changes for long run Race Analysis Pull Driver/ Review Data Chassis adjustment minor adjustments Chassis adjustment Driver Feedback on Changes Fianl Run End of test Debreif Distance 1.658 Tires 1008 1008 1008 1010 1010 1010 1012 1012 1012 1012 1014 1014 1014 1014 1016 1016 1018 1018 1018 60 15 0 30 0 20 0 20 T-Session 600min T-Pit (min) 0 5 0 25 0 10 0 10 0 25 0 10 0 15 0 5 0 5 0 65 0 5 0 10 0 5 0 10 Lap Time Fuel Mileage 1.3 0.5 T-Run (min) Miles 26 33.16 13 13 10.4 28.6 13 6.5 6.5 6.5 28.6 13 19.5 13 3.9 6.5 45.5 16.9 19.5 13 16.58 16.58 13.264 36.476 16.58 8.29 8.29 8.29 36.476 16.58 24.87 16.58 4.974 8.29 58.03 21.554 24.87 16.58 Laps F-Start 22 17 14.5 9.5 20 7.5 12.5 8.5 23.5 19.5 8.5 13.5 6 22 20.5 18 15.5 10.5 13 F-used 10 5 5 4 11 5 2.5 2.5 2.5 11 5 7.5 5 1.5 2.5 17.5 6.5 7.5 5 F -Left 12 12 9.5 5.5 9 2.5 10 6 21 8.5 3.5 6 1 20.5 18 0.5 9 3 8 15 0 1016 10 1018 63.004 Total time 592.9 66.32 F-Add 0 0 0 13 0 10 1010 0 20 0 0 10 0 21 0 1014 63.004 1012 61.346 66.32 1008 66.32 Tire Set Tire Miles

Sebring Test Plan Day 1

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Date 13-May-14 Run Laps 1 20 0 2 10 0 3 10 4 5 6 7 8 22 10 5 Session Day 1 Driver CRASH Test Plans Shake down Inspect Pads/ Tire pressure Adjustments 1st Test Run Driver feed back 2nd Test Run Chassis changes 3rd Test Run Minor change to Chassis 4th Test Run Review Data/ Pull Driver Brake Pressure Adjust Driver thoughts on car Chassis adjustment Data/Driver feed back Feed back on Brake/changes Review Pads and changes presure/ Chassis adjustments Review Changes/ Driver Feed back Minor change Long Test Pull Driver Lunch Discuss Results Install new Brake system Shake down Test brakes for test tmrw End of test Debreif Distance 1.658 Tires 1008 1008 1008 1010 1010 1010 1012 T-Session 600min T-Pit (min) 0 5 0 25 0 10 0 10 0 25 0 10 0 15 0 5 0 5 0 65 240 0 60 Lap Time Fuel Mileage 1.3 0.5 T-Run (min) Miles 26 33.16 13 13 10.4 28.6 13 6.5 16.58 16.58 13.264 36.476 16.58 8.29 Laps F-Start 22 17 14.5 9.5 20 7.5 12.5 F-used 10 5 5 4 11 5 2.5 F -Left 12 12 9.5 5.5 9 2.5 10 F-Add 0 0 0 13 0 10 1010 0 66.32 1008 66.32 Tire Set Tire Miles

8
9 10

5
5 22

1012
1012 1012

6.5
6.5 28.6

8.29
8.29 36.476

8.5
23.5 19.5

2.5
2.5 11

6
21 8.5

20
0 0 1012 61.346

11

15

1014

19.5

24.87

8.5

7.5

Total time

586.6

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

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K&B Racing
Date 14-May-14 Run Laps 1 20 0 2 10 0 3 10 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 8 22 10 5 5 5 22 10 15 10 3 5 35 13 15 10 Session Day 2` Driver CRASH Test Plans Shake down Inspect Pads/ Tire pressure Adjustments 1st Test Run BRAKE Change pads/Driver feed back 2nd Test Run BRAKE Review Pads/Chassis changes 3rd Test Run BRAKE Review Pads/Compare Set 1&2 4th Test Run BRAKE Review Data/ Pull Driver Brake Pressure Adjust Driver thoughts on car Chassis adjustment Data/Driver feed back Feed back on Brake/changes Review Pads and changes presure/ Chassis adjustments Review Changes/ Driver Feed back Minor change Long Test Pull Driver Lunch Discuss Results Shake down Minor change/ check brakes New Pads analyze pads Chassis adjustment Driver thoughts on car Make changes to car Ajust Chassis Test Chassis Make changes for long run Race Analysis Pull Driver/ Review Data Chassis adjustment minor adjustments Chassis adjustment Driver Feedback on Changes Fianl Run End of test Debreif Distance 1.658 Tires 1008 1008 1008 1010 1010 1010 1012 1012 1012 1012 1014 1014 1014 1014 1016 1016 1018 1018 1018 60 15 0 30 0 20 0 20 T-Session 600min T-Pit (min) 0 5 0 25 0 10 0 10 0 25 0 10 0 15 0 5 0 5 0 65 0 5 0 10 0 5 0 10 Lap Time 1.3 T-Run (min) 26 13 13 10.4 28.6 13 6.5 6.5 6.5 28.6 13 19.5 13 3.9 6.5 45.5 16.9 19.5 13 Fuel Mileage 0.5 Miles 33.16 16.58 16.58 13.264 36.476 16.58 8.29 8.29 8.29 36.476 16.58 24.87 16.58 4.974 8.29 58.03 21.554 24.87 16.58 Laps F-Start 22 17 14.5 9.5 20 7.5 12.5 8.5 23.5 19.5 8.5 13.5 6 22 20.5 18 15.5 10.5 13 F-used 10 5 5 4 11 5 2.5 2.5 2.5 11 5 7.5 5 1.5 2.5 17.5 6.5 7.5 5 F -Left 12 12 9.5 5.5 9 2.5 10 6 21 8.5 3.5 6 1 20.5 18 0.5 9 3 8 15 0 1022 10 1024 63.004 Total time 592.9 66.32 F-Add 0 0 0 13 0 10 1016 0 20 0 0 10 0 21 0 1020 63.004 1018 61.346 66.32 1014 66.32 Tire Set Tire Miles

Sebring Test Plan Day 2

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Date 14-May-14 Run Laps 1 20 0 2 10 0 3 10 4 5 6 7 8 9 10 8 22 10 5 5 5 22 Session Day 2 Driver CRASH Test Plans Install new Brake system Shake down Test brakes for test tmrw Lunch Shake down Inspect Pads/ Tire pressure Adjustments 1st Test Run Driver feed back 2nd Test Run Chassis changes 3rd Test Run Minor change to Chassis 4th Test Run Review Data/ Pull Driver Brake Pressure Adjust Driver thoughts on car Chassis adjustment Data/Driver feed back Feed back on Brake/changes Review Pads and changes presure/ Chassis adjustments Review Changes/ Driver Feed back Minor change Long Test Pull Driver Discuss Results Distance 1.658 Tires 1014 T-Session 600min T-Pit (min) 240 0 60 0 5 0 25 0 10 0 10 0 25 0 10 0 15 0 5 0 5 0 65 Lap Time Fuel Mileage 1.3 0.5 T-Run (min) Miles 19.5 24.87 Laps F-Start 8.5 F-used 7.5 F -Left 1 F-Add 0 Tire Set Tire Miles 1008 1008 1008 1010 1010 1010 1012 1012 1012 1012 26 13 13 10.4 28.6 13 6.5 6.5 6.5 28.6 33.16 16.58 16.58 13.264 36.476 16.58 8.29 8.29 8.29 36.476 22 17 14.5 9.5 20 7.5 12.5 8.5 23.5 19.5 10 5 5 4 11 5 2.5 2.5 2.5 11 12 12 9.5 5.5 9 2.5 10 6 21 8.5 0 0 0 13 1010 0 10 0 20 0 0 1012 61.346 66.32 1008 66.32

11 Total time

15 586.6

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

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K&B Racing
Asset Control Team Manager Technical Director Race Engineer Asst. Engineer Asst. Engineer Data Engineer Damper Engineer Gearbox Mechanic Mechanic Mechanic Mechanic Mechanic Mechanic Mechanic Cost/Hr $90.00 $85.00 $68.00 $33.00 $33.00 $29.00 $30.00 $31.00 $24.00 $24.00 $24.00 $24.00 $24.00 $24.00 RFP Mgmt Y Y N N N N N N N N N N N N RFP Eng. N N Y Y N N N N N N N N N N Brake Inst. N N N N N N N N N N Y Y Y Y CONTROLS Brake Remv. N N N N N N N N N N Y Y Y Y Test 1 Y Y Y Y Y Y Y Y Y Y Y Y Y Y Test 2 Y Y Y Y Y Y Y Y Y Y Y Y Y Y Report N N Y Y Y N N N N N N N N 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 Labor Rate & Time Team Manager Technical Director Race Engineer Asst. Engineer Data Engineer Damper Engineer Gearbox Mechanic Mechanic Per Diem Sub Tasks Time RFP Management RFP Engineering Brake Install Brake Removal Test 1 Test 2 Report Writing INPUTS $/Hr $90.00 $85.00 $68.00 $33.00 $29.00 $30.00 $31.00 $24.00 $3.33 Days 12 4 1 1 3 2 4 9 $/Day $810.00 $765.00 $612.00 $297.00 $261.00 $270.00 $279.00 $216.00 $30.00 Man Hours 108 36 6 4.5 30 20 36 Occurrence 1 1 4 3 1 1 1 Asset Control Team Manager Technical Director Race Engineer Asst. Engineer Asst. Engineer Data Engineer Damper Engineer Gearbox Mechanic Mechanic Mechanic Mechanic Mechanic Mechanic Mechanic Cost/Hr $90.00 $85.00 $68.00 $33.00 $33.00 $29.00 $30.00 $31.00 $24.00 $24.00 $24.00 $24.00 $24.00 $24.00 Man Hours Total Cost $14,220.00 $13,430.00 $8,296.00 $4,026.00 $2,838.00 $1,450.00 $1,500.00 $1,550.00 $1,200.00 $1,200.00 $1,452.00 $1,452.00 $1,452.00 $1,452.00 RFP Mgmt Y Y N N N N N N N N N N N N 108 RFP Mgmt (1) $9,720.00 $9,180.00 RFP Mgmt $18,900.00 $18,900.00 $1,575.00 RFP Eng. N N Y Y N N N N N N N N N N 6 RFP Eng. (1) $2,448.00 $1,188.00 RFP Eng. $3,636.00 $3,636.00 $909.00 Brake Inst. N N N N N N N N N N Y Y Y Y 6 Brake Inst. (4) $144.00 $144.00 $144.00 $144.00 Brake Inst $2,304.00 $576.00 $2,304.00 CONTROLS Brake Remv. N N N N N N N N N N Y Y Y Y 4.5 Brake Remv. (3) $108.00 $108.00 $108.00 $108.00 Brake Remv. $1,296.00 $432.00 $1,296.00 Test 1 Y Y Y Y Y Y Y Y Y Y Y Y Y Y 30 Test 1 (1) $2,700.00 $2,550.00 $2,040.00 $990.00 $990.00 $870.00 $900.00 $930.00 $720.00 $720.00 $720.00 $720.00 $720.00 $720.00 Test 1 $16,290.00 $16,290.00 $16,290.00 Test 2 Y Y Y Y Y Y Y Y Y Y Y Y Y Y 20 Test 2 (1) $1,800.00 $1,700.00 $1,360.00 $660.00 $660.00 $580.00 $600.00 $620.00 $480.00 $480.00 $480.00 $480.00 $480.00 $480.00 Test 2 $10,860.00 $10,860.00 $5,430.00 Report N N Y Y Y N N N N N N N N N 36 Report (1) $2,448.00 $1,188.00 $1,188.00 Report $4,824.00 $4,824.00 $1,206.00 Labor per Task Team Manager Technical Director Race Engineer Asst. Engineer Asst. Engineer Data Engineer Damper Engineer Gearbox Mechanic Mechanic Mechanic Mechanic Mechanic Mechanic Mechanic

Facilty Costs Laguna seca Kansas

Amount $9,000.00 $11,500.00

Min. Man Hours 10 10

Road Travel Costs Car Van Semi Rig

Fuel Cost/Gal. $3.50 $3.50 $3.75

MPG 25 15 5

Cost Per Task Cost Per Occurrence Cost Per Day

Testing Expenses Laguna seca Sebring Total Program Cost Non- Recurring Labor Recurring Labor Testing Travel Total

Facilty $9,000.00 $23,000.00 Cost $54,510.00 $3,600.00 $32,000.00 $18,645.90 $108,755.90

w/Travel $20,147.70 $23,000.00

Laguna Seca Destination Personnel Laguna Seca Per Diem 12 $1,800.00 Transportation Est Milage Fuel Cost 4590 $3,442.50 45 $25.20 Flights Cost Total $655.00 $6,550.00 Hotel Nights Cost/Night 4 $120.00 Repeat $11,147.70 1 $11,147.70 Test Days 3 Duration 5 Destination Personnel # of Vech. 1 4 Rental Price 78 Rental Total $1,585.20 Sebring

Seabring Test Days 2 Per Diem $1,440.00 Duration 4

Semi Rig Car Tickets 10 Rooms 9 Trip Cost Complete Cost

Semi Rig Car Tickets 10

Total $4,320.00

Rooms 9 Trip Cost Complete Cost

12 Transportation Est Milage Fuel Cost # of Vech. 1 2060 $1,545.00 4 45 $25.20 Flights Cost Total $655.00 $6,550.00 Hotel Nights Cost/Night Total 3 $120.00 $3,240.00 Repeat $7,498.20 1 $7,498.20

Rental Price 78 Rental Total $1,273.20

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K&B Racing
MONTHLY OVERHEAD COST Type Items Electricity Heating Gas Water Sewerage Internet Connection Phone Service Amount $100.00 $150.00 $60.00 $50.00 $100.00 $150.00 Utilities Insurance Machineries and Equipments Furnitures Computers Fixtures Accident at job site Company vehicle $100.00 $40.00 $40.00 $150.00 $150.00 $150.00 Monthly Overhead $610.00 Utilities Insurance $330.00 Property $300.00 Liability $7,400.00 Administrative $2,000.00 Rent $10,640.0 Monthly Total 0 Project Overhead Calculation Days 27 % of Facilty Usage per Month 39% Project Overhead $4,186.23 Property

Long-term Costs
New System Costs FasterThnU Carbon Ceramic Brake Package Quantity 1.00 Quantity 13.00 100.00 8.00 Quantity 1.00 laksfdjla;kdjf;alskjf Fasterthu Decal Area RW Endplate Bottom of Door Sym? Y Y H (in) 2 5 W (in) 6 16 $/in^2 250 220 Total $3,000.00 $17,600.00 Cost Each $147,000 Cost Each $58.96 $2.20 $38.28 Cost Each $700.00 Cost $147,000.00 Cost $766.48 $220.00 $306.24 Cost $700.00

Liability

Administrative

Accounting security HR and personal Salaries and fringe benefit

$900.00 $700.00 $800.00 $5,000.00

Parts Needed to Update Car Brake Fluid Brake Line Brake Pressure Sensors System Upkeep Lathe Tooling

Rent

office space rent

$2,000.00

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53

K&B Racing
Conclusions

54

K&B Racing
Final 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
Final Verdict on Fasterthnu Business Relationship

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
Final Verdict on Fasterthnu Business Relationship

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
Internal 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 Costs Labor Travel Testing Overhead Long Term Design & Manufacture Total Project Cost $58,110.00 $18,645.90 $32,000.00 $4,186.23 $19,592.72 $147,000.00 $279,534.85