Run @ Rate(GP-9)
- DSEC education day
on June, 2014
Overseas QA
Director Youngbae Lee
GP-9 Run at Rate # 21738
DSEC Quality
1
Class Agenda
→ Run at Rate activity at each valve
• Overview of Run at Rate
• Review Run at Rate Procedure
• Review Run at Rate
Attachments(Example)
•Q&A
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The Focus of Each (Valve→ SRV)
APQP Valve A
(SRV 1)
Assess
APQP Valve B
(SRV 2)
Assess
Design Review
Assess
Assess
Commercial Issues
Assess
Assess
Plant Layout & Process Flow
Assess
Assess
DFMEA
Assess
Assess
Lessons Learned & Warranty
Assess
Assess
Gage & Tooling Equipment Review
Assess
Assess
Validation & ADVP&R
Assess
Assess
PFMEA & Error Proofing
Assess
Assess
Process Control Plan
Assess
Assess
Dimensional Plan
Assess
Assess
Materials / DCS File Logs
Assess
Assess
Design Appearance Quality
Assess
Assess
Containerization
Assess
Assess
Tier 2 Supply Base
Assess
Assess
PPAP
Assess
Assess
Run @ Rate
Assess
Assess
Assess
GP-12
Assess
Assess
Assess
QSB
Assess
Assess
APQP Task:
Timing Charts / Open Issues
GP-9 Run at Rate # 21738
PPAP Review
(SRV 3)
Run @ Rate
Review
Assess
Assess
Assess
Assess
Assess
Assess
20. Operator training plan
21. Launch build plan
Assess
Assess
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R@R General Requirements
Timing:
R@R is timed 8 weeks prior to SORP ( SOPR 8주전에 수행)
Ownership:
R@R shall be coordinated by the supplier with input from the SQE to meet
program timing (program timing을 만족시키기 위해 SQE 협조로 Supplier가 준비)
R@R shall be attended by:
• Supplier: Quality and Manufacturing
• GM: SQE and Buyer (optional)
Deliverables:
Successful R@R event
Successful R@R 진행결과 (1927-35)
Red, Yellow, or Green status shall be identified for each items listed per Appendix B1 and
documented according to GM-1927-11 in the APQP module. (Valve Assessment _ Updated by
SRV application )
Appendix B1 에 list 된 각각의 item 에 대하여 Red, Yellow, Green status 를
확인하고 APQP module 에있는 1927-11 에 따라 document 한다
GP-9 Run at Rate # 21738
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Run @ Rate at APQP Kick off meeting
Standard questions
Evidence
Contract volume & hour 을
buyer 와 확인
Contract document 확인
Contract 를 만족시키기 위한
operating plan 이 있는가?
(tooling, operator, machine,
working hour)
Manufacturing plan & Shared
capacity 확인
SORP 8주전에 R@R 를
실시해야 하는 것을 이해하고,
실패로 인하여 GM plant 에 문제
발생시 절차를 이해하고
있는가? (GP-5, CS1&2, NBH)
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Run @ Rate at Valve A (SRV 1)
Standard questions
Supplier 는 Buyer 로 부터
LCR/QTC 정보를 입수하였는가?
Evidence
Shared capital capacity 가 포함된
초기 이론적 capacity 분석을 review
Sourcing 정보 대로 capacity 를
만족시킬 수 있고, GM GP-9 의
requirement 에 따라 program
milestone 이전에 R@R 를 pass 할
수 있는가?
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Run @ Rate at Valve A (SRV 1)
Escalation Drop Down:
•
•
•
•
•
•
G – Contracted Daily Capacity, operating hours, and capacity plans are documented
and show adequate coverage
Contracted daily capacity, operating hours and capacity plan 이 문서화 되어있고
충분한 capa를 보여준다
Y – Contracted Daily Capacity requirements are not adequately covered, but a
recovery plan is in place to ensure coverage
Contracted daily capacity는 불만족하지만 이에 대한 recovery plan 을 가지고 있다
Y – Run @ Rate event plans are not documented
Run@Rate event plan 이 문서화 되어있지 않다
R – Contracted Daily Capacity requirements are not documented
Contracted Daily capacity requirements 가 문서화 되어있지 않다
R – Contracted Daily Capacity requirements are not covered by current plans,
and an adequate recovery plan is not in place
Contracted Daily Capacity requirements 를 현재 plan 으로 만족시킬 수 없고 이에
대한 recovery plan 이 없다
R – The supplier has not performed capacity planning for these parts
Supplier가 개발parts 에 대하여 capacity planning을 이행하지 않고있다.
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Run @ Rate at Valve B (SRV 2)
Standard questions
Tooling 은 capacity, EWO,
parameter change 에 대하여
R@R 를 pass 할 수 있는가?
Contract daily capacity 나
시간이 변경되었다면 supplier
는 이를 수용할 수 있는가?
GP-9 Run at Rate # 21738
Evidence
Shared capital capacity 를
포함한 Capacity 분석 자료 참조
Buyer 와 current contract 확인
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Run @ Rate at Valve B (SRV 2)
Escalation Drop Down:
• G – Capacity plans show adequate coverage
Capacity plan 이 충분한 능력을 보여준다
• Y – Contracted Daily Capacity requirements are not adequately covered,
but a recovery plan is in place to ensure coverage
Contracted daily capacity requirements 를 만족 못하지만, recovery plan있다
• R – Contracted Daily Capacity requirements are not covered by current plans, and
an adequate recovery plan is not in place
Contracted Daily Capacity requirements 에 대하여 current plan이 meet하지
못하고 recovery plan 이 없다
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Run @ Rate at PPAP (SRV 3)
Standard questions
Tooling 은 capacity, EWO,
parameter change 에 대하여
R@R 를 pass 할 수 있는가?
GP-9 Run at Rate # 21738
Evidence
PPAP requirement 의 SPR 자료
참조
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Quality
Purpose of Run at Rate
To verify that a supplier’s production process is
capable of producing quality products at
contracted production rates on a sustained
basis.
협력업체의 양산 공정이 품질을 갖춘 제품으로 계약된 연속생산율을
충족하는지 검증.
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Run at Rate Purpose
To verify that a supplier’s actual manufacturing process, while
operating under normal operating conditions, and under total
customer requirement, is:
•
•
Capable of producing quality components / systems /
modules as stated in PPAP and;
Capable of meeting or exceeding the “daily contracted
capacity within one production day” on a sustained basis.
Important Point ! -- Daily Contracted Capacity to be supplied daily by supplier
Run @ Rate 활동의 목적은 정상적인 양산조건 및 “전체 고객 요구사항(TCR)”에 따라
협력업체의 실제 제조공정이 가동되는 동안 다음 사항을 만족하는지 검증하기 위함이다.
- 양산부품승인절차(PPAP)에서 규정된 요구사항과 동일한 품질의 부품/시스템/
모듈을 생산할 수 있는 능력 및
- “일일 생산시간 동안의 일일 계약 생산능력”을 충족하거나 이를 초과하여 연속적으로
생산할 수 있는 능력
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What is Contracted Capacity?
Supplier’s capacity for a part as shown on the purchase order
(contract) as “Daily Capacity” may also be called Quoted Tool
Capacity (QTC).
Number of parts that is to be produced by the supplier in one
production day is identified on the contract
•
Gross number of operating hours within “one production day”
is defined on the contract
Established by the Buyer
구매 요구(계약)에 나타나 있는 부품의 협력업체 생산 능력
협력업체가 하루에 생산 할 수 있는 부품의 수량
- 계약서에 설정된 하루 작업 시간
(예) Allison 공장의 경우 하루 20시간, 주 5일, 년 235일 작업)
Buyer에 의해서 설정
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GPSC Policy re. Supplier Capacity
The Supplier’s operating plan must demonstrate that they can meet
the daily LCR, service parts schedules, non-GM requirements and
Run at Rate GP-9 requirements (including planned downtime for
preventative maintenance) in one production day.
협력업체 운영계획은 하루 생산일에 일일 LCR, 서비스 부품 스케쥴, GM
요구사항에 없는 사항 그리고 Run at Rate GP-9 요구사항(예방보존을 위한
계획된 라인정지 포함)을 만족 할 수 있음을 증명해야만 한다
Contracted Capacity must meet LCR and current model service
while providing certainty of supporting the MCR on a MAXIMUM
SUSTAINABLE basis without additional GM resources.
계약생산능력은 LCR과 GM의 추가적인 자원 지원 없이 최대
연속생산능력에서 MCR을 확실하게 지원하는 동안 현재 모델 서비스를
만족해야만 한다.
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LCR’s - QTC’s – Contract Capacities 란?
행동순서 – SOR to SSF
•
•
Suppliers SOR에 사용을 위해 계획된 LCR이 결정된다.
•
•
Buyer는 반드시 QTC가 LCR보다 크거나 같도록 해야 한다.
•
•
SOP 12개월 전 시점에 MMDB 정보가 load된다.
Supplier는 LCR 을 만족하기 위한 그들의 Quoted Tool Capacity
(QTC)에 대한 회신이 요구된다.
Advanced Buyer는 Sourcing Approval 후 30일 이내에 Nomination
contract를 issue하여야 한다. ( 45일 이내에 Part를 Production
Buyer에게 인계하여야 한다) 이때에 QTC는 Contract Daily Capacity를
전환되어진다.
양산 Buyer는 Contract daily capacity가 여전히 MMDB의 LCR보다
크거나 같은지 확인한다. 필요 시 Supplier와 contact하여 Contract를
변경한다.
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Responsibilities for Capacity
It is the SQE’s responsibility to verify that the
supplier’s process can meet the contracted capacity.
협력업체 공정이 계약된 생산능력을 만족할 수 있음을 검증하는 것이 SQE의
책임이다
It is the Buyer’s responsibility to negotiate and contract with the
supplier to ensure that the supplier has enough capacity to support
GM’s planned rates.
협력업체가 GM의 계획된 생산율을 지원하기 위해 충분한 생산능력을 가지고
있음을 보증하기 위해 협력업체와 협상하고 계약 하는 것은 Buyer의 책임이다.
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What are LCR’s and MCR’s?
Lean Capacity Rate (LCR)
Straight time level of capacity required to support vehicle assembly operating
plans – base hours and base pay, no premiums
•
•
•
차량 조립 운영 계획을 지원할 수 있도록 요구되는 직접시간 수준의 생산능력
Daily rate representing 1/5 of the planned number of units which could be
required to support vehicle assembly during any given week
Daily rate(일일 생산율)은 주어진 한 주 동안 차량 조립을 지원하기 위해
요구되어지는 계획 생산 대수의 1/5을 나타낸다
This means Monday through Friday (5 days). Globally GM Assembly plants
very seldom work more than 5 days a week for LCR.
LCR은 월~금까지 생산대응, GM은 5일을 초과하여 작업을 거의 하지 않는다.
Maximum Capacity Rate (MCR)
• LCR (or Daily Contracted Capacity if it is higher) + 15%
• Must be achievable on a sustained basis without additional GM expense
GM의 추가비용 없이 연속생산을 달성해야만 함
• Is not part of Run at Rate daily volume requirements Daily volume 아니다.
• Normally done on Saturdays or Sundays 일반적으로 토/일요일에 생산
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Run @ Rate - Contract vs.. Plant LCR vs..
Schedule
MCR
1200
Run @ Rate Deadline
Weekly Volume
900
600
300
Contract Daily Capacity
LCR
Schedules/Releases
Start of Production
0
W
k
ee
2)
1
(W
k
ee
)
(-8
W
k
ee
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)
(-4
W
k
ee
0
W
k
ee
4
W
k
ee
8
W
k
ee
12
W
k
ee
16
W
k
ee
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W
k
ee
24
18
Supplier Working More Than 5 Days per Week
• 계약서에 주당 혹은 년당 작업일수가 거의 정의되지 않는다.
• 하지만, 협력업체들은 하루의 생산량으로 GM조립공장의 하루
사용량을 공급해야 한다고 요청을 받는다.
• 대부분의 GM 플랜트는 잔업 없이 주당 5일 근무를 한다.
• 1년의 작업일수는 공휴일로 인해 지역 및 국가별로 다를 수
있다.
• 주당 5일을 초과하는 근무는 일반적인 글로벌프로세스가
아니므로 예외사항은 Buyer와 협력업체 동의로서 계약서에
명기되어야 한다.
• 5일을 초과하는 작업일수에 대해서 계약서에 명기되지 않으면
허용될 수 없다.
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Plant Build vs. Supplier Builds
요구사항은 ?
250
Contract Daily Capacity = 200 Supplier Daily =158
•
GM협력업체의
생산능력은 계약품목에
대한 일일 순 생산량으로
정의된다.
•
협력업체의 공장
운영계획은 하루 생산일에
일일LCR을 만족하는 것을
보여야 한다.
•
예외조항은 부품품질
임원진과 구매임원의 공동
승인이 있어야 가능하다.
이 승인은 업체선정 결정
이전에 이뤄져야 한다.
Wkly LCR / 6 days
Daily Volume
200
150
100
50
Plant Daily Build =
190
Wkly LCR / 5 days
Supplier Daily = 136
Wkly LCR / 7 days
0
Monday
Tuesday Wednesday Thursday
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Saturday
Sunday
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20
Working days per week….does it matter if it is 5,6 or 7
days?
1200
Contracted 5 day Capacity
200
Supplier Weekly Build = 680
7 days
400
Supplier Week Build = 790
6 days
600
160 short
to schedule
Plant Weekly Usage = 950
5 days
Weekly Volume
800
Contracted Weekly Capacity = 1000
1000
270 short
to
schedule
What about:
• MCR ? (+ 15% )
• Inventory
Management?
• Recovery Capacity?
?
0
5 Day Week
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Supplier Installed Capacity
How does a Supplier know what capacity to
install?
•
•
협력업체는 계약을 수주하는 시점부터 인지한다.
협력업체는 QTC, 일일 작업시간, 주당 그리고 년간 작업일수를
알고 있다.
How is it supposed to be done?
•
협력업체가 TS16949를 획득했다면 다음 프로세스를 따를
것이다.
• 생산시스템 설계 프로세스를 갖고 있어야 한다
• 그 프로세스는 입력물로 계약생산수량을 취해야 하며
출력물(생산부품)을 얻기 위하여 제안된, 이론적인
제조공정을 가동해서 입력물과 비교해야 한다
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TS 16949
Additional requirements over QS 9000
Requirement for documented procedures to develop and verify the
design of processes used in product realization (Sec. 7.3.1)
Requirement for process design input requirements to be identified,
documented and reviewed (Sec. 7.3.2.2)
Requirement for process design output to be expressed in terms that
can be verified and validated against process design input (Sec. 7.3.3.2)
Requirement for process design output to be verified against design
input requirements (Sec. 7.3.4 & 7.3.5)
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What about 6 & 7 day operations?
질문: 만일 Supplier가 한 공정에서 여러 장비를 운영할 경우,
24 hours x 7 days, 어떻게 우리는 Pass를 시키고,
여전히 GP9 요구사항을 만족하는가?
Machine 1
Machine 2
Op 10
Machine 3
Machine
1
Op 10
Machine 4
Machine
1
Op 10
Machine 5
Machine
1
Op 10
Machine 6
Machine
1
Op 10
Machine 7
Machine
1
Op 10
Machine
8
Machine
1
Op 10
Machine 1
Op 10
GP-9 Run at Rate # 21738
답변: Contract에 명시되지 않았으면,
허용될 수 없다.!!!!
이것은 Spec.에 대한 요구사항 불만족시의
PPAP fail과 동일하게 다루어진다.
Supplier가 도면 또는 Cpk limit를
만족시키거나, 실제사항을 수집하여 도면
변경을 요청 해야한다.
R@R경우, Contract의 daily capa를
만족시키든지 Supplier가 Contract 변경을
요청해야한다.
GLOBAL PURCHASING AND SUPPLY
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24
Observations and Comments
•
GM 절차(구매, 품질, Tooling, GMS 등)들은 Supplier의 6일 또는 7일
가동에 대해 support하지 않는다, 그래서 좀처럼 contact상에서 찾아보기
힘들다.
•
만일 구매 또는 SQ management에서 공식적으로 6&7일 가동을
승인하지 않으면, 왜 SQE들은 Supplier에게 R@R을 “Pass”로 판정하여
6&7일 가동을 승인하는가?
•
Supplier가 7일 가동을 하면서 어떻게 MCR(+15%)를 만족할 것인가?
• 모든 Supplier는 다른 고객에 영향(선적 량 감소) 을 주지 않고 더 많은
부품을 생산할 수 없다. 왜냐하면 1주일에 모든 가용한 시간을 벌써 사용해
버렸기 때문이다.
•
Supplier는 언제 Planned maintenance를 실시하는가 ?
• 그들은 unplanned downtime과 Supply chain risk를 증가시키는 것을 하지
않는다.
•
Supplier는 매일(월-금) Contract보다 적은 수량을 생산하게 될 것을
알면서, 어떻게 완성된 양품 inventory를 운영할 것인가 ?
• 극히 일부 업체들만 그것을 고려한다.
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Finished Goods - Controlled and Managed with Upper
and Lower Limits
No Assy Plant Production
Inventory Level
UCL
LCL
Mon
Tue
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Thu
Fri
Sat
DSEC Quality
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26
7 Day Operation - Comments
•
•
일반적으로, 7일 가동은 허용되지 않는다.
•
•
7일 가동은 Supplier의 정당화도 GM의 승인도 매우 어렵다.
신고하지 않고, 간과된 7일 가동은 Supplier를 support하는 것처럼
보여져서는 안 된다.
Supplier가 7 일 가동을 승인받으려고 한다면,
• MCR을 만족하는 계획을 만들어라(Must)
• Supplier 공정의 생산 수량의 변화 및 GM의 생산 계획변경을
대응하기 위한 충분한 완성품 재고를 확보해라(Must)
• 계획 보전(Planned Maintenance) 실시계획을 수립해라.
• 모든 Unplanned downtime에 대응키 위한 능력을 증명해야
하고, GM 및 타 고객들의 계약 수량을 만족할 수 있어야 한다.
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Supplier Installed Capacity less than
Contract…
What Do You do?
•
Always use the existing contract to determine status
R@rate status는 항상 최종 Contract 사항을 Check한 후 결정
•
Advise supplier to contact buyer, if contract changes are needed
모든 Contract변경은 Buyer와 협의할 것
•
GM Purchasing has a defined process to manage changes that
needs to be used.
GM구매는 Contract 변경에 관한 규정된 절차를 가지고 있다
•
Remember: Purchasing is the only authorized group to change
contracts.
구매부서만이 Contract변경에 대한 권한을 가지고 있다
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Run at Rate Scope
Applicable to manufacturing and assembly processes contracted to:
제조와 조립 공정에 적용되는 계약된 다음 항목에 대해서 적용
• Produce new parts 신규부품
 Increase existing capacity 기존 생산능력 증대
 Tool and equipment moves to new
manufacturing locations 새로운 생산 장소로 금형과 장비 이동
Exemptions are only allowed with written approval from the Supplier
Quality and Purchasing directors of the procuring division.
이 절차 적용의 예외는 부품품질과 구매임원에 의한 문서상의 승인을 통해서만
허용된다
No written approval – not exempt…….not even if the parts are circled
as exempt on the PSA……….must have written approval.
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Duration and Timing
Default length = daily contracted hours 기본 수행 시간 = 일일 계약 시간
Can be deviated to run for less time……….but
never less the 4 hours => deleted
SQE may deviate from the default length upon approval from
management due to items such: SQE는 다음 항목들에 대해
상관(경영진)의 승인아래 기본 수행 시간을 조정 할 수 있다
•
•
•
•
storage and packaging 저장 및 포장 비용
shelf life 재고품의 저장 수명 시간
cost
Engineering changes
Should be performed
•
•
after PPAP and
no later than eight weeks prior to Start of Production (SOP).
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Run at Rate Results
Pass
•
All requirements met
Fail
•
Requirements not met by supplier.
Conditional pass
•
•
Met production volume requirements by the Program Team but
did NOT meet the contracted capacity
The plan (including re-scheduled date) to meet the contracted
capacity was approved by the GM SQ Manager.
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Run at Rate Attachments
• Capacity Analysis Workbook (GM1927-35) w/example
• Contents
• Run @ Rate Form
• Data Sheet - Optional
• Sign Off Sheet – Optional
ALWAYS DOWNLOAD THE
RUN AT RATE (GM1927-35)
WORKBOOK FROM GM
SUPPLYPOWER TO STAY
CURRENT
* Run @ Rate New form(GM1927-35)
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R@R 이 보여주는 것은 ?............
OPEN
Planned
Downtime
Unplanned
Downtime
Total Scrap
Total Gross Time
In One Day
R@R
Part
Other
Customers
Or Other
GM Parts
Excess Capacity
Protective Capacity
(Additional capacity required
to offset the effect of
variability and dependency)
Productive Capacity
(The basic capacity required
to meet customer demand)
이것은 우리에게 C2와 비교하여 생산 system이 어떻게 가동되는지 말해준다.
“Audit”라고 생각하라…. C2는 우리에게 어떻게 될 것이라고 말해준다.
R@R는 우리가 들은 것이 유효하고 사실인지를 보기 위한 검증 또는 확인이다.
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R@R vs. C2 Example
OPEN
Planned
Downtime
OPEN
Unplanned
Downtime
Planned
Downtime
Unplanned
Downtime
Total Scrap
R@R
Part
Total Scrap
One
Production
Day
Other
Customers
Or Other
GM Parts
R@R form
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Need to run
more than one
production day
OR…..
More downtime
than expected
Scrap higher
than R@R form
R@R
Part
Other
Customers
Or Other
GM Parts
R@R Actual Performance
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R@R vs. C2 Example
OPEN
Planned
Downtime
OPEN
Unplanned
Downtime
Planned
Downtime
Unplanned
Downtime
Total Scrap
R@R
Part
Total Scrap
One
Production
Day
Other
Customers
Or Other
GM Parts
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R@R
Part
Other
Customers
Or Other
GM Parts
No recovery capacity !!
More downtime
than expected
Scrap higher
than R@R form.
Who doesn’t get
their contracted
parts ?
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After the Run at Rate
Communicate results
Determine if an additional Run at Rate is required
Review the corrective actions and verify
implementation (if applicable)
Escalate and communicate all failed R@R’s
결과통보
추가적인 R@rate실시가 요구되는지 결정
개선활동검토 및 적용검증
Failed R@rate 보고 및 협의
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Q&A
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Typical Questions / Concerns
1. What do I do if Purchasing does not have a Contract for the
part I need to do a R@R on? QTC가 나와있는지 사전확인필요
•
•
Without a contract we don’t know what the R@R requirements
are and therefore can not do a R@R.
Notify the buyer and request a contract.
•
Remember, without a contract, a R@R can not be done.
2. Purchasing says they don’t know what capacity to put on
the Contract. What should I do? 구매는 정확한 QTC를 알아야 함
•
•
It is true, purchasing may not know what the right capacity to put
on the contract. Purchasing does not “create” the daily capacity,
they are told what it should be by the Program Manager or the
PDT.
Purchasing needs to obtain the correct daily capacity if they do
not know it.
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Typical Questions / Concerns
3. How do we do R@R’s at suppliers in our country where it is
normal to work 6 days a week? 6 일 가동문제
•
•
•
First, does the GM assembly plant that the supplier supplies to also
work 6 days? If yes, then one day production at supplier does meet
one day need at GM plant – No Problem
If the part is used local (6 days) and is an export, then supplier must
meet the tighter restriction of meeting contract in 5 days
If purchasing decides to change the contract to allow what we use
in 5 days to be met with a supplier working 6 days, then also there
is no problem since supplier will meet the contract
4. Supplier has operations that are shared with other customers,
but they refuse to fill out the “Shared Capacity Sheets”
•
•
•
In order to get the business, the supplier committed that they had open
capacity – the R@R is intended to verify this
Additionally, the supplier agreed to participate in all GM requirements
of which this is one that is openly shown in GM Supply Power.
If supplier refuses to fill out the required documents, we can not do a
R@R and it needs to be resolved by purchasing
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Typical Questions / Concerns
5. In the past we have done some R@R’s using the LCR
volumes and not Contract. Why has this changed? LCR로
R@rate하지말라
• We found that SQE’s were in violation of the R@R process by
doing them at LCR. Doing a R@R at LCR volumes has never been
in the process.
• NEVER use LCR’s to do a R@R
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THE END
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Reference data
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Run at Rate Attachments - Run @ Rate Form
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Run at Rate Attachments - Run @ Rate Form
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Run at Rate Attachments - Run @ Rate
Form
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Run at Rate Attachments - Run @ Rate
Form
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Run at Rate Attachments - Data Sheet(Optional)
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Run at Rate Attachments – Sign off sheet(Optional)
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Run at Rate Attachments –
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Run @ Rate New form
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Run at Rate Attachments - Run @ Rate Form
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