Capacity Analysis Process Steps and Resources

Process Steps (Do the following as appropriate) Available Resources Additional details

Go to this link and follow

instructions in the Value Stream
Map Process under Capacity
1 Value Stream Map the process Value Stream Mapping Resources
2 Confirm the source of the capacity requirements Capacity Requirements
Determine the manufacturing Operating Pattern Go to the Capacity Training,
3 Assumptions Capacity Planning Web Guide Module 4

Go to the Capacity Training,

4 Collect data showing historical performance Go to the Historical Mfg Performance sheet
Validation
in this of
document
Surrogate and Historical Performance Data Module 4
Develop historical/ surrogate OEE/capacity growth
5 curve and target Production Support Plan / Rate of Climb Chart

Identify all other business for the shared loading Go to the Capacity Training,
6 analysis Detailed Shared Loading Tool Go to worksheet labeled "Shared Loading Plan" in this document Module 4
Use the Deltailed Shared Loading tool if initial
7 total loading > 90% Detailed Shared Loading Tool Go to worksheet labeled "Shared Loading Plan" in this document
Complete the Capacity Planning Analysis
8 worksheet Go to worksheet labeled "Capacity Planning" in this document

Update the Shared Loading analysis worksheet or

9 the Detailed Shared Loading Tool for Phase 0 Detailed
Go to worksheet labeled "Shared Loading Shared
Plan" in Loading Tool
this document
Track progress on the OEE/capacity growth Production Support Plan / Rate of
10 curve Climb Chart Example OEE Rate of Climb chart
Reconfirm the capacity requirements, and run
11 Phase 0 Capacity Requirements Complete the sheet labeled Phase 0 PPAP (Run @ Rate)

Confirm that all Sub Tier Capacity is in place to

support capacity requirements using the sub-tier
12 APQP/PPAP Matrix Sub-tier APQP PPAP Matrix
Reconfirm the capacity requirements and run Production Support Plan / Rate of
13 Phase 0 for Phase 2, track on growth curve Capacity Requirements Complete the sheet labeled Phase 0 PPAP
Climb
(Run
Chart
@ Rate)
Reconfirm the capacity requirements, and run
14 Phase 3, track on growth curve Capacity Requirements Complete the sheet labeled Phase 3 PPAP
Production
(Cap Ver)
Support Plan / Rate of Climb Chart

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Page 1 of 12 12:29:35
 CAR (Capacity Analysis Report)
Capacity Analysis Introduction

In the blue-shaded cell below, please identify the scenario or reason for the CAR submission. If unsure, then contact STA site engineer.

Capacity Planning

The 7 sheets identified below are required or suggested when submitting a pdf, hard-copy or facsimile of this CAR file to an agent of Ford Motor Company.

7 Sheets Required or Suggested for Submission

1 Capacity Planning

1 Shared Loading Plan - only if the manufacturing process is being used to make more than one part
1 Detailed Shared Loading plan- only if Total Allocation > 90%

1 Historical Mfg Performance (if used for shared loading OEE)

1 Value Stream Map (VSM)

1 Production Support/ Rate of Climb Chart

1 Supplier Declarations and Notes

Phase 0 for
additional
manufacturing Phase 0 for all
lines (may remaining Quarterly APPC
require additional manufacturing and MPPC
Capacity Initial Phase 0 completed CAR lines Reporting / Web
Name of Sheet / CAR Type Planning (for Phase 1) form) (for Phase 2) Phase 3 Capacity Uplift Quote, etc.
Capacity Planning R S S S S S S
Shared Loading Plan R* R* R* R* R* R* R*
R if total R if total R if total R if total R if total R if total R if total
Detailed Shared Loading plan allocation>90% allocation>90% allocation>90% allocation>90% allocation>90% allocation>90% allocation>90%
Phase 0 PPAP (Run @ Rate) R R R S
Phase 3 PPAP (Cap Ver) R R R
Historical Mfg Performance R R R R R R R
Value Stream Map (VSM) R R R R R
Production Support/ Rate of Climb
Chart R R R R R
Supplier Declarations and Notes R R R R R R R

R = Required
S = Suggested
R * = May be required under certain circumstances, see below for examples
Shared Loading Plan is required when there is more than one part in the manufacturing process being analyzed for capacity.
The best practice is to complete the CAR and submit all sheets to Ford, filled out or not.

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12:29:36
 Capacity Planning
A. New Model Required OEE (Overall Equipment Effectiveness) -
Select for
A1) Supplier & Part Information A2) Capacity Requirements APW MPW Analysis A3) Key Contacts
Supplier Name Program Code <PA> Requirements Name Phone # Email
Location/Site Code Model Year Revised Requirements STA Site Engineer
Part Name Part PPAP Level Source Capacity Req ATP or Study Supplier Lead
Part Number Date of Study GCP/MCPV Ford Buyer
Capacity Requirements Supplier to demonstrate APW of parts per week operating no more than 5 days per week
Supplier to demonstrate MPW of parts per week operating no more than 6 days per week

A4) Planned Departmental Operating Pattern Process 1 Process 2 Process 3 Process 4 Process 5 Process 6 Process 7 Process 8
& Net Available Time for All Customers APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan
A Process description (in value stream order)
B Days / Week
C Shifts / Day
D Total Hours / Shift
E Contractual Downtime - lunch, breaks, etc. (min/shift)
F Dedicated or Shared Process
F1 Allocation Percent (automatically displayed)
G Net Available Time (hours / week) [B*C*(D-(E/60))*F1] - - - - - - - - - - - - - - - -
G1 Planned Minutes per Changeover (into this part #)
G2 Planned Changeover Frequency / Week (into this part #)

A5) Required Good Parts / Week APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan
H Percent of parts scrapped
Req'd Good Parts / Week to Support Next Process
J
(Accounts for the scrap loss of each process)
- - - - - - - - - - - - - - - -
Avg. Weekly Max Weekly

Required Incoming Parts for - -

A6) Required OEE (Overall Equipment Effectiveness) APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan
K Ideal Cycle Time per Tool or Machine (sec/cycle)
L # of Tools or Machines in parallel
M # of identical parts produced per Tool or Machine Cycle
N Net Ideal Cycle Time (sec/part) [K / (L*M)] - - - - - - - -
P Theoretical Parts per week at 100% OEE [G x 3600 / N] - - - - - - - - - - - - - - - -

Q Required OEE [J / P] - - - - - - - - - - - - - - - -
R Percent of parts reworked (re-run through process)
Can process contain its changeover, scrap & rework
S assumptions? [Is J/(100%-H) + (JxR) + (G1x60xG2/N) <= P]
- - - - - - - - - - - - - - - -

% Remaining for Availability & Performance Efficiency losses

T - - - - - - - - - - - - - - - -
{P - [(J/(100%-H)) + (JxR) + (G1x60xG2/N)]} / P

Enter any other assumptions for clarification

(Process details and further clarifications)

A7) Shared Process - Total Allocation Plan - - - - - - - -

U Total % Allocation from "Shared Loading Plan" Sheet

B. Supplier Demonstrated OEE (Overall Equipment Effectiveness) - Historical Performance

B1) Historical Performance (from Historical Mfg Performance Summary)
Process Description - - - - - - - -

V Supplier Name
W Supplier Location
X Site Code for Surrogate Process
Y Surrogate Customer & Program Reference (~Ford P221)
List reference Surrogate Process (~Stamping Press #12)
Z Average Historical OEE - - - - - - - -
Enter any other assumptions for clarification
(Part Number, Annual Volume, Operating Pattern, etc.)

B2) Process Specific Weekly Part Estimate [P * Z] - - - - - - - - - - - - - - - -

C. Gap Analysis - Required OEE vs. Demonstrated OEE; Predicted Good Parts / Week
Process Description
APW Result MPW Result APW Result MPW Result APW Result MPW Result APW Result MPW Result APW Result MPW Result APW Result MPW Result APW Result MPW Result APW Result MPW Result

Capacity Analysis Results

Predicted Good Parts per wk Average Maximum Req'd OEE at APW Req'd OEE at MPW Historical Demonstrated OEE

Required Capacity
Histor
(APW/MPW) 1200%
Check Decl. Check Decl. and
Planned Capacity
and Notes Notes 1000%

Commitment (APPC/MPPC)
800%
NOTES Req'd
600%
OEE %

Req'd

400%

200%

0%
Capacity
Run-at-
Verificati
Appro
Reje
Rate
oncted
ved
SUPPLIER OPERATION MANAGEMENT APPROVAL FOR STA USE
(Phase 0)
(Phase 3)
Version 5.6
Approved
Authorized Representative Name / Title Email Site Engineer STA LL6 Supervisor
Rejected
© 2018 Ford Motor Company
Signature Date Phone Number Signature/Date Signature/Date

671233721.xlsx Page 3 of 12
Date Printed:06/08/2023
12:29:36
 Shared Loading Plan
Shared-Loading Plan for PROCESS 1 0

Shared Process Loading Plan NICT = Net Ideal Cycle Time (sec/part) Date of Study

Study Phase
Capacity Planning PROCESS 1 -
(please enter in "Introduction" TAB)

Planned Departmental Operating Pattern for All Customers for Average Weekly Planned Departmental Operating Pattern for All Customers for Max Weekly

Days / Week
Shifts / Day
Total Hours / Shift
Contractual Planned Downtime - lunch, breaks, etc.
(minutes/shift)
Type the Net Available Time (NAT) (hrs/week)
letter 'X' in
one of the
cells below Demonstrated OEE (Overall Equipment Effectiveness):
to identify Enter average OEE from most recent production performance - -
the part that data (from updated Historical Mfg. Performance)
is analyzed
during
Capacity
Planning.
Loading Plan to meet Average Weekly Loading Plan to meet Max Weekly
Req'd Tool Req'd Tool
Mark one Application Time Req'd @ % Allocation % Allocation Time Req'd @ % Allocation % Allocation
Good Changeover % Additional Good Changeover % Additional
part per Part / Vehicle Ford Part # or "Non-Ford" NICT Demonstrated Minimum Total NICT Demonstrated Minimum Total
Parts / Time Allocation Parts / Time Allocation
process Line OEE (hrs/week) Required Required OEE (hrs/week) Required Required
Week (min/week) Week (min/week)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Select "Unhide rows" 49 Other % Allocation - Description
for more parts 50 Other % Allocation - Description
Percentage of Net Available Time not utilized for production (%) {PM, etc.}
Total % Allocation
If Total % Allocation > 100%, loading plan exceeds capacity

DATE OF REVIEW OF ALL SHARED LOADINGS OR THE MASTER SUPPLIER OPERATION MANAGEMENT APPROVAL
0

Signature / reviewed by

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12:29:36
 Phase 0 PPAP (Run @ Rate)
A. New Model Required OEE (Overall Equipment Effectiveness) -
Select for
A1) Supplier & Part Information A2) Capacity Requirements APW MPW Analysis A3) Key Contacts
Supplier Name Program Code <PA> Requirements Name Phone # Email
Location/Site Code Model Year Revised Requirements STA Site Engineer
Part Name Part PPAP Level Source Capacity Req ATP or Study Supplier Lead
Part Number Date of Study GCP/MCPV Ford Buyer
Capacity Requirements Supplier to demonstrate APW of parts per week operating no more than 5 days per week
Supplier to demonstrate MPW of parts per week operating no more than 6 days per week

A4) Planned Departmental Operating Pattern Process 1 Process 2 Process 3 Process 4 Process 5 Process 6 Process 7 Process 8
& Net Available Time for All Customers APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan
A Process description (in value stream order)
B Days / Week
C Shifts / Day
D Total Hours / Shift
E Contractual Downtime - lunch, breaks, etc. (min/shift)
F Dedicated or Shared Process
F1 Allocation Percent (automatically displayed)
G Net Available Time (hours / week) [B*C*(D-(E/60))*F1] - - - - - - - - - - - - - - - -
G1 Planned Minutes per Changeover (into this part #)
G2 Planned Changeover Frequency / Week (into this part #)

A5) Required Good Parts / Week APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan
H Percent of parts scrapped
J Req'd Good Parts / Week to Support Next Process
(Accounts for the scrap loss of each process)
- - - - - - - - - - - - - - - -
Avg. Weekly Max Weekly

Required Incoming Parts for - -

A6) Required OEE (Overall Equipment Effectiveness) APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan
K Ideal Cycle Time per Tool or Machine (sec/cycle)
L # of Tools or Machines in parallel
M # of identical parts produced per Tool or Machine Cycle
N Net Ideal Cycle Time (sec/part) [K / (L*M)] - - - - - - - -
P Theoretical Parts per week at 100% OEE [G x 3600 / N] - - - - - - - - - - - - - - - -
Q Required OEE [J / P] - - - - - - - - - - - - - - - -
R Percent of parts reworked (re-run through process)
S Can process contain its changeover, scrap & rework
- - - - - - - - - - - - - - - -
assumptions? [Is J/(100%-H) + (JxR) + (G1x60xG2/N) <= P]
T % Remaining for Availability & Performance Efficiency losses
- - - - - - - - - - - - - - - -
{P - [(J/(100%-H)) + (JxR) + (G1x60xG2/N)]} / P

Enter any other assumptions for clarification

(Process details and further clarifications)

A7) Shared Process - Total Allocation Plan - - - - - - - -

U Total % Allocation from "Shared Loading Plan" Sheet

B. Supplier Demonstrated OEE - Phase 0 PPAP (Run @ Rate)

B1) Equipment Availability - - - - - - - -

V Total Available Time (ACTUAL changeover NOT included for

Shared) (minutes)
W Planned Downtime - lunches/breaks/mtgs. (minutes)
X Net Available Time (minutes) [V - W] - - - - - - - -
Y Shared Equip Changeover Time ACTUAL (minutes) NOT REQUIRED NOT REQUIRED NOT REQUIRED NOT REQUIRED NOT REQUIRED NOT REQUIRED NOT REQUIRED NOT REQUIRED
Z Shared Equip Changeover Time Weekly Scaled (minutes)
- - - - - - - -
[(G1 * G2 * X) / (60*G - (G1 * G2))]
AB Observed Unplanned Downtime (minutes)
AC Operating Time (minutes) [X - AB] - - - - - - - -
AD Equipment Availability [(X - AB) / (X + Z) * 100] - - - - - - - -
B2) Performance Efficiency
AE Total Parts Run (Good, Scrapped, & Reworked)
AF1 # of CURRENT Tools or Machines in parallel
AF2 # of identical parts produced per Tool or Machine Cycle
AF Planned Net Ideal Cycle Time (sec/part) [K/(AF1*AF2)] - - - - - - - -
AG Performance Efficiency (AE * AF / AC) - - - - - - - -
AH "Availability" and/or "Performance Efficiency" Losses Not
- - - - - - - -
Captured (minutes) [AC - (AE * AF)]

B3) Quality Rate # % # % # % # % # % # % # % # %

AJ # Parts Scrapped - - - - - - - -
AK # Parts Reworked - - - - - - - -
AL Quality Rate [(AE - AJ - AK) / AE] - - - - - - - -
B4) Overall Equipment Effectiveness (OEE)
AM Phase 0 OEE [AD * AG * AL] - - - - - - - -
B5) Process Specific Weekly Part Estimate [P * AM] - - - - - - - - - - - - - - - -
B6) Observed Average Cycle Time (sec/cycle)
C. Gap Analysis - Required OEE vs. Demonstrated OEE; Predicted Good Parts / Week
Process Description
APW Result MPW Result APW Result MPW Result APW Result MPW Result APW Result MPW Result APW Result MPW Result APW Result MPW Result APW Result MPW Result APW Result MPW Result

Capacity Analysis Results

Predicted Good Parts per wk Average Maximum Req'd OEE at APW Req'd OEE at MPW Demonstrated OEE

Required Capacity 1200%

(APW/MPW)
Phase 0 Check Decl. Check Decl. and 1000%
Demonstrated Capacity and Notes Notes
Phase 0 Capacity with current Check Decl. Check Decl. and 800%
installation and Notes Notes
OEE %

Commitment (APPC/MPPC) 600%

NOTES 400%

200%

0%

SUPPLIER OPERATION MANAGEMENT APPROVAL FOR STA USE

Version 5.6
Approved
Authorized Representative Name / Title Email Site Engineer STA LL6 Supervisor
Rejected
© 2018 Ford Motor Company
Signature Date Phone Number Signature/Date Signature/Date

671233721.xlsx Page 5 of 12 Date Printed:06/08/2023

12:29:36
 Phase 3 PPAP (Capacity Verification)
A. New Model Required OEE (Overall Equipment Effectiveness) -
Select for
A1) Supplier & Part Information A2) Capacity Requirements APW MPW Analysis A3) Key Contacts
Supplier Name Program Code <PA> Requirements Name Phone # Email
Location/Site Code Model Year Revised Requirements STA Site Engineer
Part Name Part PPAP Level Source Capacity Req ATP or Study Supplier Lead
Part Number Date of Study GCP/MCPV Ford Buyer
Capacity Requirements Supplier to demonstrate APW of parts per week operating no more than 5 days per week
Supplier to demonstrate MPW of parts per week operating no more than 6 days per week

A4) Planned Departmental Operating Pattern Process 1 Process 2 Process 3 Process 4 Process 5 Process 6 Process 7 Process 8
& Net Available Time for All Customers APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan
A Process description (in value stream order)
B Days / Week
C Shifts / Day
D Total Hours / Shift
E Contractual Downtime - lunch, breaks, etc. (min/shift)
F Dedicated or Shared Process
F1 Allocation Percent (automatically displayed)
G Net Available Time (hours / week) [B*C*(D-(E/60))*F1] - - - - - - - - - - - - - - - -
G1 Planned Minutes per Changeover (into this part #)
G2 Planned Changeover Frequency / Week (into this part #)

A5) Required Good Parts / Week APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan
H Percent of parts scrapped
J Req'd Good Parts / Week to Support Next Process
(Accounts for the scrap loss of each process)
- - - - - - - - - - - - - - - -
Avg. Weekly Max Weekly

Required Incoming Parts for - -

A6) Required OEE (Overall Equipment Effectiveness) APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan APW Plan MPW Plan
K Ideal Cycle Time per Tool or Machine (sec/cycle)
L # of Tools or Machines in parallel
M # of identical parts produced per Tool or Machine Cycle
N Net Ideal Cycle Time (sec/part) [K / (L*M)] - - - - - - - -
P Theoretical Parts per week at 100% OEE [G x 3600 / N] - - - - - - - - - - - - - - - -
Q Required OEE [J / P] - - - - - - - - - - - - - - - -
R Percent of parts reworked (re-run through process)
S Can process contain its changeover, scrap & rework
- - - - - - - - - - - - - - - -
assumptions? [Is J/(100%-H) + (JxR) + (G1x60xG2/N) <= P]
T % Remaining for Availability & Performance Efficiency losses
- - - - - - - - - - - - - - - -
{P - [(J/(100%-H)) + (JxR) + (G1x60xG2/N)]} / P

Enter any other assumptions for clarification

(Process details and further clarifications)

A7) Shared Process - Total Allocation Plan - - - - - - - -

U Total % Allocation from "Shared Loading Plan" Sheet

B. Supplier Demonstrated OEE - Phase 3 PPAP (Capacity Verification)

B1) Equipment Availability - - - - - - - -

V Total Available Time (Include ACTUAL changeover time for

Shared) (minutes)
W Planned Downtime - lunches/breaks/mtgs. (minutes)
X Net Available Time (minutes) [V - W] - - - - - - - -
Y Shared Equip Changeover Time ACTUAL (minutes)
Z Shared Equip Changeover Time Weekly Scaled (minutes)
- - - - - - - -
[Y * (X / 60) / (G / G2)]
AB Observed Unplanned Downtime (minutes)
AC Operating Time (minutes) [X - Y - AB] - - - - - - - -
AD Equipment Availability [(X - Z - AB) / X * 100] - - - - - - - -
B2) Performance Efficiency
AE Total Parts Run (Good, Scrapped, & Reworked)
AF Net Ideal Cycle Time (seconds/part) [N] - - - - - - - -
AG Performance Efficiency (AE * AF / AC) - - - - - - - -
AH "Availability" and/or "Performance Efficiency" Losses Not
- - - - - - - -
Captured (minutes) [AC - (AE * AF)]

B3) Quality Rate # % # % # % # % # % # % # % # %

AJ # Parts Scrapped - - - - - - - -
AK # Parts Reworked - - - - - - - -
AL Quality Rate [(AE - AJ - AK) / AE] - - - - - - - -
B4) Overall Equipment Effectiveness (OEE)
AM Phase 3 OEE [AD * AG * AL] - - - - - - - -
B5) Process Specific Weekly Part Estimate [P * AM] - - - - - - - - - - - - - - - -
B6) Observed Average Cycle Time (sec/cycle)
C. Gap Analysis - Required OEE vs. Demonstrated OEE; Predicted Good Parts / Week
Process Description
APW Result MPW Result APW Result MPW Result APW Result MPW Result APW Result MPW Result APW Result MPW Result APW Result MPW Result APW Result MPW Result APW Result MPW Result

Capacity Analysis Results

Predicted Good Parts per wk Average Maximum Req'd OEE at APW Req'd OEE at MPW Demonstrated OEE

Required Capacity 1200%

(APW/MPW)
Phase 3 Check Decl. Check Decl. and 1000%
Demonstrated Capacity and Notes Notes
Commitment (APPC/MPPC) 800%
NOTES
OEE %

600%

400%

200%

0%

Rejected
SUPPLIER OPERATION MANAGEMENT APPROVAL FOR STA USE
Version 5.6
Approved

Authorized Representative Name / Title Email Site Engineer STA LL6 Supervisor
Rejected
© 2018 Ford Motor Company
Signature Date Phone Number Signature/Date Signature/Date

671233721.xlsx Page 6 of 12 Date Printed:06/08/2023

12:29:36
 Historical Mfg Performance

Demonstrated GPP = Good Parts Produced NICT = Net Ideal Cycle Time (sec/part) NAT = Net Available Time (hrs/wk) OEE = Overall Equipment Effectiveness [GPP/(NAT/NICT)]
Performance History
(could be surrogate)
WK# Date GPP NICT NAT OEE GPP NICT NAT OEE GPP NICT NAT OEE GPP NICT NAT OEE GPP NICT NAT OEE GPP NICT NAT OEE GPP NICT NAT OEE GPP NICT NAT OEE
WK1 - - - - - - - -
WK2 - - - - - - - -
WK3 - - - - - - - -
WK4 - - - - - - - -
WK5 - - - - - - - -
WK6 - - - - - - - -
WK7 - - - - - - - -
WK8 - - - - - - - -
WK9 - - - - - - - -
WK10 - - - - - - - -
WK11 - - - - - - - -
WK12 - - - - - - - -
WK13 - - - - - - - -
WK14 - - - - - - - -
WK15 - - - - - - - -
WK16 - - - - - - - -
WK17 - - - - - - - -
WK18 - - - - - - - -
WK19 - - - - - - - -
WK20 - - - - - - - -
WK21 - - - - - - - -
WK22 - - - - - - - -
WK23 - - - - - - - -
WK24 - - - - - - - -
WK25 - - - - - - - -
AVERAGE OEE - - - - - - - -
REQUIRED OEE 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0%

Chart Title Chart Title Chart Title Chart Title

OEE REQUIRED OEE OEE REQUIRED OEE OEE REQUIRED OEE OEE REQUIRED OEE

100% 100% 100% 100%

90% 90% 90% 90%

80% 80% 80% 80%

70% 70% 70% 70%

Historical OEE

Historical OEE
Historical OEE

Historical OEE
60% 60% 60% 60%

50% 50% 50% 50%

40% 40% 40% 40%

30% 30% 30% 30%

20% 20% 20% 20%

10% 10% 10% 10%

0% 0% 0% 0%

Chart Title Chart Title Chart Title Chart Title

OEE REQUIRED OEE OEE REQUIRED OEE OEE REQUIRED OEE OEE REQUIRED OEE

100% 100% 100% 100%

90% 90% 90% 90%

80% 80% 80% 80%

70% 70% 70% 70%

Historical OEE

Historical OEE

Historical OEE

Historical OEE
60% 60% 60% 60%
50% 50% 50% 50%
40% 40% 40% 40%
30% 30% 30% 30%
20% 20% 20% 20%
10% 10% 10% 10%
0% 0% 0% 0%

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12:29:36
 Supplier Declarations and Notes

Item # Declaration/Note User Response (orange shaded cells)

Supplier confirms that all sub-tier suppliers have been verified to meet capacity
requirements for the phase (No / Capacity Planning / Phase 0/ Phase 3 / Not applicable
1 when no sub-tier suppliers):
TOTAL Number of sub-tier suppliers

Number of sub-tier suppliers COMPLETED for the corresponding phase

2 Supplier used the following method to complete sub-tier supplier capacity analysis:

All Committed capacity declared in Ford GCP/MCPV capacity planning systems based on
this CAR assessment are validated throughout the value chain and are sustainable as
3 demonstrated by continuous monitoring of manufacturing OEE and Shared Loading.

4 Date on which Capacity Planner completed CAR training:

5 Name of Capacity Planner: 0

6 Email of Capacity Planner: 0

7 This row is reserved for an alert pertaining to 24-hour work pattern.

This row is reserved for an alert pertaining to Study Date - Capacity Planning
8 0

9 This row is reserved for an alert pertaining to Study Date - Phase 0 0

10 This row is reserved for an alert pertaining to Study Date - Phase 3 0
11 Part in cell B6 of the source for Shared-Loading PlanCapacity Planning 0 0
12 Part number marked for analysis in Shared-Loading Plan for Process 1:

13 Part number marked for analysis in Shared-Loading Plan for Process 2:

14 Part number marked for analysis in Shared-Loading Plan for Process 3:

15 Part number marked for analysis in Shared-Loading Plan for Process 4:

16 Part number marked for analysis in Shared-Loading Plan for Process 5:

17 Part number marked for analysis in Shared-Loading Plan for Process 6:

18 Part number marked for analysis in Shared-Loading Plan for Process 7:

19 Part number marked for analysis in Shared-Loading Plan for Process 8:

20 This row is reserved for an alert pertaining to OEE - Capacity Planning

21 This row is reserved for an alert pertaining to OEE - Phase 0

22 This row is reserved for an alert pertaining to OEE - Phase 3

This row is reserved for an alert pertaining to the part marked for analysis on SLP (Shared
23 Loading Plan).

24 Current/System/Print date: 8-Jun-2023

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12:29:36
 PPC confirmation

For all APPC/MPPC submissions, please paste a screen shot of the corresponding system:
For Phase 3, PPC quarterly maintenance & Capacity Study --> Screen shot of GCP/MCPV (PPC maintenance Page)

For Capacity Planning --> Screen shot of Webquote (Capacity ATP response page)

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12:29:36
 CAR Submission history

CAR Submission History

CAR Submission when change ocurred:

Date:

All Processes APW / MPW

Working pattern (NAT) Capacity Planning

P NICT Phase 0
R
O
C
E 0 Total Allocation for Shared lines Phase 3
S
S

1 Demonstrated OEE Capacity Study

Scrap % Quarterly maintenance

Planned Scrap/ Rework
Rework %

Working pattern (NAT)

P
NICT
R
O
C
E 0 Total Allocation for Shared lines
S
S

2 Demonstrated OEE

Scrap %
Planned Scrap/ Rework
Rework %

Working pattern (NAT)

P
NICT
R
O
C
E 0 Total Allocation for Shared lines
S
S

3 Demonstrated OEE

Scrap %
Planned Scrap/ Rework
Rework %

Working pattern (NAT)

P NICT
R
O
C
E 0 Total Allocation for Shared lines
S
S

4 Demonstrated OEE

Scrap %
Planned Scrap/ Rework
Rework %

Working pattern (NAT)

P NICT
R
O
C
E 0 Total Allocation for Shared lines
S
S

5 Demonstrated OEE

Scrap %
Planned Scrap/ Rework
Rework %

Working pattern (NAT)

P
NICT
R
O
C
E 0 Total Allocation for Shared lines
S
S

6 Demonstrated OEE

Scrap %
Planned Scrap/ Rework
Rework %

Working pattern (NAT)

P
NICT
R
O
C
E 0 Total Allocation for Shared lines
S
S

7 Demonstrated OEE

Scrap %
Planned Scrap/ Rework
Rework %

Working pattern (NAT)

P NICT
R
O
C
E 0 Total Allocation for Shared lines
S
S

8 Demonstrated OEE

Scrap %
Planned Scrap/ Rework
Rework %

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Capacity Analysis Process

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 1. Added Capacity Analysis resources on new sheets labeled "Capacity_Analysis_Process" and "Detailed Process".
2. Removed certain automatically copied values on the Phase 0 and Phase 3 worksheets, originating on the Capacity Planning worksheet.

Summary of changes to CAR between Sept-2015 and January-2018 (version 5.5 to version 5.6)
I) GENERAL
I-1 Added Conditional colour if cells do not have data (orange), to ensure all required cells are fulfilled
I-2 Added Conditional colour if cells do not have proper data (Red), to help to correct the data
I-3 Added Conditional colour to highlight capacity risk (Yellow), to help further analysis
I-4 Comments reviewed and updated, including colour codes explanation
I-5 Printing adjusted for all sheets
I-6 Added two new tabs: "PPC confirmation" and “CAR Submission history”

II) INTRODUCTION SHEET

II -1 Aligned the required forms with the Capacity Analysis and Resources

CAPACITY PLANNING, PHASE 0 & PHASE 3

III) A) Section
III-1 A2) Section : Updated APW & MPW definitions in comments.
III-2 Added two fields: "Part PPAP level" & "ATP or Study Number"
III-3 Capacity Planning: Added GCP/MPV field, same as Phase 0 & 3
III-4 A4) Section: Clarified the description: Planned Departmental Operating Pattern & Net Available Time for All Customers
III-5 Increased robustness to place the corresponding allocation:
F: Drop list to select "Dedicated" or "Shared".
F1: Automatically places 100% for Dedicated or the corresponding allocation % from shared loading (from part marked with x).
III-6 A4) A5) A6) Sections: In case of Shared Lines, it compares the following data with the corresponding Shared loading plan and shows red if any incongruence:
Net Available Time (G) [it compares the Working pattern (B, C, D & E)] , Required Good parts (J) and Cycle time (N)
III-7 A6) Section: Removed "Round down" of Theoretical Parts per week at 100% OEE (P) to avoid false risk on low volume parts
III- 8 Unified the Cycle time calculation for APW & MPW, combining both cells into one for the rows K, L, M & N
III- 9 Added conditional format "Yellow" if "% Remaining for Availability & Performance Efficiency losses" (T) >=10%, to review OEE feasibility
A7) Section: Locked Total % Allocation from "Shared Loading Plan" Sheet (U) to avoid manual wrong input

IV) B) Section
IV-1 Capacity Planning - B1): Average Historical OEE (Z) is blocked to ensure data is placed on the Historical Manufacturing Performance Sheet
IV-2 Phase 0 - B2): Added AF1 & AF2 to identify the production streams available during the Phase 0 run
IV-3 Locked Planned Net Ideal Cycle Time (AF), it is automatically calculated based on the production streams available (AF1 & AF2)
IV-4 Phase 3 - B2): Locked Net Ideal Cycle Time (AF), it is automatically linked to N. If planned cycle time is not achieved, it will penalize the Efficiency.
IV-5 For lines with Change Over time (G1 &G2), it is mandatory to place data in "Shared Equip Changeover Time ACTUAL" (Y), to ensure the Change over penalized the OEE.
IV-6 "Shared Equip Changeover Time Weekly Scaled" (Z) will be highlighted in Yellow if "Changeover Time ACTUAL" (Y)> 10% of <50% than "Planned Minutes per Changeover" (G1)

V) C) Section
V-1 Added robustness to identify risks, placing RED and the following messages:
"See Row S" --> Process cannot contain Changeover, Scrap & Rework assumptions
"See Row U" --> Total allocation is not in place (the corresponding Phase needs to be selected in the Introduction Sheet) or Total allocation is higher than 100%
V-2 Phase 0: Added section "Phase 0 Capacity with current installation", it calculates the current capacity based on current production streams available.
V-3 Phase 0 & 1: Added Commitment (APPC/MPPC), same as Phase 3.
V-4 ALL: Commitment (APPC/MPPC):
Warning message RED if lower
when Commitment than is
volume Required
more thanCapacity or if higher
10% higher than
than the Demonstrated
Required Capacity.
Capacity, . Phase 3 OEE can be sustained based on Historical
to ensure
V-5 Data and verify capacity for all Tier N sub suppliers. It is strongly recommended to perform a new CAR with these committed volumes
V-6 Planned/Demonstrated capacity is linked to Supplier Declarations and Notes. It needs to be properly filled to display the results.
V-7 Planned/Demonstrated capacity is also linked to all processes identified in the A) section (A and/or F). If missing information for a process it will not display the results.
V-8 Planned/Demonstrated capacity is calculated with the worst downstream scrap: planned or demonstrated during the run.

VI) Shared loading

VI-1 More
Threerows added
columns to place
added: parts, up toVehicle
“Application/ 50. Select rows
Line” , "%34 & 63 to unhide
Additional and see
Allocation" and additional rowsTotal Required", to ensure proper tracking of total allocation for those cases that
"% Allocation
VI-2 an specific part requires more allocation than minimum.
VI-3 NICT of MPW is automatically linked to NICT of APW
VI-4 Warning message
Automatically placeofthe
"Detailed
RequiredShared
Goodloading Required"
parts , NICT whenChangeover
and Tool Total Allocation
Time,is when
>90%the “X” is selected for the corresponding part.
VI-5
VI-6 Addition of "Date of Review of all Shared loading or the Master", to ensure all Shared loadings are up to date & Supplier Signature of the Shared loading.
Without date or if date is prior to Date of Study of the corresponding phase, it will display the Total allocation in RED

VII) Historical Mfg Performance

VII-1 Reinforce robustness: if any OEE data is >100%, it will not calculate Average OEE as data collection system is not appropriate.

VII-2 Allow average OEE calculation if first week there is no data for a process
VII-3 Added Required OEE from the Corresponding Phase, in value and in the chart
VII-4 Weekly OEEs lower than Required OEE are highlighted in YELLOW
VII-5 Net Available Time > than 144 hours (24 hours x 6 days) is highlighted in YELLOW

VIII) Supplier Declarations and Notes

VIII-1 Item 1 clarified fore the different Capacity Phases
VIII-2 Added the Total number of sub tiers and the Number of sub tiers completed for the corresponding phase
VIII-3 Added item 3
VIII-4 Removed error checks that cannot take place with this version

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