Capacity Verification Run at Rate Ipa

IPA Form No. EE517 Issue 1

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 68 Process Description

Units9 Working hours/shift hours

10 Shifts/ day shifts11 Days/ week days12 Weeks/ year weeks13 hours

14 % of line for XXX parts (Allocation %) %15 Quoted Production Rate (part # item 1) pcs/hour16 Quoted % scrap %17 Quoted % line efficiency %18 pcs/hour 19 pcs/year 20 %21 Bottleneck operation X

22 Trial run duration hour23 Total parts produced pcs24 Number of bad parts pcs25 %26 pcs27 pcs/ hour28 pcs/ hour29 Downtime hour

30Reason text

31 %32 Bottleneck operation X

SHADED CELLS ARE CALCULATED and protected 35

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

Auditor Information

The attached capability study results meet XXX requirements: Utilization % Name:

Corrective actions are required: Date:0.00% Acceptable

Company:

New production readiness trial run is required: Date: Location:

36 Supplier representative signature: Auditor signature:

CAPACITY VERIFICATION (Production Readiness Review / RUN@RATE)

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Total hours/year (9*10*11*12)

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Adjusted production rate (15*(1-16)*17)

Available capacity (15*14*(1-16)*17)*13

Utilization % (3/19)

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First time capability % ((23-24)/24)*100

Number of good parts (23-24)

Net output (26/22)

Takt Time Rate (Target) (3/13*14)

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

34 SUMMARY

IPA In terco nne ct

P roduc tA ssem bly A S


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 68 Process Description Stamp Part CNC #1 CNC #2 Weld Fasteners Paint

Units9 Working hours/shift hours 7.5 8.5 7.0 7.0 10.510 Shifts/ day shifts 3 2 3 3 111 Days/ week days 5 5 5 5 512 Weeks/ year weeks 48 48 48 48 4813 hours 5400 4080 5040 5040 2520

14 % of line for XXX parts (Allocation %) % 100% 87% 100% 100% 50%15 Quoted Production Rate (part # item 1) pcs/hour 720.0 210.0 164.0 240.0 1200.016 Quoted % scrap % 2% 2% 5% 9% 5%17 Quoted % line efficiency % 97% 94% 95% 92% 95%18 pcs/hour 684 193 148 201 1,083 19 pcs/year 3,695,933 686,677 745,970 1,012,677 1,364,580 20 % 19% 102% 94% 69% 51%21 Bottleneck operation X X

22 Trial run duration hour 2.00 1.00 2.00 1.25 1.0023 Total parts produced pcs 929 249 290 252 79424 Number of bad parts pcs 5 2 4 12 425 % 99.46% 99.20% 98.62% 95.24% 99.50%26 pcs 924 247 286 240 79027 pcs/ hour 462 247 143 192 79028 pcs/ hour 130 197 139 139 55629 Downtime hour 0.5

30Reason text Reprogramming

31 % 28.1% 79.8% 97.1% 72.3% 70.3%32 Bottleneck operation X X

SHADED CELLS ARE CALCULATED and protected 35

33

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

Auditor Information

The attached capability study results meet XXX requirements: Utilization % Name: Gerald Biggs

Corrective actions are required: Date: April 1, 240497.13% Acceptable

Company: XXX

New production readiness trial run is required: Date: May 16, 2004 Location: Mesa, AZ

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

CAPACITY VERIFICATION (Production Readiness Review / RUN@RATE)

I - S

uppl

ier

Wor

king

S

tand

ards

Total hours/year (9*10*11*12)

II -

Sup

plie

r C

apac

ity

Dat

a

Adjusted production rate (15*(1-16)*17)

Available capacity (15*14*(1-16)*17)*13

Utilization % (3/19)

III -

RU

N@

RA

TE

Res

ults

First time capability % ((23-24)/24)*100

Number of good parts (23-24)

Net output (26/22)

Takt Time Rate (Target) (3/13*14)

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

34 SUMMARY

IPA In terco nne ct

P roduc tA ssem bly A S


SUPPLIER PROCESS CAPABILITY

SECTION 1 -SPECIFICATION DATA AND MEASUREMENT RESULTS

Part Number Sample Size Note: If no USL/LSL, then leave cell blank

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IPA Interconnect

Produc tAssem bly A S


SUPPLIER PROCESS CAPABILITY

SECTION 1 -SPECIFICATION DATA AND MEASUREMENT RESULTS

Part Number Sample Size 30 Note: If no USL/LSL, then leave cell blank


1 Hole Diameter 3.5 mm 3.4800 0.0300 3.5500 3.4500 0.333

2 6.8 mm dimension 6.7900 0.0500 6.8200 6.7800 0.067

3 .5 radius 0.4990 0.0100 0.5100 0.4950 0.133

4 .05 chamfer 0.0510 0.0010 0.0550 0.0450 1.333

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30301458B

IPA Interconnect

Produc tAssem bly A S

Documents

Capacity Verification Run at Rate Ipa