CAPACITY VERIFICATION
1 Part Number 4 Run@Rate Date
2 Part Description 5 Supplier Name
3 TRW Annual Capacity Planning Volume pcs/year 6 Supplier Location
7 Process Step STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6
8 Process Description
Units
9 Working hours/shift hours
I - Supplier
Standards
Shifts/ day shifts
Working
10
11 Days/ week days
12 Weeks/ year weeks
13 Total hours/year (9*10*11*12) hours
14 % of line for TRW parts (Allocation %) - See Example %
II - Supplier Capacity
15 Quoted Production Rate (part # item 1) pcs/hour
16 Quoted % scrap %
Quoted % line efficiency %
Data
17
18 Adjusted production rate (15*(1-16)*17) pcs/hour
19 Available capacity (15*14*(1-16)*17)*13 pcs/year
20 Utilization % (3/19) %
21 Bottleneck operation X
22 Trial run duration hour
23 Total parts produced pcs
III - RUN at RATE Results
24 Number of bad parts pcs
25 First time capability % ((23-24)/23)*100 %
26 Number of good parts (23-24) pcs
27 Net output (26/22) pcs/ hour
28 Takt Time Rate (Target) (3/13*14) pcs/ hour
29 Downtime hour
Reason text
30
31 Run-Off utilization % (3/(27*13*14)) % 0.0% 0.0% 0.0% 0.0% 0.0% 0.0%
32 Bottleneck operation X X X X X X X
SHADED CELLS ARE CALCULATED and protected 34 SUMMARY 35
e RUN@RATE results are acceptable and meet TRW capacity planning volume requirements: Overall Process Auditor Information
Status
The attached capability study results meet TRW requirements: Utilization % Name:
33
Corrective actions are required: Date: Company:
0.00% Acceptable
New production readiness trial run is required: Date: Location:
36 Supplier representative signature: Auditor signature:
Date: 03 Sep 2005 53123415.xls; Run at Rate Form Process Owner / Department:
Rev: D K. Gillis / Supplier Development
Doc No: D_020_4_12 Approved By:
Page 1 of 7 E. Carpenter / VP Purchasing
CAPACITY VERIFICATION
1 Part Number 30301458B 4 Run@Rate Date February 14, 2004
2 Part Description Inflator retainer bracket 5 Supplier Name Acme Machining
3 TRW Annual Capacity Planning Volume pcs/year 700,000 6 Supplier Location Cleveland, OH
7 Process Step STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6
8 Process Description Stamp Part CNC #1 CNC #2 Weld Fasteners Paint
Units This is the actual time
spent producing product
9 Working hours/shift hours and should exclude such 7.5 8.5 7.0 7.0 10.5
I - Supplier
Standards
Shifts/ day shifts things as breaks, meals, 3 2 3 3 1
Working
10
11 Days/ week days preventative maintainance 5 5 5 5 5
etc.
12 Weeks/ year weeks 48 48 48 48 48
13 Total hours/year (9*10*11*12) hours 5400 4080 5040 5040 2520
14 % of line for TRW parts (Allocation %) - See Example % 100% 87% 100% 100% 50%
II - Supplier Capacity
15 Quoted Production Rate (part # item 1) pcs/hour 720.0 210.0 164.0 240.0 1200.0
16 Quoted % scrap % 2% 2% 5% 9% 5%
Quoted % line efficiency % 97% 94% 95% 92% 95%
Data
17
18 Adjusted production rate (15*(1-16)*17) pcs/hour 684 193 148 201 1,083
19 Available capacity (15*14*(1-16)*17)*13 pcs/year 3,695,933 686,677 745,970 1,012,677 1,364,580
20 Utilization % (3/19) % 19% 102% 94% 69% 51%
21 Bottleneck operation X X
22 Trial run duration hour 2.00 1.00 2.00 1.25 1.00
23 Total parts produced pcs 929 249 290 252 794
III - RUN@RATE Results
24 Number of bad parts pcs 5 2 4 12 4
25 First time capability % ((23-24)/23)*100 % 99.46% 99.20% 98.62% 95.24% 99.50%
26 Number of good parts (23-24) pcs 924 247 286 240 790
27 Net output (26/22) pcs/ hour 462 247 143 192 790
28 Takt Time Rate (Target) (3/13*14) pcs/ hour 130 197 139 139 556
29 Downtime hour 0.5
Reason text Reprogramming
30
31 Run-Off utilization % (3/(27*13*14)) % 28.1% 79.8% 97.1% 72.3% 70.3% 0.0%
32 Bottleneck operation X X
SHADED CELLS ARE CALCULATED and protected 34 SUMMARY 35
The RUN@RATE results are acceptable and meet TRW capacity planning volume requirements: YES Overall Process Auditor Information
Status
The attached capability study results meet TRW requirements: NO Utilization % Name: Gerald Biggs
33
Corrective actions are required: NO Date: April 1, 2404 Acceptable with Company: TRW
97.13%
New production readiness trial run is required: NO Date: May 16, 2004 Caution Location: Mesa, AZ
36 Supplier representative signature: Tom Alison Auditor signature: Gerald Biggs
Date: 03 Sep 2005 53123415.xls; Run at Rate Form Example Process Owner / Department:
Rev: D K. Gillis / Supplier Development
Doc No: D_020_4_12 Approved by:
Page 2 of 7 E. Carpenter / VP Purchasing
RUN AT RATE ACTION PLAN
DATE
ITEM STANDARD CHECKLIST ITEMS RESPONSE REQUIRED ACTION RESPONSIBLE PARTY COMMENTS
DUE COMPLETED
1 ARE ALL TOOLING GAGES AND FIXTURES IN PLACE?
2 IS A MANUFACTURING FLOOR PLAN DEVELOPED?
3 ARE ALL PACKAGING REQUIREMENTS MET?
4 IS PREVENTATIVE MAINTENANCE IN PLACE?
5 IS MISTAKE PROOFING ACCEPTABLE?
6 ARE BOTH THE SUPPLIER AND RUN-OFF UTILIZATIONS <100%
7 ARE ALL OPERATIONS ABOVE 70% FIRST TIME CAPABILITY?
8 IS SPC IN PLACE AND VISUAL NEAR PRODUCTION?
9 HAS THE RAMP PLAN BEEN DISCUSSED AND VERIFIED?
10 HAVE ALL OPEN 8-D'S AND DEVIATIONS BEEN REVIEWED?
11 ARE MANUFACTURING INSTRUCTIONS IN PLACE AND VISUAL?
12 HAS A CONTINGENCY PLAN BEEN DEVELOPED?
13 ARE ALL CAPABILITY STUDIES ACCEPTABLE?
DATE
ITEM ADDITIONAL ISSUES/ACTION ITEMS RESPONSE REQUIRED ACTION RESPONSIBLE PARTY COMMENTS
DUE COMPLETED
14
15
16
17
18
19
20
21
22
23
24
25
Date: 03 Sep 2005 53123415.xls; Run at Rate Action Plan Process Owner / Department:
Rev: D K. Gillis / Supplier Development
Doc No: D_020_4_12 Approved by:
Page 3 of 7 E. Carpenter / VP Purchasing
SUPPLIER PROCESS CAPABILITY
SECTION 1 -SPECIFICATION DATA AND MEASUREMENT RESULTS
Part Number Sample Size Note: If no USL/LSL, then leave cell blank
Critical and
Signficant?
Lower
Standard Upper
Characteristic or Specification Average Specification PpK
Deviation Specification Limit
Limit
7
Part Number Sample Size Note: If no USL/LSL, then leave cell blank
Critical and
Signficant?
Lower
Standard Upper
Characteristic or Specification Average Specification PpK
Deviation Specification Limit
Limit
7
Part Number Sample Size Note: If no USL/LSL, then leave cell blank
Critical and
Signficant?
Lower
Standard Upper
Characteristic or Specification Average Specification PpK
Deviation Specification Limit
Limit
7
Part Number Sample Size Note: If no USL/LSL, then leave cell blank
Critical and
Signficant?
Lower
Standard Upper
Characteristic or Specification Average Specification PpK
Deviation Specification Limit
Limit
Date: 03 Sep 2005 53123415.xls; Process Capability Process Owner / Department:
Rev: D K. Gillis / Supplier Development
Doc No: D_020_4_12 Approved by:
Page 4 of 7 E. Carpenter / VP Purchasing
SUPPLIER PROCESS CAPABILITY
SECTION 1 -SPECIFICATION DATA AND MEASUREMENT RESULTS
Part Number Sample Size Note: If no USL/LSL, then leave cell blank
Signficant?
Critical and
Lower
Standard Upper
Characteristic or Specification Average Specification PpK
Deviation Specification Limit
Limit
Date: 03 Sep 2005 53123415.xls; Process Capability Process Owner / Department:
Rev: D K. Gillis / Supplier Development
Doc No: D_020_4_12 Approved by:
Page 5 of 7 E. Carpenter / VP Purchasing
SUPPLIER PROCESS CAPABILITY
SECTION 1 -SPECIFICATION DATA AND MEASUREMENT RESULTS
Part Number 30301458B Sample Size 30 Note: If no USL/LSL, then leave cell blank
Critical and
Signficant?
Upper Lower
Standard
Characteristic or Specification Average Specification Specification PpK
Deviation
Limit Limit
1 Hole Diameter 3.5 mm YES 3.4800 0.0300 3.5500 3.4500 0.333
2 6.8 mm dimension YES 6.7900 0.0500 6.8200 6.7800 0.067
3 .5 radius YES 0.4990 0.0100 0.5100 0.4950 0.133
4 .05 chamfer YES 0.0510 0.0010 0.0550 0.0450 1.333
7
Part Number Sample Size Note: If no USL/LSL, then leave cell blank
Critical and
Signficant?
Upper Lower
Standard
Characteristic or Specification Average Specification Specification PpK
Deviation
Limit Limit
Date: 03 Sep 2005 53123415.xls; Process Capability Example Process Owner / Department:
Rev: D K. Gillis / Supplier Development
Doc No: D_020_4_12 Approved by:
Page 6 of 7 E. Carpenter / VP Purchasing
ALLOCATION WORKSHEET
1 Working hours/shift 7.5
2 Shifts/ day 3
3 Days/ week 5
4 Weeks/ year 48
5 Available hours per year 5400
6 Available Hours per month 450
A B C D E F G H I J
G+available
G/Total of time/H (For
A B C D 3600/D A/D + B*C F*12 #5 G TRW)
Monthly Number of Setup Adjusted Production Total monthly Total Total Required Max
Volume Setups per time/run Cycle Time Rate in pcs/hr working hrs Annual available Allocation Allocation %
month (hrs) required working hrs time/yr %
required
TRW 52,000 2 1.5 15 240.00 219.67 2636.00 66.97% 75.93% á
Customer B 12,000 4 2 12 300.00 48.00 576.00 14.63% 10.67% â
Customer C 15,000 2 1 14 257.14 60.33 724.00 18.39% 13.41% â
Total Requirements (Units) 79,000 328.00 3936.00 5400 100% 100%
Overall Utilization 73%
Available Time (hours/yr) 1464.00
Date: 03 Sep 2005 53123415.xls; Allocation % Example Process Owner / Department:
Rev: D K. Gillis / Supplier Development
Doc No: D_020_4_12 Approved by:
Page 7 of 7 E. Carpenter / VP Purchasing
