You are on page 1of 91

PDR Date

:
Vehicle / MY:
Commodity:
Customer Plant Type:
Cust. Plant Country:
Customer Plant Name:
Plant Code:

Supplier:
Supplier Code:
Sup. Mfg. Location:

Square Color Key
(Where Data
Originates)

Supplier

Capacity Database (FCA US)

SQE

Contract (FCA Italy(

Contract

Calculated (Not Manual Input)

Part Information

PRE-PDR DATA

Part Number

Part Description

Contract Capacity (Daily
Tool Capacity)

Annual Capacity

Capacity Planning Volume

Annual Projected Volume

Contract Capacity (Daily Tool
Capacity) 1
1000

Vehicle / Model 2

Contract Capacity (Daily
Tool Capacity) 2

Are these parts included in a Common Process Group (CPG)?
If yes, input the CPG Daily Capacity here:
Is this a Shared Line?
Are these parts used on other vehicles?

Yes

Part Number

Part Description

0
0
0
0
0
0

0
0
0
0
0
0

Vehicle / Model 1
JC 2015

Vehicle / Model 3

Contract Capacity (Daily
Tool Capacity) 3

Total Additional
Capacity
1000
0
0
0
0
0

Include Total Additional Capacity in calculations?

PROCESS INFORMATION
PROCESS
Process #
1

Next Process(es)
Process Description
#
2
fundicion

OPERATING PATTERN
Shifts /
Day
3
2
2

Shifts / Week
15
10
10

Hours /
Shift
8
10
10

Working Days /
Week
5
5
5

DOWNTIME
Scheduled Breaks / Lunch
(min/shift)
50
50
50

Changeovers (min/shift)

Planned Maintenance (min/shift)

20
10
0

15
15
15

Est. Unplanned Downtime
(min/shift)
40
30
15

Time Scheduled for Other Parts /
Customers (min/shift)
120
0
0

Ideal Cycle Time
(seconds)
30
50
65

Fraction of Total Capacity
Required for this Process Step
1
1
1

Part Number

0

PDR RESULTS

PROCESS
Next Process(es)
Process #
Process Description
#
1
2
fundicion
2
0
3
0
4
0
5
0
6
0
7
0
8
0
9
0
10
0
11
0
12
0
13
0
14
0
15
0

Part Number

Actual Downtime (min)

0
0
0
0
0
0
0
0
0
0
0
0
0
0

PDR Start Time (24h
format)
9:00
9:30
10:30

PDR End Time (24h format)

Planned

Unplanned

Total Parts Attempted

12:43
15:12
17:29

40
40
40

0
11
0

376
369
352

PDR End Time (24h format)

Planned

Total Good Parts
Produced
369
352
350

40
51
40
0
0
0
0
0
0
0
0
0
0
0
0

0
PROCESS

Next Process(es)
Process #
Process Description
#
1
2
fundicion
2
0
3
0
4
0
5
0
6
0
7
0
8
0
9
0
10
0
11
0
12
0
13
0
14
0
15
0

Actual Downtime (min)
PDR Start Time (24h
format)
0
0
0
0
0
0
0
0
0
0
0
0
0
0

Unplanned

Total Parts Attempted

Total Good Parts
Produced
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

Part Number

0

PDR RESULTS

PROCESS
Next Process(es)
Process #
Process Description
#
1
2
fundicion
2
0
3
0
4
0
5
0
6
0
7
0
8
0
9
0
10
0
11
0
12
0
13
0
14
0
15
0

Part Number

Actual Downtime (min)
PDR Start Time (24h
format)

PDR End Time (24h format)

Planned

Unplanned

Total Parts Attempted

Total Good Parts
Produced
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0
0
0
0
0
0

0
PROCESS

Next Process(es)
Process #
Process Description
#
1
2
fundicion
2
0
3
0
4
0
5
0
6
0
7
0
8
0
9
0
10
0
11
0
12
0
13
0
14
0
15
0

Actual Downtime (min)
PDR Start Time (24h
format)
0
0
0
0
0
0
0
0
0
0
0
0
0
0

PDR End Time (24h format)

Planned

Unplanned

Total Parts Attempted

Total Good Parts
Produced
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

Part Number 0 PROCESS PDR RESULTS Process # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Next Process(es) Process Description # 2 fundicion 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Part Number Actual Downtime (min) PDR Start Time (24h format) PDR End Time (24h format) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Unplanned Total Parts Attempted Total Good Parts Produced 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 PROCESS Process # Planned Next Process(es) Process Description # 2 fundicion 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Actual Downtime (min) PDR Start Time (24h format) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 PDR End Time (24h format) Planned Unplanned Total Parts Attempted Total Good Parts Produced 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 .

SIGNATURE DATE ENGINEER SIGNATURE DATE SUPPLIER . Acc Sub-Component Req'd Capac.PURCHASE ORDER PA READINESS EVALUATION SCORE* CONSTRAINT ANALYSIS CAPABILITY DATA 3 . % Perf. Actual Capac. Actual Capac.0% 3 Avail. Impact on Equipment / Tools / Human Resources if capacity increased: 10%: 25%: 50%: SQE SIGNATURE DATE SUPPLIER . 5 3 ( D a PProcess Performance and CapabilityConstraint Management ) 5 FINAL RESULTS Actual Line FTC % Speed #DIV/0! 98. Supplier: P DATE ACC? #DIV/0! * Performance cannot exceed 100%.RESULTS Tooling Status & Operating Conditions Capacity Verification A 5 5 2 Spare / Service Parts Operator Skill Level Sub-tier Capacity 5 5 B Required Capacity 0 Process fundicion 0 0 0 0 0 0 0 0 0 0 0 0 0 0 PPAP / FULL APPROVAL PDR STAGE 2 Date PDR SCORE 2 *The Readiness Evaluation should have a score of 3 or higher before running the PDR Stage 1 or Corrective Actions have been implemented to bring score to 3 or higher 2 . Actual Capac. "Red" cells indicate an actual cycle time that is less than the "Ideal Cycle Time". SIGNATURE DATE Actual Capac.QUALITY MGR.PRODUCTION DEMONSTRATION RUN NAFTA Part Number(s): PDR STAGE Part Description(s): Vehicle / MY: Commodity: Supplier Code: PA READINESS EVALUATION Supplier Manufacturing Location: PA PROCESS EVALUATION Date PDR STAGE 1 Date BLOCK DIAGRAM OPEN ISSUES Date DATA SHEET CAPACITY ANALYSIS SCORING CAPABILITY SUMMARY 1 . this should be modified on the Data Sheet Sub-Component Req'd Capac.PROCESS Contracted Capacity R E L Date E A S E T O 5 . Acc Sub-Component Req'd Capac. Acc Sub-Component Req'd Capac.RESULTS Line Utilization % 0.PLANT MGR.0 4 . %* OEE % 0% #DIV/0! #DIV/0! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! Const.RESULTS P First Time Capability Line Utilization R O D . Acc .1% Required Line Speed 0.

PDR Process Block Diagram Part Number(s): Part Description(s): Vehicle / M. Location: .Y.: Supplier: Commodity: Supplier Code: Supplier Mfg.

.

.

.

Supplier Name Part Number(s) Part Description(s) Contracted Capacity. of process Next process(es) PRODUCTION SYSTEM 1 2 List each separate process fundicion OVERALL PROCESS Shifts Per Week Working Days Per Week 15 5 15 5 . Total Annual: 0 Increased Contracted Capacity / Capacity Planning Volume Annual: 0 No.

of process Next process(es) 1 2 List each separate process fundicion Total Downtime Availability 40 51 40 0 0 0 0 0 0 0 0 0 0 0 0% #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 0 #VALUE! PDR Start Time PDR End Time 9:00 9:30 10:30 12:43 15:12 17:29 Next process(es) No.No. of process Part #: List each separate process .

Next process(es) No. of process Part #: List each separate process PDR Start Time PDR End Time List each separate process PDR Start Time PDR End Time Next process(es) No. of process Part #: .

Next process(es) No. of process Part #: . of process Part #: List each separate process PDR Start Time PDR End Time List each separate process PDR Start Time PDR End Time Next process(es) No.

of process Part #: List each separate process PDR Start Time PDR End Time .Next process(es) No.

PDR SUMMARY FORM Daily: 0 Daily: 0 NAFTA SYSTEM AVAILABILITY (TIME) Shifts Per Day [=Shifts per Week / Working Days] Minutes Per Shift Gross Min Available Per Day 3 480 1440 Scheduled Changeover / Tool Break/Lunch Changes [minutes [minutes per day] per day] 150 60 8 PDR STUDY RESULTS .

] PDR Good Parts Produced [pcs.] Base Required PDR Line Speed (Parts/hour) 0.Performance #DIV/0! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! Length of PDR (minutes) PDR Total Parts Attempted [pcs.0 376 369 0.] PDR Good Parts Produced [pcs.0 #VALUE! PDR STUDY RESULTS PDR Actual Downtime [minutes] Length of PDR (minutes) PDR Total Parts Attempted [pcs.] 40 51 40 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 376 369 352 0 0 0 0 0 0 0 369 352 350 0 0 0 0 0 0 0 Base Required PDR Line Speed (Parts/hour) .

] PDR Good Parts Produced [pcs.] 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Base Required PDR Line Speed (Parts/hour) .] 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Base Required PDR Line Speed (Parts/hour) PDR STUDY RESULTS PDR Actual Downtime [minutes] Length of PDR (minutes) PDR Total Parts Attempted [pcs.] PDR Good Parts Produced [pcs.0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 PDR STUDY RESULTS PDR Actual Downtime [minutes] Length of PDR (minutes) PDR Total Parts Attempted [pcs.

] PDR Good Parts Produced [pcs.] PDR Good Parts Produced [pcs.] 0 0 0 0 0 0 0 0 Base Required PDR Line Speed (Parts/hour) .0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 PDR STUDY RESULTS PDR Actual Downtime [minutes] Length of PDR (minutes) PDR Total Parts Attempted [pcs.] 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Base Required PDR Line Speed (Parts/hour) PDR STUDY RESULTS PDR Actual Downtime [minutes] Length of PDR (minutes) PDR Total Parts Attempted [pcs.

] 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Base Required PDR Line Speed (Parts/hour) .0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 PDR STUDY RESULTS PDR Actual Downtime [minutes] Length of PDR (minutes) PDR Total Parts Attempted [pcs.] PDR Good Parts Produced [pcs.

Planned Maintenance [minutes per day] DY RESULTS 45 Unscheduled Net Min Available Downtime [minutes Per Day per day] 120 1065 Time Scheduled for Other Parts / Customers [minutes per day] Net minutes available / day for Study parts 360 705 .

Additional Parts/Hr required (due to true scrap) Actual PDR Line Speed [Parts/hour] Actual PDR >= Required Line Speed + Additional Req'd Parts? PDR FTC (%) 0.1% Actual PDR Line Speed [Parts/hour] Actual PDR >= Required Line Speed + Additional Req'd Parts? PDR FTC (%) #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! DY RESULTS Additional Parts/Hr required (due to true scrap) #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! .0 #DIV/0! #DIV/0! 98.

#VALUE! #VALUE! #VALUE! #VALUE! #VALUE! DY RESULTS Additional Parts/Hr required (due to true scrap) Actual PDR Line Speed [Parts/hour] Actual PDR >= Required Line Speed + Additional Req'd Parts? PDR FTC (%) Actual PDR Line Speed [Parts/hour] Actual PDR >= Required Line Speed + Additional Req'd Parts? PDR FTC (%) #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! DY RESULTS Additional Parts/Hr required (due to true scrap) #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! .

#VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! DY RESULTS Additional Parts/Hr required (due to true scrap) Actual PDR Line Speed [Parts/hour] Actual PDR >= Required Line Speed + Additional Req'd Parts? PDR FTC (%) Actual PDR Line Speed [Parts/hour] Actual PDR >= Required Line Speed + Additional Req'd Parts? PDR FTC (%) #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! DY RESULTS Additional Parts/Hr required (due to true scrap) #VALUE! #VALUE! .

#VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! DY RESULTS Additional Parts/Hr required (due to true scrap) #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! Actual PDR Line Speed [Parts/hour] Actual PDR >= Required Line Speed + Additional Req'd Parts? PDR FTC (%) .

86% 0.Completed by: SYSTEM CAPACITY (UNITS) Ideal Cycle Time [seconds] % Scrap % True Scrap (Total Loss) Estimated Throughput For Study Parts Per Day 30 1.00% 1410 Required / Contracted Parts Per Day 0 0 .

] 7 17 2 0 0 0 0 0 0 0 .] 7 PDR Actual Scrap [pcs.PDR Actual Scrap [pcs.

] 0 0 0 0 0 .0 0 0 0 0 PDR Actual Scrap [pcs.] 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 PDR Actual Scrap [pcs.

0 0 0 0 0 0 0 0 0 0 PDR Actual Scrap [pcs.] 0 0 .] 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 PDR Actual Scrap [pcs.

0 0 0 0 0 0 0 0 0 0 0 0 0 PDR Actual Scrap [pcs.] 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 .

00% RESULT: Possible Constraint Operation (>90%) Are Marked [X] Minimum Maximum .by: Post Process Buffers % Utilization 0.

.

.

.

.

.

.

.

.

.

of operation Contracted Capacity 0 0 Minutes Per Shift List each separate SEQUENTIAL OPERATION in the Constraint Line Shift 1 Shift 2 Op1 600 600 Op2 600 600 Op3 600 600 Op4 600 600 Op5 600 600 .Supplier Name Part(s) Description Part(s) Number Increased Contracted Capacity / Capacity Planning Volume Annual: Next operation(s) Annual: No.

of operation PRODUCTION SYSTEM List each separate SEQUENTIAL OPERATION in the Production Line PDR Start Time PDR End Time .No. of operation Next operation(s) OPERATIONS 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 List each separate SEQUENTIAL OPERATION in the Constraint Line Op1 Op2 Op3 Op4 Op5 Shifts Per Week 10 10 10 10 10 Gross Min Available Per Day 0 0 0 0 0 0 0 0 0 1200 1200 1200 1200 1200 0 0 0 0 0 0 0 0 0 0 0 Next operation(s) No.

0 0 Op1 10:30 17:29 0 0 Op2 10:30 17:29 0 0 Op3 10:30 17:29 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Op4 10:30 17:29 Op5 10:30 17:29 0 0 0 0 0 0 0 0 0 0 0 0 0 0 This form to be used by the Supplier to identify a constraint operation when a process h .

PDR SUMMARY FORM Daily: Daily: 0 CONSTRAINT PRODUCTION L 0 Minutes Per Shift Scheduled Break/Lunch (minutes) Shift 3 Per Day Shift 1 Shift 2 Shift 3 0 1200 50 50 0 0 1200 50 50 0 0 1200 50 50 0 0 1200 50 50 0 0 1200 50 50 0 0 0 0 0 0 0 0 .

] MCBF [cycles] PDR Good Parts Produced [pcs.0 0 0 OPERATION AVAILABILITY (TIME) Scheduled Changeover / Tool Break/Lunch Changes [minutes [minutes per day] per day] Planned Unscheduled Maintenance Downtime [minutes [minutes per day] per day] 100 100 100 100 100 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 20 20 30 20 20 0 0 0 0 0 0 0 0 0 30 30 30 30 30 0 0 0 0 0 0 0 0 0 0 0 0 0 PDR Actual Planned Downtime [minutes] PDR Actual Unplanned Downtime [minutes] Length of PDR (minutes) PDR Total Parts Attempted [pcs.] .

0 350 350 #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! n when a process has been flagged as a potential constraint.0 352 350 40 0 379. .40 0 379.0 352 352 40 0 379.0 350 350 40 0 379.0 352 352 40 0 379.

RAINT PRODUCTION LINE: minutes) Changeovers/Tool Changes (minutes) Per Day Shift 1 Shift 2 Shift 3 Per Day 100 0 0 0 0 100 0 0 0 0 100 0 0 0 0 100 0 0 0 0 100 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 .

0 0 0 0 0 0 MTTR [minutes] Time allocated for Net minutes Net Min Available other PN's (FIAT. available / day for Per Day Chrysler. or others) Study parts [minutes per day] 1050 1050 1040 1050 1050 0 0 0 0 0 0 0 0 0 1050 1050 1040 1050 1050 0 0 0 0 0 0 0 0 0 0 0 Cycle Time [seconds] 55 55 65 50 55 PDR STUDY RESULTS Base Required Additional Parts/Hr PDR Line Speed required (due to (Parts/hour) true scrap) Actual PDR Line Speed [Parts/hour] Actual PDR >= Required Line Speed + Additional Req'd Parts? .

0 0.0 55.0 55.4 YES 0.0 55.7 YES 0.4 YES 0.0.0 0.0 0.4 YES #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! Overall FTC .0 55.0 55.0 0.0 0.7 YES 0.

Date: Completed by: Planned Maintenance (minutes) Unschedu Shift 1 Shift 2 Shift 3 Per Day Shift 1 10 10 0 20 15 10 10 0 20 15 15 15 0 30 15 10 10 0 20 15 10 10 0 20 15 0 0 0 0 0 0 0 .

0
0
0

OPERATION CAPACITY (UNITS)

Buffer Before
Operation

Buffer After
Operation

% True Scrap
(Total Loss)

Estimated
Throughput For
Study Parts Per
Day

#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!

0
0
0
0
0
0
0
0
0
0
0
0
0
0

1145
1145
960
1260
1145
0
0
0
0
0
0
0
0
0

#VALUE!

0

0

Availability

Performance

% Scrap

0.00%
0.00%
0.57%
0.00%
0.00%

PDR
FTC
(%)

PDR Actual Scrap
[pcs.]

Overall Equipment Effectiv
(OEE)

100.0%

0

100.0%

85.1%

100.0%

0

100.0%

85.1%

99.4%

2

100.0%

100.6%

100.0%

0

100.0%

77.0%

100.0%

0

100.0%

84.7%

85.1%
85.1%
100.0%
77.0%
84.7%

#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!

#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!

#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!

#VALUE!

#VALUE!

#VALUE!

#VALUE!

#VALUE!

#VALUE!

99.4%

Unscheduled Downtime (minutes)

Shift 2

Shift 3

Per Day

15

0

30

15

0

30

15

0

30

15

0

30

15

0

30
0
0
0
0
0
0
0

00% 0. or CPG l Equipment Effectiveness (OEE) % Utilization RESULT: Possible Constraint Operation (>90%) Are Marked [X] 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% #NAME? 0.00% 0.00% 0.00% 0.0 0 0 Contracted Parts Per Day (Includes Spare Parts).00% 0.00% #NAME? True Scrap of Production Lines DOWNSTREAM to Constraint #NAME? #NAME? #NAME? #NAME? #NAME? #NAME? #NAME? #NAME? #NAME? #NAME? .00% 0.00% 0. Daily Tooling Capacity.

85.1%
85.1%
100.0%
77.0%
84.7%
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!

.

aprile 2011 Current No new supplier technology location Pagina 58 di 91 . etc. and in production facilities." chart. etc. with production tooling. Otherwise. 3) (max. etc. and be intended production operators. 2B Operator Skill Level 3A Capacity Verification 3B Sub-tier Capacity The Supplier shall perform PDR (and other Process Audit) activities on their sub-tier suppliers and components (see 2E on the Process Audit tool).# Item Guidelines NAFTA The contracted capacity (Daily Tooling Capacity) shall be enough to meet Customer requirements. If the Increased Contract Capacity (FIAT) or Capacity Planning Volume (CPV) exceeds the contract capacity. If a constraint is identified. tools. & gages. if applicable) must meet or exceed the Required Line Speed. Rework and repair are NOT counted in the number of acceptable parts. FTC shall each be calculated separately. as shown on the "Performance Capability Reqs. overtime. performed. When running higher volumes. 2A Tooling Status & Operating Conditions The PDR shall be run on production tooling.). the Supplier shall demonstrate correct management techniques to ensure the constraint is optimized. For multiple production lines. Verify that all sub-tier suppliers are able to provide the required number of parts per day. plan FIAT design increase/new for current limited but issues needs responsible tooling supplier resources exist to improvement location (max. and/or cavities. Operating conditions shall mimic those of regular production. 4B Process Performance and Capability The parts shall meet all Performance and Capability requirements. 4A First Time Capability The Supplier shall demonstrate a First Time Capability (FTC) of 90% or greater. Part loading and unloading responsibility shall be assigned and itemized in operator instructions.) Assessmen t (Sup. Operators used in the PDR shall be fully trained on the process. quality controls. with required breaks. the Constraint Analysis shall be performed with appropriate contingency (Risk Mitigation) plans in place. and buffer/WIP quantities before and after identified and managed. the Supplier shall still be able to do all required maintenance activities.. 3) meeting them (max. it shall be temporary and the Supplier shall be able to meet these requirements through standard means (e. 1A Contracted Capacity 1B Spare / Service Parts The Supplier's volumes of parts intended for Spare Parts (After Sales) shall be considered into the evaluation of Supplier's production capacity. maintenance. PDR SUMMARY FORM PCPA .g. good plan them for management Supplier New Past launch Some significDesign incomple of Incomplete Appearance paaware Supplier awareTooling Kick-o One or more keSupplier has aSupplier is "y Supplier not me Part or related Part or related part has some historical warranty (no field actions) Chrysler / Capacity commodity issues or requirements list. equipment. The Supplier shall meet the Required Line Speed with the Spare Parts included.) Line Utilization shall be 90% or less for all production lines. 3) other (see other (see other (see other (see other (see other (see other (see other (see other (see other (see other (see other (see other (see other (see other (see other (see Comments) Comments) Comments) Comments) Comments) Comments) Comments) Comments) Comments) Comments) Comments) Comments) Comments) Comments) Comments) Comments) Review the * Minimum Review the * Minimum Quality Quality Requireme Requireme nts (SQE) nts (SQE) * * Statement Manufactu of ring Requireme Feasibility nts (Sup. weekend runs. The throughput of the Final process or operation (and also that of the Constraint process or operation. 5A Line Utilization 5B Constraint Management Minimal/minor Initial design Customer impac Carryover design The Supplier's volumes of parts intended for Spare Parts (After Sales) shall be considered into the eval Past successful launches Supplier awareTooling Kick-ofKey program de Supplier has aSupplier is "g Supplier meetin Part or related Part or related part has low historical warranty (no field actions) Complete and Supplier acceptable aware of list of special requirements characteristic and can meet s.

PDR SUMMARY FORM AUDITOR REMARKS (SQE) BOX SCORE Supplier _________________ (Name Signature) OPEN ISSUE CORRECTIVE ACTION RESPONSIBLE DEPARTMENT SQE_____________________ (Name Signature) .

AUDITOR REMARKS (SQE) OPEN DATE Supplier _________________ (Name Signature) TARGET DATE ACTUAL DATE STATUS SQE_____________________ (Name Signature) .

etc. etc. field campaigns.PDR SUMMARY FORM Score Classification Advance Quality D JOB STOPPER • Very late to required milestone and will cause othe required milestone/vehicle launch • Risk Mitigation Plan does not exist • Certain to cause delay in milestone/vehicle launch • Has resulted in critical build/launch issues and cer production (yardholds.) • Chronic quality system or systemic control failures MODERATE RISK • Potentially late to required milestone • Risk Mitigation Plan exists and is acceptable • Moderate Risk to milestone/vehicle launch • May result in moderate quality spills in production characteristics • Non-chronic quality system or systemic control fai 4 LOW RISK • Progressing according to required milestone timin • Low Risk to milestone/vehicle launch • Isolated documentation issue 5 IMPLEMENTED ACTIVITY NA NOT APPLICABLE NV NOT EVALUATED 1 2 3 Complete and approved . PRIs.) • Total lack of quality system or systemic control JOB STOPPER RISK • Late to required milestone and may cause other d milestone/vehicle launch • Risk Mitigation Plan exists but is not acceptable or milestone • May cause delay in milestone/vehicle launch • Has resulted in moderate build/launch issues or m production (yardholds. PRIs. field campaigns.

will be evaluated at a later date. . etc.) or systemic control nd may cause other deliverables to be late to their required ut is not acceptable or requires unrealistic timing to meet e/vehicle launch ild/launch issues or may cause critical quality spills in eld campaigns.ance Quality Definition ne and will cause other required deliverables to be late to their nch t exist lestone/vehicle launch launch issues and certain to cause critical quality spills in eld campaigns. etc.) stemic control failures milestone nd is acceptable vehicle launch ity spills in production not impacting critical / safety or systemic control failures uired milestone timing e launch e Item does not apply for this audit Item was not evaluated at this audit.

verification on-going Continuous improvement activities ongoing Isolated documentation issue • Complete and approved • Best practice not apply for this audit his audit. Results in process producing defective material with no adequate controls in place Total lack of quality system or systemic control • Has resulted in moderate quality spills (NCTs.) or may result in critical quality spills in the future • Corrective Action Plan exists but is not acceptable. needs containment action • Can result in process producing defective material with inadequate controls in place • Chronic quality system or systemic control failures • May result in moderate quality spills in the future not impacting critical / safety characteristics • Corrective Action Plan exists and is acceptable • Can result in process becoming unstable (may need additional controls added) • Non-chronic quality system or systemic control failures • • • • Low risk for quality spills Corrective Action Plan / corrective actions initially implemented. . PRIs.) Corrective Action Plan does not exist. will be evaluated at a later date. etc. Bills. field campaigns.Current Production Definition • • • • Has resulted in critical quality spills (yardholds. etc.

Characteristic Description 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 .Supplier Name Part(s) Description Part(s) Number Quantity of Parts Measured Char. # Quantity of Parts Accepted Class.

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 .

PDR SUMMARY FORM Initial Process Study / Pro Specification and Tolerance Attribute / Variable Process or Machine Char? 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 .

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 .

67 2 Initial Process Study / Process Performance and Capability All parts OK? (Y/N) Required PP / PPK PP PPK #DIV/0! .PDR SUMMARY FORM 1.33 1.

.

Attribute Variable Process Machine Yes No Date: Completed by: bility Required CP / CPK CP CPK #DIV/0! Required CM / CMK CM .

.

00% 0.00% 0.00% 0.00% 0.00% Acceptable? (Y/N) .00% 0.00% 0.00% 0.CMK Gage R&R % #DIV/0! 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.

0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% .00% 0.00% 0.00% 0.00% 0.00% 0.

Stoplight CAPABILITY .Char # Classification Characteristic Description PDR SUMMARY FORM REGULATORY .Homologation <H> CRITICAL .Safety <S> / Report REGULATORY .Emissions <E> REGULATORY .Diamond <D> / 1D CRITICAL .Qh General / Non-critical .

Specification USL LSL Attribute/Variable Attribute Variable .

Process or Machine? Process Machine 1 2 3 4 5 6 7 8 9 10 .

11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 .

26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 .

41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 .

56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 .

71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 .

86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 .

819 3.847 2.895 3.97 3.532 3.326 2.588 3.704 2.689 3.735 3.778 3.059 2.472 3.336 3.128 1.Gage R&R1 Gage R&R2 Gage R&R3 Gage R&R4 Mean #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Range #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! 1.407 3.64 3.173 3.931 .078 3.258 3.534 2.693 2.858 3.

Dev.Subgroup Size Avg. Est. #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! d2 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A Std. Dev. Range Std. (Ravg/d2) #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A Dimensionally Correct? #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! .

PP PPK #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! CP CPK #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! CM CMK #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! Ppu / Cmu #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! .

Ppl / Cml #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! Cpu #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! Cpl #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! .

.

.

7 .5 05-Dec-14 2.1 19-Sep-13 2.Date Revision Number 21-Dec-12 2.6 27-Feb-15 2.3 14-Aug-14 2.2 14-Mar-14 2.4 05-Sep-14 2.0 12-Feb-13 2.

added logos to remaining sheets. along with Availability % and Perfo % Added Customer plant codes. new PDR Summary form. fixed bug on Capacity Analysis when manually altering cell of PDR Summary changed to match other tools Fixed bug on PDR Summary. revised Open Issues (added Open Date and Actual D columns). and locations Split Actual Downtime in the PDR Results section into Planned and Unplanned downtime Revised method of determining additional parts required due to true scrap. a comments to cells on Data Sheet. added "Custo Plant" and "Customer Plant Loc" to data sheet. Revised comments for downtime factors Added note and conditional formatting for when Performance calculation exceeds 100% Changed sector names to region names Updated capability requirements to match global commonized standards Fixed error on Capacity Analysis with Annual contracted capacities . add to allow sector logo to switch when different sectors are chosen on the PDR Summary sheet. keyed assumed working days to "Customer Pla Removed assumed working days (made manual entry for annual volumes).Revision Description Renamed tabs. Revised FIAT Industrial logo to CNH Industrial. added Capability Requirements. removed CNH Ind added Maserati Added OEE calculations (Overall Equipment Effectiveness). eliminated rounding errors on capacity analysis. added Data Sheet. Unprotected Operating Pattern cells Revised scoring (Moderate Issue to Moderate Risk. added Requirements tab Fixed truescrap function for when scrap is zero Added "Department" column and conditional formatting to Status column on Open Issues. names. No Risk to Low Risk) Plant name and code are manual entry Revised logo to FCA logo Added comments to Open Issues sheet Revised "Planned Cycle Time" to "Ideal Cycle Time" and clarified comments. revised Capacity Analysis and Co Analysis.

Capability Reqs. Capacity Analysis Data Sheet PDR Summary PDR Summary Performance . PDR Summary. Capacity Analysis All PDR Summary. Open Issues.Sheet All Capacity Analysis Data Sheet. Capacity Analysis . Capacity Analysis. Constraint Analysis Data Sheet Data Sheet Capacity Analysis Data Sheet Scoring Data Sheet All Open Issues Data Sheet.