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conditions and the expected improved conditions should be stated in terms normally applied to the actual quantities, dollars, or rates per hour, etc.</li>\n<li>Presenting this information in tabular form is usually most helpful. Cost savings projects, except for extraordinary circumstances, should always be financially justified. In addition to the usual CER requirements, a cost savings project documentation should:</li>\n</ul>\n<ol>\n<li>Justify investment on hard savings only. While this is not always possible, it is the most likely scenario that will actually occur in reality. Hard savings are those costs that are readily identifiable before and after a project is executed and can be documented as eliminated or reduced by the project. Examples of hard savings are reduced headcount plus fringe benefits, reduced scrap, substitution of lower cost materials or components, reduced utilities or supplies, etc.</li>\n<li>Base hard savings on historical activity or volume levels whenever possible. If the savings are based on a declining or rising activity or volume level, explain methodology on how that rate of decrease or increase was estimated. Compare the projected rates to historical rates and explain variances where they occur.</li>\n<li>Include all soft savings such as reduced cycle times, partial headcount savings, increased efficiencies, etc.</li>\n<li>Discuss other benefits such as quality improvements, just-in-time manufacturing, reduced or minimized environmental impact, safety and ergonomic improvements, added capacity, improved features and functions, etc.</li>\n<li>Provide sufficient detail to demonstrate how savings were computed and how savings will be verified in a post completion audit (PCA). Note and footnote the submitted pages wherever necessary to enable an uninformed reader to follow the flow of the savings computations. Whatever worksheets or support are provided, they should indicate where the data flows into summary documents and the DCF model.</li>\n<li>For a project that includes headcount reduction initiatives, identify whether there will be a direct reduction in force, or a reduction via attrition. For direct reduction in force, the project should include any severance or one-time costs to execute that change. For attrition, identify the historical attrition rate experienced by that unit. Schedule savings in accordance with that rate of attrition unless special circumstances dictate otherwise.</li>\n</ol>\n<p><strong>Capacity Projects </strong></p>\n<ul>\n<li>It is understood that most capacity projects are usually updates or enhancements to existing processes and therefore primarily eliminate or minimize bottlenecks in the manufacturing system.</li>\n<li>While a particular capacity project usually does not provide all of the functions to produce a product or component from start to finish, it is the means which enables a line or facility to produce more volume.</li>\n<li>Thus the margin of the incremental volume should be credited to the particular capacity project under consideration.</li>\n</ul>\n<p>Business justification of a capacity project hinges on and should always begin with:</p>\n<ol>\n<li>The latest forecast of demand (sales $ or units) for the product, manufacturing line, or facility for the period of time projected by the CER. Comparison to historical rates and justification of increases is required.</li>\n<li>Current theoretical and practical capacity, description of methodology of its computation, and basis (hours per shift; 1,2, or 3 shifts; 5, 6, or 7 days per week; etc.) of computation.</li>\n<li>Expected or post-project theoretical and practical capacity, description of methodology of its computation, and basis (hours per shift; 1,2, or 3 shifts; 5, 6, or 7 days per week; etc.) of computation.</li>\n<li>Suggestion: a table or graph depicting the above information can be very helpful in explaining the before and after views of the project.</li>\n<li>Capacity projects, except for extraordinary circumstances, should always be financially justified.</li>\n</ol>\n<p>In addition to the usual CER requirements, a capacity project should include:</p>\n<ol start=\"6\">\n<li>Current margins and expected margins, if any change is expected.</li>\n<li>Identification of incremental fixed costs, if any, to ramp production up to the new practical capacity level.</li>\n<li>Computation of incremental working capital that will be accumulated due to the increase in capacity.</li>\n<li>Discuss other benefits such as quality improvements, cost savings, just-in-time manufacturing, safety and ergonomic improvements, improved features and functions, etc.</li>\n<li>Provide sufficient detailed worksheets to demonstrate how incremental margins were computed and how incremental margins will be verified in a post completion audit (PCA). Note and footnote on the submitted schedules wherever necessary to enable an uninformed reader to follow the flow of the margin computations. Whatever worksheets or support are provided, they should indicate where the data flows into summary documents and the DCF model.</li>\n</ol>\n<p><strong>New Product Projects </strong></p>\n<ul>\n<li>The basis for new product project justification is a thorough description of the opportunity that the new product introduction is addressing whether it is a response to a competitive threat, coverage of a previously exposed price range, new design or features, new market, or all of the above.</li>\n<li>New product analysis must address strategic fit with existing product line, cannibalization or obsolescence of existing product offering, and competitive response.</li>\n<li>Investment in new product tooling and equipment must also address capacity impact on any existing machinery, supply chain, or distribution capacities of the firm and include the necessary investments in those areas that is necessary to launch the new product.</li>\n</ul>\n<p>New Product Projects, except for extraordinary circumstances, should always be financially justified. In addition to the usual CER requirements, a New Product Project should include:</p>\n<ol>\n<li>Unit and sales forecast for the product and explanation of how that forecast was derived.</li>\n<li>Analysis and explanation of market growth and market penetration assumptions.</li>\n<li>Comparison and explanation of selling price assumptions versus existing products and competitor products.</li>\n<li>Documentation of how the product cost was developed.</li>\n<li>Explanation of incremental operating expenses, fixed and variable, for the new product and basis for those estimates.</li>\n<li>Comparison and analysis of gross / contribution margin of the new product versus existing products.</li>\n<li>Incremental working capital assumptions to be entered into the DCF model and basis of those assumptions.</li>\n<li>Discuss other benefits such as quality improvements, capacity additions, cost savings, just-in time manufacturing, safety and ergonomic improvements, improved features and functions, etc.</li>\n<li>Provide sufficient detailed worksheets to demonstrate how new product profitability was computed and how new product profitability will be verified in a post completion audit (PCA). Note and footnote on the submitted schedules wherever necessary to enable an uninformed reader to follow the flow of the new product sales and cost computations. Whatever worksheets or support are provided, they should indicate where the data flows into summary documents and the DCF model.</li>\n</ol>\n<p><strong>Replacement Projects </strong></p>\n<ul>\n<li>Replacement projects, that basically keep the existing processes operating, often do not have high financial return rates.</li>\n<li>They are maintaining the asset base that is producing the return the business is already earning in the marketplace.</li>\n<li>These projects, in general, tend to require significant investments.</li>\n<li>In addition, the decision process on replacement projects is often dependent on subjective management decisions.</li>\n<li>As assets age management must balance business risk against cash flow and investment return optimization. The result of these factors and forces are projects that are difficult to explain and justify to business managers and the CAPEX Committee.&nbsp;</li>\n</ul>\n<p>To deal with this &ldquo;gray area&rdquo; of investment where the numbers do not necessarily yield a decisive economic decision point, the following information should be provided:</p>\n<ol>\n<li>Describe what is at risk. Why has this project been selected at this time? If the project is not done, then what key component will not be produced? Will lack of replacement and possible subsequent breakdown result in slower production, or no production out of a department, an entire product line, or the entire factory? Could continuing operation of a machine, if not replaced, result in expensive tooling or dies being destroyed? {Include the time it would take to get a rush (and more expensive) replacement}</li>\n<li>What statistical process control data can be supplied that will empirically support the worsening condition of the machine. Provide a summary (numerical, chart, etc.) of downtime or outages or maintenance calls or increased maintenance time for the item that is being replaced. Provide statistics on rising scrap rates or quality variances or number of customer returns.</li>\n<li>Why this year? What has changed in the operation of the equipment from last year to this year that this project is now identified as a must do item to be replaced? Why is it necessary to replace now after, for example, 20 years when the equipment was fully depreciated at 12 years? What if delayed for another year?</li>\n<li>What other empirical justification is there to replace the asset?\n<ol style=\"list-style-type: lower-alpha;\">\n<li><em>Increase quality </em></li>\n<li><em>Meet competitive standards </em></li>\n<li><em>Improve appearance </em></li>\n<li><em>Ability to produce other products now or in the future </em></li>\n<li><em>Accommodates JIT manufacturing, or CFM, of DFT, etc. </em></li>\n<li><em>Greater customer satisfaction </em></li>\n<li><em>A competitive advantage </em></li>\n<li><em>Improve product function or features </em></li>\n<li><em>Comply with new / existing laws </em></li>\n<li><em>Improve safety and / or ergonomics </em></li>\n<li><em>Improve environmental aspects of project &ndash; discharges, waste </em></li>\n<li><em>Make work easier </em></li>\n<li>Etc.</li>\n</ol>\n</li>\n<li>Why can&rsquo;t additional spare parts and some additional maintenance labor be utilized to keep the process running for another year?</li>\n<li>Replacement 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