Plant Dingolfing

TG-40
05.11.2020
KPI based on IPS-Q.
Page 1
Overview definiton.
• Direct Runner (DR)
• Rework Minutes (RW Min)
• Defects per 100 Vehicles (RT)
• Defects per 100 Vehicles (WT)
• Defect per Unit (DPU)
• Q-Index (QI)
• Short Track (ST)
• Damaged Rate (based on DRQ)
Plant Dingolfing
TG-40
05.11.2020
KPI based on IPS-Q.
Page 2
Direct Runner (DR).
Definition:
Percent the number of non side track F2 vehicles. The calculation of the plant value takes place by including all
report relevant series. Launched derivatives are relevant from 3 months after SOP.

𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑠𝑖𝑑𝑒 𝑡𝑟𝑎𝑐𝑘 𝐹2 𝑣𝑒ℎ𝑖𝑐𝑙𝑒𝑠 Date: 01.09.2020

Calculation: 1− Definition: Plant Cockpit
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝐹2 𝑣𝑒ℎ𝑖𝑐𝑙𝑒𝑠
QKM: confirmed

Time periods:
• F2 Date (Vehicles)
• F2 Date (Reworks)

Data:
• measuring relevant F2 vehicles
• measuring rework with rework duration > 30 min.

Restriction:
All reworks (main or consequential, no totals) with minutes greater than 30 minutes(*) that occur after Assembly
ON will be considered in the calculation. The rework activity “checked ok" caused no side track vehicle.
The recording of the rework duration takes place in accordance with the valid work instruction rework recording assembly DID-DE-
(*)

0162450 or DID-DE-2788418.

Summary Direktläuferquote / Direct Pass: DID-DE-0226682

(If a side track vehicle is assigned two debited cost centre, this vehicle is calculated in both quota, in the quota for the higher
level of the hierarchy are counted only once.)
Plant Dingolfing
TG-40
05.11.2020
KPI based on IPS-Q.
Page 3
Direct Runner (DR).
valid until 08/31/2020
Definition:
Percent the number of non offline reworked F2 vehicles. The calculation of the plant value takes place by
including all report relevant series. Launched derivatives are relevant from 3 months after SOP.

Offline vehicles Date: 01.03.2017

Calculation: 1 Definition: Plant Cockpit
Number of F 2 vehicles
QKM: confirmed

Time periods:
• F2 Date (Vehicles)
• F2 Date (Reworks)

Data:
• measuring relevant F2 vehicles
• measuring relevant offline reworks (on credit cost centre or station)

Restriction:
The rework activity “checked ok" or rework minutes(*) equal 0 minute are not considered offline vehicle
defects. Only defects and rework that occur after Assembly ON will be considered in the calculation.

The recording of the rework duration takes place in accordance with the valid work instruction rework recording assembly DID-DE-
(*)

0162450 or DID-DE-2788418.

Summary Direktläuferquote / Direct Pass: DID-DE-0226682

(If a offline vehicle is assigned two debited cost centre, this vehicle is calculated in both offline quota, in the offline quota for
the higher level of the hierarchy are counted only once.)
Plant Dingolfing
TG-40
05.11.2020
KPI based on IPS-Q.
Page 4
Direct Runner (DR).
Calculation in QRP:
Measuring relevant F2 vehicles Measuring relevant offline reworks
(QRP_IPS-Q_nn_TS_EV) (QRP_IPS-Q_nn_RW_EV)

Select > 0 Min.

Measure of DR

1 - [Offline Vehicle].[No. of Select Offline

Vehicles]/[F2 Vehicle].[No. of Vehicles]
Select w/o Control characteristic
 Format as Percentage
Plant Dingolfing
TG-40
05.11.2020
KPI based on IPS-Q.
Page 5
Rework Minutes (RW Min).
Definition:
Total of rework minutes (Inline + Outline) divided by the number of vehicles F1. The calculation of the plant
value takes place by including all report relevant series. Launched derivatives are relevant from 3 months after
SOP.

Total rework duration Date: 01.03.2017

Calculation: Definition: Plant Cockpit
F1Volume
QKM: confirmed

Time periods:
• F1 date (Vehicles)
• Rework date (Rework duration)

Data:
• measuring relevant F1 vehicles
• measuring relevant reworks (on credit cost centre or station)

Restriction:
Rework period corresponds to F1 period (there are all yesterday's Rework defects in relation to all yesterday’s
F1 vehicles yesterday set). Only reworks that occur after Assembly ON and rework minutes greater than 0
minute(*) will be considered in the calculation.

The recording of the rework duration takes place in accordance with the valid work instruction rework recording assembly DID-DE-
(*)

0162450 or DID-DE-2788418.

Summary Nacharbeit / Rework: DID-DE-0226910

Plant Dingolfing
TG-40
05.11.2020
KPI based on IPS-Q.
Page 6
Rework Minutes (RW Min).
Calculation in QRP:
Measuring relevant F1 vehicles Measuring relevant inline/offline reworks
(QRP_IPS-Q_nn_TS_EV) (QRP_IPS-Q_nn_RW_EV)

Select > 0 Min.

Measure of RWQ
Sum([RW Rework Duration (Key
count]/[F1 Vehicle].[No. of Vehicles]
Hint:
If [Last Paint Date] isn‘t useable then make an own filter like this:
[Rework Date] greater than or equal [Entry Date Assembly]

 Format as Number (1,234.57;-1,234.57)

Plant Dingolfing
TG-40
05.11.2020
KPI based on IPS-Q.
Page 7
Defects per 100 Vehicles (RT).
Definition:
Number of defects BI 1-7 in Road Test (RT) in relation to the number of vehicles tested in the Road Test
(based on 100 tested vehicles). The calculation of the plant value takes place by including all report relevant
series. Launched derivatives are relevant from 3 months after SOP.

Number of defects Date: 13.05.2014

Calculation: 100 Definition: Plant Cockpit
tested vehicles RT
QKM: confirmed

Time periods:
• Capture date (Vehicles)
• Capture date (Defects)

Data:
• measuring relevant tested vehicles
• measuring relevant defects (on Road Test)

Restriction:
Capture period is valid for both issues, vehicles and defects (there are all yesterday's captured defects in
relation to the tested vehicles yesterday set). There are all captured defects viewed. PMG2 defects are not
included.

Technische Umsetzung:
SPC_PE_REDUNDANT.NERGEBNIS = 1
AND IBSVI_BT_INFO_MEASURE_REL.MEASURE_RELEVANT = “J”
AND SPA_KOPF.NBUSINESSRATIO = 1
AND M_NAERG_MM_ZUW. NSTEUERFLAG = 0
Plant Dingolfing
TG-40
05.11.2020
Kennzahlen aus IPS-Q.
Page 8
Defects per 100 Vehicles (WT).
Definition:
Number of defects BI 1-7 in Water Test (WT) in relation to the number of vehicles tested in the Water Test
(based on 100 tested vehicles). The calculation of the plant value takes place by including all report relevant
series. Launched derivatives are relevant from 3 months after SOP.

Number of defects Date: 13.05.2014

Calculation: 100 Definition: Plant Cockpit
tested vehicles (WT )
QKM: confirmed

Time periods:
• Capture date (Vehicles)
• Capture date (Defects)

Data:
• measuring relevant tested vehicles
• measuring relevant defects (on Water Test)

Restriction:
Capture period is valid for both issues, vehicles and defects (there are all yesterday's captured defects in
relation to the tested vehicles yesterday set).

Technische Umsetzung:
SPC_PE_REDUNDANT.NERGEBNIS = 1
AND IBSVI_BT_INFO_MEASURE_REL.MEASURE_RELEVANT = “J”
AND SPA_KOPF.NBUSINESSRATIO = 2
AND M_NAERG_MM_ZUW. NSTEUERFLAG = 0
Plant Dingolfing
TG-40
05.11.2020
KPI based on IPS-Q.
Page 9
Defect per Unit (DPU).
Definition:
Unique number of defects of reworks divided by the number of F1 vehicles multiplied by 1,000,000 in ppm. The
calculation of the plant value takes place by including all report relevant series. Launched derivatives are relevant
from 3 months after SOP.
Date: 13.05.2014
No. of defects Definition: Plant Cockpit (not integrated, planned)
Calculation: 1000000
F1 Vehicles QKM: New request, since 1. April 14
(All plants report to AQ-20)

Time periods:
• F1 Date (Vehicles)
• Rework Date (Reworks)

Data:
• measuring relevant F1 vehicles
• measuring relevant reworks

Restriction:
Only causal defects with rework duration greater than or equal 1 minute(2) are considered, recorded after
assembly ON. The inline error handling (1) and defects with the rework activity ‘Checked OK‘ will not be
considered.
The defects correspond to the error slip, which is defined by the fact that the fault generation, detection and correction has not taken
(1)

place in one of this conditions: Defect processing in the own Process Leader Area; Defect detection in own area, rework inline; Defect
processing in the following Lead Area/Process Leader Area.

The recording of the rework duration takes place in accordance with the valid work instruction rework recording assembly DID-DE-
(2)

0162450 or DID-DE-2788418.

Summary Fehler pro Einheit / Defects per Unit: DID-DE-0173681

Plant Dingolfing
TG-40
05.11.2020
KPI based on IPS-Q.
Page 10
Defect per Unit (DPU).
Inline error handling in their own Process Leader Area (PLA):
Rework recording assembly DID-DE-0162450, DID-DE-2788418 (Extract).
Plant Dingolfing
TG-40
05.11.2020
KPI based on IPS-Q.
Page 11
Defect per Unit (DPU).
Calculation in QRP:
Measuring relevant F1 vehicles Measuring relevant reworks

Measure of DPU
Plant Dingolfing
TG-40
05.11.2020
KPI based on IPS-Q.
Page 12
Q-Index (QI).
Definition:
Number of Test-/Rework-BI 1-7 rated defects in Road Test (RT) and Water Test (WT) multiplied with
corresponding BI weighting divide by number of checked vehicles in RT/WT. Launched derivatives are relevant
from 3 months after SOP.
Date: 13.05.2014
Calculation: Q  Index  Q  Index RT  Q  Index WT Definition: Plant Cockpit
QKM: confirmed

Time periods:
• Capture date (Vehicles)
• Capture date (Defects)

Data:
• measuring relevant tested vehicles
• measuring relevant captured defects

Restriction:
Capture period is valid for both issues, vehicles and defects (there are all yesterday's captured defects in
relation to the checked vehicles yesterday set). There are all captured defects viewed. PMG1 and PMG2
defects are not included.

Summary Q-Index: DID-DE-0240173

Plant Dingolfing
TG-40
05.11.2020
KPI based on IPS-Q.
Page 13
Q-Index (QI).
Calculation in QRP:
Measuring relevant checked vehicles
(QRP_IPS-Q_nn_TS_EV)

Select „yes“

Road Test

Select „yes“

Water Test
Plant Dingolfing
TG-40
05.11.2020
KPI based on IPS-Q.
Page 14
Q-Index (QI).
Calculation in QRP:
Measuring relevant defects (BI 1-7)
(QRP_IPS-Q_nn_TS_EV)

Select „yes“

Select „1,2,3,4,5,6,7“
Road Test
Without PMG1
Without PMG2

Select „yes“

Select „1,2,3,4,5,6,7“
Water Test
Without PMG1
Without PMG2
Plant Dingolfing
TG-40
05.11.2020
KPI based on IPS-Q.
Page 15
Short Track (ST).
Definition:
Unique number of defects (BI 1-7) of short track reworks divided by the number of tested vehicles multiplied
by 1000000.

Number of defects ( ST ) Date: 26.02.2015

Calculation: 1000000 Definition: Plant Cockpit (not integrated, planned)
F1 vehicles
QKM: confirmed
(all plants reported to AQ-20)

Time periods:
• F1 date (Vehicles)
• Rework date (Defects)

Data:
• measuring relevant F1 vehicles
• measuring relevant reworked defects

Restriction:
Rework period corresponds to F1 period (there are all yesterday's rework defects in relation to the F1 vehicles
yesterday). All reworks captured in Short Track with greater than 0 minutes(*) and not with rework activity
“checked ok" are considered.

The recording of the rework duration takes place in accordance with the valid work instruction rework recording assembly DID-DE-
(*)

0162450 or DID-DE-2788418.
Plant Dingolfing
TG-40
05.11.2020
KPI based on IPS-Q.
Page 16
Short Track (ST).
Technische Umsetzung:
1. Anzahl F1 Fahrzeuge
Plant Dingolfing
TG-40
05.11.2020
KPI based on IPS-Q.
Page 17
Short Track (ST).
Technische Umsetzung:
1. Eindeutige Fehleranzahl KPS

Berichtsrelevante Baureihen

Ja

Werksabhängig, z.B. Allgemeiner Prüfschritt KPS

Ohne Steuermerkmal

Nur Nacharbeiten in der Montage

überprüft i.O.

> 0 Min.

BI 1-7
Plant Dingolfing
TG-40
05.11.2020
KPI based on IPS-Q.
Page 18
Damage Rate (based on DRQ).
Definition:
Percentage of damaged(1,2), reworked F2 vehicles that each had at least one rework of more than 30 minutes.

𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑑𝑎𝑚𝑎𝑔𝑒𝑑 𝑠𝑖𝑑𝑒 𝑡𝑟𝑎𝑐𝑘 𝐹2 𝑣𝑒ℎ𝑖𝑐𝑙𝑒𝑠 Date: 01.09.2020

Calculation: 1− Definition: Plant Cockpit
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝐹2 𝑣𝑒ℎ𝑖𝑐𝑙𝑒𝑠
QKM: confirmed

Time periods:
• F2 date

Data:
• measuring relevant F2 vehicles with reworked defects

Restriction:
All reworks (main or consequential , no totals) with the defect types on slide 22 with minutes greater than 30
minutes(*) that occur after Assembly ON will be considered in the calculation. The rework activity “checked ok"
caused no side track vehicle.

The recording of the rework duration takes place in accordance with the valid work instruction rework recording assembly DID-DE-
(*)

0162450 or DID-DE-2788418.
Plant Dingolfing
TG-40
05.11.2020
KPI based on IPS-Q.
Page 19
Damage Rate (based on DRQ).
valid until 08/31/2020
Definition:
Percentage of damaged offline(*) reworks F2 vehicles.
Date: 16.03.2014
damaged offline vehicles
Calculation: Definition: Plant Cockpit
F 2 vehicles QKM: confirmed

Time periods:
• F2 date (Vehicles)
• Rework date (Reworks)

Data:
• measuring relevant F1 vehicles
• measuring relevant reworked defects

Restriction:
The rework activity “CHECKED OK” and reworks with 0 minutes(*) are not considered vehicle defect. Only
defects and rework that occur after Assembly ON will be considered in the calculation. The Offline definition
depends on plant. Either cost centre or station.

The recording of the rework duration takes place in accordance with the valid work instruction rework recording assembly DID-DE-
(*)

0162450 or DID-DE-2788418.
Plant Dingolfing
TG-40
05.11.2020
KPI based on IPS-Q.
Page 20
Damage Rate (based on DRQ).
VFC Catalog E00 Catalog
No. Defect Type No. Defect Type
00001 Damage, deformation 028 SCRATCH
00017 High spot 029 DENT
00019 Dent 073 DAMAGED
00022 Point of impact 131 PRESSURE MARK INDENTATION
00241 Scratches 143 DENT
00246 Paint Peeling, chipping | flaking (1) (2) 500 PART DAMAGED
00247 Paint defect due to contact 529 HIGHSPOT
00879 Damage 798 CHIP
01354 Pit mark

Only in ZA is the Defect Type description ‘Paint

Peeling, flaking’
Only in UK is used 00246 instead of 00247 (wrong
mapping)

500: PART DAMAGED

Plant Dingolfing
TG-40
05.11.2020
KPI based on IPS-Q.
Page 21
Damage Rate (based on DRQ).
Calculation:

2measuring relevant F2 vehicle measuring relevant Side Track Vehicle

Damaged
Plant Dingolfing
TG-40
05.11.2020
Kennzahlen aus IPS-Q.
Page 22
Anzeigerelevanz/Messrelevanz.
Plant Dingolfing
TG-40
05.11.2020
KPI based on IPS-Q.
Page 23
BI Definition Revision PMG 1-5.