IPA Form No.

EE517 Issue 1

CAPACITY VERIFICATION (Production Readiness Review / RUN@RATE)

1

Part Number

Run@Rate Date

Part Description

Supplier Name

XXX Annual Capacity Planning Volume

Supplier Location

pcs/year
Process Step
Process Description
Units
hours
shifts
days
weeks
hours

II - Supplier Capacity
Data

I - Supplier
Working
Standards

Working hours/shift
Shifts/ day
11 Days/ week
12 Weeks/ year
13 Total hours/year (9*10*11*12)
9

10

14
15
16
17
18
19
20
21

III - RUN@RATE Results

22
23
24
25
26
27
28
29

% of line for XXX parts (Allocation %)

Quoted Production Rate (part # item 1)
Quoted % scrap
Quoted % line efficiency
Adjusted production rate (15*(1-16)*17)
Available capacity (15*14*(1-16)*17)*13
Utilization % (3/19)
Bottleneck operation

%
pcs/hour
%
%
pcs/hour
pcs/year
%
X

Trial run duration

Total parts produced
Number of bad parts
First time capability % ((23-24)/24)*100
Number of good parts (23-24)
Net output (26/22)
Takt Time Rate (Target) (3/13*14)
Downtime

hour
pcs
pcs
%
pcs
pcs/ hour
pcs/ hour
hour

Reason

text

Run-Off utilization % (3/(27*13*14))

Bottleneck operation

%
X

STEP 1

STEP 2

STEP 3

STEP 4

STEP 5

STEP 6

30
31
32

SHADED CELLS ARE CALCULATED and protected

34

RUN@RATE results are acceptable and meet XXX capacity planning volume requirements:
33

36

The attached capability study results meet XXX requirements:

Corrective actions are required:

Date:

New production readiness trial run is required:

Date:

Supplier representative signature:

SUMMARY

Overall Process
Utilization %
0.00%

35

Status
Acceptable

Auditor signature:

Auditor Information
Name:
Company:
Location:

IPA Form No. EE517 Issue 1

CAPACITY VERIFICATION (Production Readiness Review / RUN@RATE)

1

Part Number

30301458B

Run@Rate Date

Part Description

Inflator retainer bracket

Supplier Name

XXX Annual Capacity Planning Volume

pcs/year

Supplier Location

II - Supplier Capacity
Data

I - Supplier
Working
Standards

Working hours/shift
Shifts/ day
11 Days/ week
12 Weeks/ year
13 Total hours/year (9*10*11*12)
9

10

14
15
16
17
18
19
20
21

III - RUN@RATE Results

22
23
24
25
26
27
28
29

Process Step
Process Description
Units
hours
shifts
days
weeks
hours

700,000
STEP 1
Stamp Part

STEP 2
CNC #1

February 14, 2004

Acme Machining
Cleveland, OH

STEP 3
CNC #2

STEP 4
Weld Fasteners

STEP 5
Paint

STEP 6

7.5
3
5
48
5400

8.5
2
5
48
4080

7.0
3
5
48
5040

7.0
3
5
48
5040

10.5
1
5
48
2520

% of line for XXX parts (Allocation %)

Quoted Production Rate (part # item 1)
Quoted % scrap
Quoted % line efficiency
Adjusted production rate (15*(1-16)*17)
Available capacity (15*14*(1-16)*17)*13
Utilization % (3/19)
Bottleneck operation

%
pcs/hour
%
%
pcs/hour
pcs/year
%
X

100%
720.0
2%
97%
684
3,695,933
19%

87%
210.0
2%
94%
193
686,677
102%
X

100%
164.0
5%
95%
148
745,970
94%

100%
240.0
9%
92%
201
1,012,677
69%

50%
1200.0
5%
95%
1,083
1,364,580
51%

Trial run duration

Total parts produced
Number of bad parts
First time capability % ((23-24)/24)*100
Number of good parts (23-24)
Net output (26/22)
Takt Time Rate (Target) (3/13*14)
Downtime

hour
pcs
pcs
%
pcs
pcs/ hour
pcs/ hour
hour

2.00
929
5
99.46%
924
462
130

1.00
249
2
99.20%
247
247
197
0.5

2.00
290
4
98.62%
286
143
139

1.25
252
12
95.24%
240
192
139

1.00
794
4
99.50%
790
790
556

Reason

text

Run-Off utilization % (3/(27*13*14))

Bottleneck operation

%
X

72.3%

70.3%

Reprogramming

30
31
32

28.1%

79.8%

97.1%
X
34 SUMMARY

SHADED CELLS ARE CALCULATED and protected

33

36

Overall Process
Utilization %

RUN@RATE results are acceptable and meet XXX capacity planning volume requirements: YES
The attached capability study results meet XXX requirements: NO
Corrective actions are required: YES
New production readiness trial run is required: YES
Supplier representative signature:

Date:

April 1, 2404

Date:

May 16, 2004

Tom Alison

97.13%

35

Status
Acceptable

Auditor signature:

Auditor Information
Name: Gerald Biggs
Company: XXX
Location: Mesa, AZ

Gerald Biggs

IPA Form No. EE518 Issue 1

SUPPLIER PROCESS CAPABILITY

SECTION 1 -SPECIFICATION DATA AND MEASUREMENT RESULTS

Sample Size

Characteristic or Specification

Critical and
Signficant?

Part Number

Average

Note: If no USL/LSL, then leave cell blank

Standard
Deviation

Upper
Specification Limit

Lower
Specification
Limit

PpK

1
2
3
4
5
6
7

Sample Size

Characteristic or Specification

Critical and
Signficant?

Part Number

Average

Note: If no USL/LSL, then leave cell blank

Standard
Deviation

Upper
Specification Limit

Lower
Specification
Limit

PpK

1
2
3
4
5
6
7

Sample Size

Characteristic or Specification

Critical and
Signficant?

Part Number

Average

Note: If no USL/LSL, then leave cell blank

Standard
Deviation

Upper
Specification Limit

Lower
Specification
Limit

PpK

1
2
3
4
5
6
7

Sample Size

Characteristic or Specification

Critical and
Signficant?

Part Number

Average

Note: If no USL/LSL, then leave cell blank

Standard
Deviation

Upper
Specification Limit

Lower
Specification
Limit

PpK

1
2
3
4
5
6
7

Sample Size

Characteristic or Specification

1
2
3
4
5
6
7

Critical and
Signficant?

Part Number

Average

Note: If no USL/LSL, then leave cell blank

Standard
Deviation

Upper
Specification Limit

Lower
Specification
Limit

PpK

IPA Form No. EE518 Issue 1

SUPPLIER PROCESS CAPABILITY

SECTION 1 -SPECIFICATION DATA AND MEASUREMENT RESULTS

30301458B

Sample Size

30

Note: If no USL/LSL, then leave cell blank

Critical and
Signficant?

Part Number

Average

Standard
Deviation

Upper
Specification
Limit

Lower
Specification
Limit

PpK

YES

3.4800

0.0300

3.5500

3.4500

0.333

YES

6.7900

0.0500

6.8200

6.7800

0.067

.5 radius

YES

0.4990

0.0100

0.5100

0.4950

0.133

.05 chamfer

YES

0.0510

0.0010

0.0550

0.0450

1.333

Characteristic or Specification

Hole Diameter 3.5 mm

6.8 mm dimension

5
6
7

Sample Size

Characteristic or Specification

Critical and
Signficant?

Part Number

Average

Note: If no USL/LSL, then leave cell blank

Standard
Deviation

Upper
Specification
Limit

Lower
Specification
Limit

PpK

1
2
3
4
5
6
7

Sample Size

Characteristic or Specification

Critical and
Signficant?

Part Number

Average

Note: If no USL/LSL, then leave cell blank

Standard
Deviation

Upper
Specification
Limit

Lower
Specification
Limit

PpK

1
2
3
4
5
6
7

Sample Size

Characteristic or Specification

Critical and
Signficant?

Part Number

Average

Note: If no USL/LSL, then leave cell blank

Standard
Deviation

Upper
Specification
Limit

Lower
Specification
Limit

PpK

1
2
3
4
5
6
7

Sample Size

Characteristic or Specification

1
2
3
4
5
6
7

Critical and
Signficant?

Part Number

Average

Note: If no USL/LSL, then leave cell blank

Standard
Deviation

Upper
Specification
Limit

Lower
Specification
Limit

PpK