SECTION 2.

13 - HIGH VOLUME PRODUCTION TRIAL

(HVPT)
***** PRODUCTION PREPARATION *****

PURPOSE: To explain the procedure for conducting a High Volume

Production Trial.

EXPLANATION:

The goal of a High Volume Production Trial (HVPT) is to identify and

countermeasure any quality or productivity problems prior to Start of
Production in a Mass Production setting. The HVPT is a confirmation of
supplier readiness for mass production. It must be conducted early
enough to allow adequate time for improvement and countermeasure
confirmation. Requirements and timing will be provided by Reyes
Program Management Division.

Prior to the HVPT, it is the supplier’s responsibility to run production trials

at the manufacturing location using Mass Production conditions (i.e. line-
speed, tooling, cycle time, etc.) as closely as possible. The HVPT should
be the culmination of these trials and all other elements of a successful
part and process evaluation plan.

SUPPPLIER RESPONSIBILITY:

1. The HVPT shall be completed per the timing indicated on the

REYES Master Schedule. The supplier must include the specific
timing on the Quality Assurance Schedule. In some cases, REYES
SPPT will coordinate specific dates with the supplier. The trial
must be conducted early enough to allow adequate follow-up for
problems discovered prior to SOP. REYES reserves the right to
visit the supplier during any and all trials.

2. The supplier must include all required processes in the HVPT,

with special attention paid to bottlenecks, final assembly and
new processes, facilities or cells. All processes should be run in
the correct sequence and notations made to indicate any
processes which had to be run “off-line” due to new model/old
model build out or change over requirements.

3. Trials must be representative of Mass Production.

A. Facilities, tooling, and equipment must be complete.

B. Operators must be trained and must be those who will be

used for Mass Production. The trial should include
operators on all shifts.

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 SECTION 2.13 - HIGH VOLUME PRODUCTION TRIAL
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***** PRODUCTION PREPARATION *****

C. Trials shall be performed for each machine (e.g. die, mold

cavity, etc.) or process (e.g. assembly line).

D. Production method must be the same as Mass Production

and include:

1) Written Standardized work

2) Mass Production Quality Control system
3) Tool changes and set-ups
4) Mass Production line speed

E. Material must be the same as Mass Production materials,

and should be produced at the required capacity set by
REYES and/or a quantity equivalent to Mass Production
scale.

Note: All Direct Run Good Parts can be used to

support mass production shipments providing no
late ECI changes or other tuning as required by
REYES occur (any reworked parts must be approved
by REYES Quality). These parts need to be
identified as HVPT Parts or be traceable by date
code (date code is the preferred method). REYES
will not accept trial parts produced prior to supplier
receipt of Provisional Approval.

4. Trial targets for quality and quantity must be clearly specified.

Definitions

Quality – Parts produced which satisfy the approved Part

Inspection Standard, the Part Mass Production Drawing,
and boundary sample (if applicable).

Quantity – Rate of Direct Run Good Parts (no re-worked

parts) which satisfy REYES’s demand (Mass Production
volume requirement).

Example 1

Supplier A – Dedicated REYES Facility

Operating Constraints*
Total daily operating time = 8.5 hours -20 minutes real allowance
-30 minutes meal break
-19 minutes for Quality checks
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 SECTION 2.13 - HIGH VOLUME PRODUCTION TRIAL
(HVPT)
***** PRODUCTION PREPARATION *****

Net Operating Time = 7 hours 21 minutes

REYES daily requirement = 200 parts

200
Therefore, parts per hour to meet REYES demand = --------- = 27.21 parts per
hour
7.35hrs

Example 2

Supplier B – Shared Facility

Operating Constraints*
Total daily operating time = 8.5 hours -20 minutes rest allowance
-30 minutes meal break
-19 minutes for Quality Checks
-50 minutes for changeover
-151 minutes to produce another part

Net Operating Time = 4 hours

REYES daily requirement = 200 parts

200
Therefore, parts per hour to meet REYES demand = --------- = 50 parts per hr
4 hrs

* NOTE: The supplier should incorporate their own unique

operating constraints when calculating net operating
time.

5. During each individual trial, production must be continuous at

Mass Production speed with the output of the process constantly
recorded, typically for a period of 1 hour. The process should
then be stopped, reviewed, and countermeasured for
improvement and then tried again. This cycle should be
repeated until the target criteria for the process output is
achieved. The supplier must record results on the High Volume
Production Trial Status Sheet. The sheet is then evaluated
and graded Pass/Fail by the REYES evaluation team.

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 SECTION 2.13 - HIGH VOLUME PRODUCTION TRIAL
(HVPT)
***** PRODUCTION PREPARATION *****

6. The supplier should track problems found, countermeasures, and

follow-up items, and document them on a Problem Follow-Up
Sheet. The supplier should also consider workability, safety, and
ergonomics issues, as well as problems related to parts and
capacity.

7. When the trial is completed, the supplier must submit the High
Volume Production Trial Status Sheet with results, and the
Problem Follow-Up Sheet to both REYES Program Management
and REYES Quality.

Note: The supplier must complete and submit any

additional documentation (e.g. preparation
checksheet), as requested by REYES to support this
activity.

8. If the supplier is unable to achieve target levels after

countermeasuring the process, they must notify REYES Program
Management and REYES Quality immediately. This notification
should include the supplier’s plan for achieving the target.

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