GP-9 Run@Rate Training

1WorldwidePurchasingGP-9RunatRate#21738–Rev.Dec2004SUPPLIERQUALITY1GP-9RunatRate(21738)BasicsofSupplierQualityTrainingCopyright©GeneralMotorsCorporationWorldwidePurchasing,Warren,MI.AllRightsReserved.Nopartofthismaterialmaybereproducedinanyformoranymethod(electronic,photocopy,microfilm,etc..)foranypurpose,withoutthewrittenpermissionofGeneralMotorsWorldwidePurchasing.RevisedDecember20042WorldwidePurchasingGP-9RunatRate#21738–Rev.Dec2004SUPPLIERQUALITY2GP-9RunatRateClassAgenda•OverviewofGP-9changes•RunatRateProcedure•RunatRateAttachments•HowtodoaRunatRate•Closing3WorldwidePurchasingGP-9RunatRate#21738–Rev.Dec2004SUPPLIERQUALITY3PurposeofRunatRate•Toverifythatasupplier’sproductionprocessiscapableofproducingqualityproductsatcontractedproductionratesonasustainedbasis.4WorldwidePurchasingGP-9RunatRate#21738–Rev.Dec2004SUPPLIERQUALITY4RunatRatePre-Test5WorldwidePurchasingGP-9RunatRate#21738–Rev.Dec2004SUPPLIERQUALITY5RunatRatePre-Test–Page1/36WorldwidePurchasingGP-9RunatRate#21738–Rev.Dec2004SUPPLIERQUALITY6RunatRatePre-Test–Page2/37WorldwidePurchasingGP-9RunatRate#21738–Rev.Dec2004SUPPLIERQUALITY7RunatRatePre-Test–Page3/38WorldwidePurchasingGP-9RunatRate#21738–Rev.Dec2004SUPPLIERQUALITY8RunatRateProcedureOverview•Purpose•Scope•DurationandTiming•SupplierPreparation•Results9WorldwidePurchasingGP-9RunatRate#21738–Rev.Dec2004SUPPLIERQUALITY9RunatRatePurpose•Toverifythatasupplier’sactualmanufacturingprocess,whileoperatingundernormaloperatingconditions,andundertotalcustomerrequirement,is:–Capableofproducingqualitycomponents/systems/modulesasstatedinPPAPand;–Capableofmeetingorexceedingthe“dailycontractedcapacitywithinoneproductionday”onasustainedbasis.10WorldwidePurchasingGP-9RunatRate#21738–Rev.Dec2004SUPPLIERQUALITY10WhatisContractedCapacity?•Supplier’scapacityforapartasshownonthepurchaseorder(contract)•Numberofpartsthatcanbeproducedbythesupplierinoneproductionday–Numberofoperatinghourswithin“oneproductionday”isdefinedonthecontract•EstablishedbytheBuyer11WorldwidePurchasingGP-9RunatRate#21738–Rev.Dec2004SUPPLIERQUALITY11WWPPolicyre.SupplierCapacity•TheSupplier’soperatingplanmustdemonstratethattheycanmeetthedailyLCR,servicepartsschedules,non-GMrequirementsandRunatRateGP-9requirements(includingplanneddowntimeforpreventativemaintenance)inoneproductionday.•ContractedCapacitymustmeetLCRandcurrentmodelservicewhileprovidingcertaintyofsupportingtheMCRonaMAXIMUMSUSTAINABLEbasiswithoutadditionalGMresources.12WorldwidePurchasingGP-9RunatRate#21738–Rev.Dec2004SUPPLIERQUALITY12WhatareLCR’sandMCR’s?•LeanCapacityRate(LCR)–Straighttimelevelofcapacityrequiredtosupportvehicleassemblyoperatingplans–Dailyraterepresenting1/5oftheplannednumberofunitswhichcouldberequiredtosupportvehicleassemblyduringanygivenweek•MaximumCapacityRate(MCR)–LCR+15%–MustbeachievableonasustainedbasiswithoutadditionalGMexpense13WorldwidePurchasingGP-9RunatRate#21738–Rev.Dec2004SUPPLIERQUALITY13RunatRateScope•Applicabletomanufacturingandassemblyprocessescontractedto:–ProducenewpartsIncreaseexistingcapacityToolandequipmentmovestonewmanufacturinglocations•ExemptionsareonlyallowedwithwrittenapprovalfromtheSupplierQualityandPurchasingdirectorsoftheprocuringdivision.14WorldwidePurchasingGP-9RunatRate#21738–Rev.Dec2004SUPPLIERQUALITY14ResponsibilitiesforCapacity•ItistheSQE’sresponsibilitytoverifythatthesupplier’sprocesscanmeetthecontractedcapacity.•ItistheBuyer’sresponsibilitytonegotiateandcontractwiththesuppliertoensurethatthesupplierhasenoughcapacitytosupportGM’splannedrates.15WorldwidePurchasingGP-9RunatRate#21738–Rev.Dec2004SUPPLIERQUALITY15DurationandTiming•Defaultlength=dailycontractedhours•SQEmaydeviatefromthedefaultlengthuponapprovalfrommanagementduetoitemssuch:–productcomplexity–storageandpackaging–shelflife–cost–Engineeringchanges•ShouldbeperformedafterinterimorfullPPAPandnolaterthaneightweekspriortoStartofProduction(SOP).16WorldwidePurchasingGP-9RunatRate#21738–Rev.Dec2004SUPPLIERQUALITY16SupplierPreparation•PriortotheRunatRatethesuppliermust...–ConductapracticeRunatRateand/orsimulations–CompletetheRunatRateworksheetattachments–Providewrittenconfirmationofsubcontractors’abilitytomeetcapacity,qualityanddeliveryrequirements17WorldwidePurchasingGP-9RunatRate#21738–Rev.Dec2004SUPPLIERQUALITY17Results•Pass–Allrequirementsmet•Staged–Planforintroductionofcapacitymet•CustomerFail–Contractedcapacitymetbutlessthancustomerrequirements•PendingPPAP–RequirementsmetbutPPAPstatusisInterim-E•Fail–Requirementsnotmetbysupplier.18WorldwidePurchasingGP-9RunatRate#21738–Rev.Dec2004SUPPLIERQUALITY18RunatRateAttachments•GM1960-ARunatRateSummary•GM1960-BProcessControlPlanAudit•GM1960-CCapacityAnalysisWorksheets–C,C1,C2,C3ALWAYSDOWNLOADGP-9RUNATRATEATTACHMENTSFROMGMSUPPLYPOWERTOSTAYCURRENT19WorldwidePurchasingGP-9RunatRate#21738–Rev.Dec2004SUPPLIERQUALITY19AttachmentA-RunatRateSummary•Purpose:–TosummarizethefindingsoftheRunatRateactivity•Process:–SQEandSuppliercompletethesummaryattheendoftheRunatRate–SQEdeterminesRunatRatestatus–SQEandSuppliersignthecompletedform•Product:–DocumentedR