FIAT PRODUCTION AUDIT - PDR

7/21/2019 FIAT PRODUCTION AUDIT - PDR

1/10

General Navigation

D .

2

3 C

4 C

5 C

.

,

.

C

. ,

.

C .

,

Production Demonstration Run

Annual: Daily:

Annual: Daily:

uction

line

ction

line(s)

Li h d i liShiftsPer Working Days

Shifts Per

Day

[ ShifMinutes Per

Gross Min

A il bl P

Scheduled

Break/Lunch

Changeover /

Tool Changes

Planned

Maintenance

Unscheduled

DowntimeNet Min

A il bl P

0

0

0

SYSTEM AVAILABILITY(TIME)

Increased Contracted Capacity /

Capacity Planning Volume

Supplier Name

Part(s) Description

Part(s) Number

Contracted Capacity

PRODUCTION SYSTEM


2/10

Getting Started

1

C

D .

2

A A 2.

3

C C&

B D

( ).

D,

D

.

Time allocated

for other PN's

(FIAT, Chrysler,

or others)

[minutes per

day]

Net minutes

available / day

for Study

parts

Cycle Time

[seconds]% Scrap

% True Scrap

(Total Loss)

Estimated

Throughput

For Study

Parts Per Day

Contracted Parts

Per Day (Includes

Spare Parts),

Daily Tooling

Capacity, or CPG

% Utilization

RESULT:

Possible

Constraint

Operation

(>90%) Are

Marked [X]

360 705 30 2.00% 7.50% 1304 1000 76.67%

SYSTEM CAPACITY (UNITS)

PDR

Start

Time

PDR

End

Time

PDR Actual

Downtime

[minutes]

Length

of

PDR

(minutes)

PDR

Total Parts

Produced

[pcs.]

PDR

OK Parts

Produced

[pcs.]

Required

PDR Line

Speed

(Parts/hour)

Witnessed

PDR

OK Parts

per hour

[pcs.]

CHRYSLERR

un Rate:

PDR >=

Contracted

Capacity

(pcs / hour)

?

FIAT

Run Rate:

PDR >=

Contracted

Capacity

(pcs / hour)

?

PDR

FTC

(%)

PDR Actual

Scrap [pcs.]

12:00 14:00 0 120.0 400 392 85.1 196.0 YES YES 98.0% 8

PDR STUDY RESULTS

NOTES


3/10

4

A 2,

C A

A 3.

A 3 C C

, ().

l i% Scrap

% True Scrap

(Total Loss)

Estimated

Throughput

For Study

Parts Per Day

Contracted Parts

Per Day (Includes

Spare Parts),

Daily Tooling

Capacity, or CPG

% Utilization

RESULT:

Possible

Constraint

Operation

(>90%) Are

Marked [X]

2.00% 7.50% 1304 1000 76.67%

5.10% 5.61% 1121 1000 89.18%

0.54% 0.54% 955 1000 104.73% X

SYSTEM CAPACITY (UNITS)

No.

ofoperation

Nextoperation(s)

List each separate SEQUENTIAL

OPERATION in the Constraint Line

Shifts Per

Week

Gross Min

Available Per

Day

Scheduled

Break/Lunch

[minutes per

day]

Changeover /

Tool Changes

[minutes per

day]

Planned

Maintenance

[minutes per

day]

Unscheduled

Downtime

[minutes per

day]

MCBF

[cycles]

MTTR

[minutes]

Net Min

Available Per

Day

Time

allocated for

other PN's

(FIAT,

Chrysler, or

others)

[minutes per

day]

Net minutes

available / day

for Study

parts

Cycle Time

[seconds]

Buffer Before

Operation

Buffer After

Operation% Scrap

% True Scrap

(Total Loss)

Estimated

Throughput

For Study

Parts Per Day

Contracted

Parts Per Day

(Includes Spare

Parts), Daily

Tooling

Capacity, or

CPG

% Utilization

RESULT:

Possible

Constraint

Operation

(>90%) Are

Marked [X]

0 0 0 0 0 0 0 0 0 0 #VALUE! 0 0.00%

0 0 0 0 0 0 0 0 0 0 #VALUE! 0 0.00%

0 0 0 0 0 0 0 0 0 0 #VALUE! 0 0.00%

0 0 0 0 0 0 0 0 0 0 #VALUE! 0 0.00%

0 0 0 0 0 0 0 0 0 0 #VALUE! 0 0.00%

0 0 0 0 0 0 0 0 0 0 #VALUE! 0 0.00%0 0 0 0 0 0 0 0 0 0 #VALUE! 0 0.00%

0 0 0 0 0 0 0 0 0 0 #VALUE! 0 0.00%

0 0 0 0 0 0 0 0 0 0 #VALUE! 0 0.00%

0 0 0 0 0 0 0 0 0 0 #VALUE! 0 0.00%

0 0 0 0 0 0 0 0 0 0 #VALUE! 0 0.00%

0 0 0 0 0 0 0 0 0 0 #VALUE! 0 0.00%

0 0 0 0 0 0 0 0 0 0 #VALUE! 0 0.00%

0 0 0 0 0 0 0 0 0 0 #VALUE! 0 0.00%

0 0 0 0 0 0 0 0 0 0 #VALUE! 0 0.00%

0.54%

No.

ofoperation

Nextoperation(s)

List each separate SEQUENTIAL

OPERATIONin the Production Line

PDR

Start

Time

PDR

End

Time

PDR Actual

Downtime

[minutes]

Length

of

PDR

(minutes)

PDR

Total Parts

Produced

[pcs.]

PDR

OK Parts

Produced

[pcs.]

Required

PDR Line

Speed

(Parts/hour)

Witnessed

PDR

OK Parts

per hour

[pcs.]

CHRYSLERR

un Rate:

PDR >=

Contracted

Capacity

(pcs / hour)

?

FIAT

Run Rate:

PDR >=

Contracted

Capacity

(pcs / hour)

?

PDR

FTC

(%)

PDR Actual

Scrap [pcs.]

0 0 0 #VALUE!

0 0 0 #VALUE!

0 0 0 #VALUE!

0 0 0 #VALUE!0 0 0 #VALUE!

0 0 0 #VALUE!

0 0 0 #VALUE!

0 0 0 #VALUE!

0 0 0 #VALUE!

0 0 0 #VALUE!

0 0 0 #VALUE!

0 0 0 #VALUE!

0 0 0 #VALUE!

0 0 0 #VALUE!

0 0 0 #VALUE!

#NUM!

PDR S TUDYRESULTS

Process overall FTC

NOTES

True Scrap of Production Lines

DOWNSTREAM to Constraint Production

Line:

OPERATIONS

PRODUCTION SYSTEM

OPERATION AVAILABILITY(TIME) OPERATION CAPACITY (UNITS)


4/10

6

C D

. E 11

(15 /). A

4

.

E

,

,

%

C / A.

D

.

11, .

Modifying the Forms

1. "" ( ; ).

2. . A ; , .

PDR Storage

, D . E , .

Scoring the PDR

1

2

(C, B, .)

C A ;

C

C

(, ,

, .)

C A .

/

C /

/

(, , ,

.)

/

/

/

(, , , .)

C


5/10

na nv 1 2 3 4 5

8. Production of FINALoperation

9. FINAL production est.

(restricted observation)

10. All performance /capability targets met?

11. FTC and LineUtilization Acceptable?

1. Score of last / currentProcess Audit?

2. Have the Spare Partsbeen considered?

3. System under normaloperative conditions?

4. Clear responsibilityabout load / unload?

5. Tier 2 capacity risk?6. Is contracted capacity

enough to meet customer

requirements?

7. Production of

CONSTRAINT operation

Common Proc. Group

< 90%

0 > 90% < 90%

> 90% < 90%

0 > 90%

0

Required LineUtilization %

Actual LineUtilization %

All Requirements

Met?

0 > 90% < 90%

Supplier Code:

Customer monitoredMedium or High risk

Supplier monitoredLow risk

Part NumberRequired Line

SpeedDemonstrated

Line SpeedRequired FTC %

DemonstratedFTC %

10%

Shifts/Working week avail.

Weekly capacity 0

OdM / Revision:

Supplier Name:

% Spare parts:

Safety Coefficient:

Project / Vehicle & MY:

Part Number(s):

Part(s) Description:Family of Products:

Working Days / Week:

Working hours / Shift:

Supplier Plant Location:

Description of common equipments / tools:

Use of the part under investigation on other models:

Requested and Contracted Capacity for each model:

Total request:

Description of specific equipments / tools:

Qualified /Interim or IAA

% GridAbsorption

Part NumberIntermediate target

reached? [Y/N]

Requested

Capacity / CPV

Contracted Parts

Per DayProduced parts

constraint operation

Produced parts final

operation

Completion DateResponsibleScore Problem / Root CauseContainment / Corrective Actions / Risk

Mitigation Plan

SCORE

PRODUCTION DEMONSTRATION RUN (PDR)

Shifts/Working week used:

SQE:PDR Date:

SUPPLIER QUALITY


6/10


7/10


8/10


9/10


10/10

CAPABILITY DATA CHART

PDR (Production Demonstration Run)Annex 5

# / ? 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 9 6 97 98 99 1 00 &1 &2 &3 &4

. .. 2

.. .

(/2)

?

2 1,128

A 3 1,693 4 2,059

5 2,326

6 2,534

7 2,704

8 2,847

9 2,97

10 3,078

EA / 11 3,173

EA E 12 3,258

EA 13 3,336

CCA D / 1D 14 3,407

CCA 15 3,472

CAAB 16 3,532

/ 17 3,588

18 3,64

19 3,689

20 3,735

21 3,778

22 3,819

23 3,858

24 3,895

25 3,931

Annex 5

FIAT PRODUCTION AUDIT - PDR

Documents