Production Readiness / Run@Rate Checklist for Purchased Parts Supplier: ? M+H plant: Project: Supplier no.: ? ? M+H
Views 274 Downloads 90 File size 121KB
Production Readiness / Run@Rate Checklist for Purchased Parts Supplier:
?
M+H plant: Project:
Supplier no.:
? ?
M+H Part Name:
Reason for Process Release / Run@Rate:
Max. annual need: +20% Max. weekly need: +20%
? #VALUE! #VALUE! #VALUE! Dept.
Project Resp. Supplier: Quality Resp. M+H: Purchasing Resp. M+H:
?
?
? ? ?
Date/index of M+H drawing:
Working weeks / year: Start in week:
Name
?
M+H Part Number:
New product Product change Process change Relocation of product / process Quality Issues pc. pc. pc. pc.
Run@Rate Date:
? ?
?
Defined amount of parts for the R@R: Duration:
Phone: ? ? ?
?
? ?
pc. hours
Email: ? ? ?
? ? ?
1. Introduction 1.1 Target: Evaluation and approval of the manufacturing processes for on-time deliveries of quality-conforming parts in peak production quantities. 1.2 Preparation: The template Production Readiness / Run@Rate for Purchased Parts is given to the supplier in advance. The supplier shall do a self-assessment as a preparation for the Run@Rate done together with MANN+HUMMEL. 1.3 Evaluation: GREEN: Targets or deadlines achieved. No indication of deviations from what was seen during the Process Release / Run@Rate. YELLOW: Targets or deadlines partly not met. Additional actions (see action plan) and follow-up are required. RED: Critical targets or deadlines not achieved. Additional actions urgently required. SOP at risk. No serial delivery approval. Approval for limited quantity only (written concession from M+H required). Run@Rate must be repeated. Production Readiness / Run@Rate Checklist for Purchased Parts MHG-PU-F-0014
Rev.-Status: 01/2015
Page 1 of 10
Critical targets or deadlines not achieved. Additional actions urgently required. SOP at risk. No serial delivery approval. Approval for limited quantity only (written concession from M+H required). Run@Rate must be repeated.
2. Preliminary check
Documentation GREEN YELLOW
RED
2.1
Approved drawing(s) with latest change level (index) (customer and production drawings) and current BOM (bill of materials) available?
offen
offen
offen
2.2
All documents listed in the drawing(s) and PRFPP (standards, etc.) available with latest level and implemented/considered in own documents?
offen
offen
offen
2.3
If supplier is design responsible: Updated Design FMEA available, measures implemented and effectiveness confimed (new evaluation done), Special Characteristics according to PRFPP? Experience from previous projects / Leassons learned considered?
offen
offen
offen
2,4
If supplier is design responsible: Design FMEA used to develop Process FMEA (RPN, corrective actions, etc.)?
offen
offen
offen
2.5
Updated Process FMEA available (RPN acceptable, measures implemented, effectiveness confirmed by new evaluation, special characteristics accord. PRFPP, team members,date,etc.)?
offen
offen
offen
2.6
Updated Process flow chart and Control Plan available (incl. receiving, rework, scrap, inspection, shipping, labeling, finished goods, shipping areas and plant layout) and linked to PFMEA?
offen
offen
offen
2.7
Product related instructions (e.g. inspection, set-up, working, packaging instruction) available, at work station and based on Control Plan?
offen
offen
offen
2.8
Procedure available to authorize the Start of Production (e.g. process parameters incl. tolerances recorded and under control, traceability of first OK parts, flow of OK and nOK parts, etc. ("First-off" procedure))?
offen
offen
offen
2.9
Are samples sizes and check frequency for each operation reasonable and min. according the PRFPP (comparison of quality data/failures found and sample sizes and frequency)?
offen
offen
offen
2.10
Rework instructions completed and agreed with M+H, marking of part defined?
offen
offen
offen
2.11
Maintenance plan and instructions available (assembly lines, tools etc.)?
offen
offen
offen
2.12
Capability of test and control equipment confirmed (according VDA Volume 5 or MSA) and R&R < 10%?
offen
offen
offen
2.13
Machine capability (Cmk) and preliminary capability (Ppk) study for special characteristics accomplished with Cmk/Ppk ≥1,67 (≥2,0 if specified)?
offen
offen
offen
2.14
Process capability study for special characteristics installed? => at the latest 3 months after SOP proven.
offen
offen
offen
2.15
Complete initial sample report according to VDA Volume 2 or PPAP with supporting documents (product/process) available, all items from PRFPP (if applicable) adressed?
offen
offen
offen
2.16
Evidence of qualification and training for employees for all shifts (qualification matrix, training plan, training evidence) incl. Personel Employment Plan available?
offen
offen
offen
2.17
For D-part (parts where documentation is mandatory): work stations and documents identified accordingly and necessary documentation available?
offen
offen
offen
2.18
Bottleneck process identified?
offen
offen
offen
Production Readiness / Run@Rate Checklist for Purchased Parts MHG-PU-F-0014
Rev.-Status: 01/2015
Comments
Page 2 of 10
Bottleneck process identified?
2.19
If Component Cleanliness Management (CCM) requirements are applicable: all documents (requirements, instructions for cleaning, measurement, documentation, etc.) available?
2.20
IT-safety and electricity safety (back-up system, data safe, fire wall installed, video survaillance, etc.)
2.21
Is there a preparation / systematic for Requalification, Product and Process Audit for running serial production available?
2.22
Procedure available for customer shipping?
2.23
Data for tooling / equipment / gauges send to M+H (applicable only for tools/equipment/gauges payed by M+H)?
2.24
Are changes to the product or process in the course of serial production tracked and documented?
3. Preliminary check
offen
offen
offen
offen
offen
offen
offen
offen
offen
offen
offen
offen
offen
offen
offen
offen
offen
offen
offen
offen
offen
Pre-requisites for prove of serial readiness GREEN YELLOW
3.1
Machines arranged according to production layout?
3.2
Manufacturing under serial conditions (e.g. with machines, tools, process flow, operators, etc.)?
3.3
Serial testing facilities and serial inspection equipment available, used and calibrated / calibration planned?
3.4
Trained operators available for all shifts (certificates, qualification matrix, asking of operatores, etc.)?
3.5
Traceability assured to an acceptable level (e.g. lot control)?
3.6
Dispach container labeling according to M+H requirements?
4. Preliminary check
RED
offen
offen
offen
offen
offen
offen
offen
offen
offen
offen
offen
offen
offen
offen
offen
offen
offen
offen
offen
offen
Sub-Suppliers GREEN YELLOW
4.1
Procedure for incoming inspection incl. testing procedure and inspection equipment for purchased parts defined (at sub-suppliers, incoming inspection, etc.) and equipment calibrated?
4.2
Special characteristics for purchased parts defined and proof of capability available ?
4.3 4.4
RED
offen
offen
offen
offen
offen
offen
Complete Initial Sample Inspection Reports (ISIR/EMPB/PPAP/PPA) available and approved for all purchased parts ?
offen
offen
offen
Sufficient sub-supplier capacity confirmed for all purchased components and materials ? Sub-suppliers informed about the current ramp-up plan ?
offen
offen
offen
Production Readiness / Run@Rate Checklist for Purchased Parts MHG-PU-F-0014
Comments
Rev.-Status: 01/2015
Comments
Page 3 of 10
Sufficient sub-supplier capacity confirmed for all purchased components and materials ? Sub-suppliers informed about the current ramp-up plan ?
offen
offen
offen
4.5
Process Release/Run@Rates performed at sub-suppliers for important parts/processes, where specified?
offen
offen
offen
4.6
Appropriate packaging agreed with sub-suppliers for all parts?
offen
offen
offen
4.7
Purchase orders with specific requirements (orders with latest index, etc.) available?
offen
offen
offen
4.8
Are only approved/released and quality-capable suppliers selected (release process appropriate)?
offen
offen
offen
4.9
Procedure for identification, traceability, FIFO (e.g. expiration dates rubber compound) of material batches/products available and do labels of products refer to the supplier production order?
offen
offen
offen
4.10
Are only approved/released and quality-capable suppliers selected (release process appropriate)?
5. Execution
Production GREEN YELLOW
5.1
Manufacturing according to production plan and process flow-chart?
5.2
RED
offen
offen
offen
Machines / equipment set-up according to set-up instructions (e.g. process paramters) and also documented?
offen
offen
offen
5.3
Inspections done according to control plan and control instructions (for incoming materials and also production process), also after set-up processes or tool changes and are adequate aids available (pictures/parts OK/nOK, working place appropriate, etc.)?
offen
offen
offen
5.4
Boundery samples / Master Parts available to operatores and in use?
offen
offen
offen
5.5
Master Parts available for error proving devices (e.g. Poka-Yoke, leakage testing)?
offen
offen
offen
5.6
Maintenance according to maintenance plan / schedule (including preventive maintenance) for tools and equipment and are suficient spare parts available?
offen
offen
offen
5.7
Tools and gauges properly identified (incl. identification tag "Property of M+H", if the case)?
offen
offen
offen
5.8
Special product and process requirements controlled by inspection charts, process control charts, etc. and data properly recorded?
offen
offen
offen
5.9
Where SPC is requried: are data properly recorded, out of control points noted with corrective actions taken and manufacturing processes demonstrating required capability or performance?
offen
offen
offen
5.10
Pre-series capability for special characteristics (Ppk ≥1,67 (≥2,0 if specified)) confirmed with parts from internal performance test?
offen
offen
offen
5.11
Root cause analysis systematic implemented to define corrective actions for n.O.K. parts (e.g. FISTPASS-Yield, 8D-method)?
offen
offen
offen
5.12
Ergonomic, safety and environmental requirements fulfilled?
offen
offen
offen
Production Readiness / Run@Rate Checklist for Purchased Parts MHG-PU-F-0014
Rev.-Status: 01/2015
Comments
Page 4 of 10
Ergonomic, safety and environmental requirements fulfilled? 5.13
offen
offen
offen
offen
offen
offen
offen
offen
offen
offen
offen
offen
General housekeeping and cleanliness - specially in case of Component Cleanliness Mgmt. (CCM) requirements: - at workplace / test location? - in manufacturing / surroundings? - packaging and packaging area?
5.14
Deterioration of quality incl. mixing of products prevented by: - sufficient and appropriate in-house packaging? - internal transport and storage? - packaging (according to packaging instruction)?
5.15
- storage (parts, tools, devices)? n.O.K. and rework parts handling incl. setting parts: - rejection/separation according process plan, instruction for rework? - clear marking, separation ensured? - re-inspection after rework process (evidence)?
5.16
Warehousing: FIFO, logistic rules in shipping warehouse / identification before delivery to the customer available?
offen
offen
offen
5.17
Procedure for identification of quality status during production (e.g. AWAITING DECISION, ACCEPTED, REJECTED, REWORKED) available?
offen
offen
offen
5.18
Safety concept: fire prevention, quality emergency plan, work environment safety, dangerous substances?
offen
offen
offen
offen
offen
offen
6. Execution
Qualitative Evaluation Comments
6.1
Amount of parts manufactured during the Run@Rate
6.2
Amount of n.O.K. parts
6.3
pc.
? ###
- n.O.K. - visual check not according to drawing / border samples
?
pc.
### %
- n.O.K. - dimensional / material not according to drawing
?
pc.
### %
- n.O.K. - function not according to drawing / process verifification plan
?
pc.
### %
Actual scrap
###
pc.
###
%
GREEN YELLOW offen
Production Readiness / Run@Rate Checklist for Purchased Parts MHG-PU-F-0014
Rev.-Status: 01/2015
offen
RED offen Page 5 of 10
6.4
Estimated scrap (estimated by supplier)
###
6.5
Amount of rework parts
?
6.6
First Time Quality (FTQ) (Amount of O.K. parts without rework)
pc.
%
###
%
pc.
###
7. Execution
?
offen
offen
offen
### %
Quantitative Evaluation (for Bottleneck process)
Data from original Capacity Planning (from PRFPP) Bottleneck Process:
Production capacity found during R@R
?
Current shift model (as planned in serial production): ?
Peak production: (
+20%
#VALUE!
pc./week
#VALUE!
)
expected to start in week:
?
x
shifts / week
Set-up time:
?
?
=
#VALUE! min. / week
hours / shift
Data for actual performance calculation:
Planned shift model: ?
x
shifts / week
?
=
#VALUE! min. / week
hours / shift
min.
Lot size:
?
pc.
Produced good parts:
?
pc.
Produced scrap:
?
pc.
Production time without down times:
?
min.
Down times:
?
min.
Set-up time, actual:
?
min.
Lot size:
?
pc.
(e.g. process stop/tool removal/setup/process start up - last good parts until first good parts) Production time, calculated:
?
sec./ pc.
Production time, actual:
(amount of cavities to be considered) Set-up rate:
#VALUE!
sec./ pc.
Total time per piece:
#VALUE!
sec./ pc.
#VALUE!
sec./ pc.
(amount of cavities to be considered) Set-up rate, actual: Total time per piece:
#VALUE!
sec./ pc.
#VALUE!
sec./ pc.
#VALUE!
%
Scrap rate:
?
%
Scrap rate, actual:
Equipment availability:
?
%
Equipment availability, actual:
?
%
Reserved Capacity for MANN+HUMMEL:
?
%
Reserved Capacity for MANN+HUMMEL:
?
%
# of same machines used in parallel:
?
(e.g. 100% if machine only used for M+H. 100% is max.)
(> 1 only if more than 1 machine will be operating at the same time)
Estimated quantities max. pc./shift calculated
Calculated quantities (based on Run@Rate result)
#VALUE! ?
# of working days per week
#VALUE!
Production Readiness / Run@Rate Checklist for Purchased Parts MHG-PU-F-0014
pc./shift calculated at reserved capacity Rev.-Status: 01/2015
#VALUE!
max. pc./shift estipolated
#VALUE!
pc / shift at reserved capacity Page 6 of 10
?
# of working days per year
#VALUE!
pc. / day calculated at reserved capacity
#VALUE!
pc. / day at reserved capacity
#VALUE!
pc. / week calculated at reserved capacity
#VALUE!
pc. / week at reserved capacity
#VALUE!
pc. / year calculated at reserved capacity
#VALUE!
pc. / year at reserved capacity
Remarks: The amount of parts to be produced during the Run@Rate is specified by the MANN+HUMMEL Project Team depending on actual shift model, recruitment situation, quantity needed for ramp-up, etc. If peak production level cannot be met with the current shift model, measures must be defined by the supplier (e.g. increase of capacity with timing, reduction of scrap or rework rate, reduction of product cycle time, etc).
8. Result of Process Release / Run@Rate Done on:
?
Responsible MANN+HUMMEL:
?
Department:
?
offen
GREEN, successful => Approval for Serial Production (if ISIR/PPAP/PPA was also released !)
offen
YELLOW, measures required => Approval of Serial Release after verification of the measures by MANN+HUMMEL
offen
RED, without success => Evidence of Mass Production Readiness not given, measures and repetition of Process Release / Run@Rate required Repetition of Process Release / Run@Rate planned for:
?
Comments
Production Readiness / Run@Rate Checklist for Purchased Parts MHG-PU-F-0014
Rev.-Status: 01/2015
Page 7 of 10
Signatures:
Supplier
Production Readiness / Run@Rate Checklist for Purchased Parts MHG-PU-F-0014
Quality Responsible MANN+HUMMEL
Rev.-Status: 01/2015
Purchasing Responsible MANN+HUMMEL
Page 8 of 10
Supplier
?
Project:
?
M+H Part Number:
?
M+H Part Name:
?
Issue Date
?
Review date
?
Distribution list
Open Issue List (OIL) Approved by M+H
Activities No.
Decription of problem
Root cause Action
Responsible
Date
Status
Date
Yes/No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Production Readiness / Run@Rate Checklist for Purchased Parts Template: MHG-SP-F-0017
Rev.: 12/2013
Page 9 of 10
Pictures of Tools, Machines and Equipment Supplier: M+H plant: Project:
? ? ?
Supplier no.:
M+H Part Name:
?
?
Run@Rate Date:
M+H Part Number:
f o es nd ) r u a ry t c i es sa p r hin ces o f ac e t n e e , m (if h S ols nt to pme i u eq
Production Readiness / Run@Rate Checklist for Purchased Parts Template: MHG-SP-F-0017
Rev.: 12/2013
?
?