Capacity Verification Run at Rate Ipa

IPA Form No.
EE517 Issue 1
CAPACITY VERIFICATION (Production Readiness Review / RUN@RATE)

1 Part Number 4 Run@Rate Date
2 Part Description 5 Supplier Name
3 XXX 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 XXX parts (Allocation %) %
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@RATE Results
24 Number of bad parts pcs

25 First time capability % ((23-24)/24)*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)) %
32 Bottleneck operation X
SHADED CELLS ARE CALCULATED and protected 34 SUMMARY 35
RUN@RATE results are acceptable and meet XXX capacity planning volume requirements: Overall Process Auditor Information
Status
The attached capability study results meet XXX 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:

IPA Form No. EE517 Issue 1
CAPACITY VERIFICATION (Production Readiness Review / RUN@RATE)
1 Part Number 30301458B 4 Run@Rate Date February 14, 2004

2 Part Description Inflator retainer bracket 5 Supplier Name Acme Machining
3 XXX 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
9 Working hours/shift hours 7.5 8.5 7.0 7.0 10.5
I - Supplier
Standards
Shifts/ day shifts 3 2 3 3 1

Working
10
11 Days/ week days 5 5 5 5 5
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 XXX parts (Allocation %) % 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)/24)*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%
32 Bottleneck operation X X
SHADED CELLS ARE CALCULATED and protected 34 SUMMARY 35
RUN@RATE results are acceptable and meet XXX capacity planning volume requirements: YES Overall Process Auditor Information
Status
The attached capability study results meet XXX requirements: NO Utilization % Name: Gerald Biggs
33
Corrective actions are required: YES Date: April 1, 2404 Company: XXX
97.13% Acceptable
New production readiness trial run is required: YES Date: May 16, 2004 Location: Mesa, AZ
36 Supplier representative signature: Tom Alison Auditor signature: Gerald Biggs

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
Signficant?
Critical and
Lower
Standard Upper
Limit
7
Critical and
Signficant?
Lower
Standard Upper
Limit
7
Critical and
Signficant?
Lower
Standard Upper
Limit
7
Signficant?
Critical and
Lower
Standard Upper
Limit
7
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
Critical and
Signficant?
Upper Lower
Standard
Deviation
Limit Limit
7
Critical and
Signficant?
Upper Lower
Standard
Deviation
Limit Limit
7
Critical and
Signficant?
Upper Lower
Standard
Deviation
Limit Limit
7
Critical and
Signficant?
Upper Lower
Standard
Deviation
Limit Limit

Capacity Verification Run at Rate Ipa

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IPA Form No.

CAPACITY VERIFICATION (Production Readiness Review / RUN@RATE)

7 Process Step STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6

Shifts/ day shifts

15 Quoted Production Rate (part # item 1) pcs/hour

24 Number of bad parts pcs

36 Supplier representative signature: Auditor signature:

CAPACITY VERIFICATION (Production Readiness Review / RUN@RATE)

1 Part Number 30301458B 4 Run@Rate Date February 14, 2004

7 Process Step STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6

Shifts/ day shifts 3 2 3 3 1

24 Number of bad parts pcs 5 2 4 12 4

Reason text Reprogramming

36 Supplier representative signature: Tom Alison Auditor signature: Gerald Biggs

SUPPLIER PROCESS CAPABILITY

SUPPLIER PROCESS CAPABILITY

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

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