GM 1927-35 Run at Rate Form_121049_01032010151508

Print Date: 04/19/2023 Run @ RateGM 1927-35

document.xlsx

Section 1: GENERAL INFORMATION

Key InformationPart Number Daily LCR

Daily Contracted Daily LCR

Daily ContractedPart Name 20859367 Capacity HoursSupplier Name SIGMA VIBRACOUSTIC INDIA PVT.LTD 20859367 1062 1062 22 Capacity HoursPlant Location ( Country, City, etc..) India 92245258 1062 1062 22 1062 1062 22Manufacturing Duns No. 918432084 13503549 1062 1062 22Supplier Contact Name Manil Gogia, Naveen Arora Run @ Rate ExemptionSupplier Contact Phone # Complete this section if exempting parts from Run@RateSupplier Contact Email [email protected], [email protected] or Supplier Monitored Customer Exempting?GM Representative Name Sandeep GargRun at Rate Activity Code (from GQTS) ReasonTotal # of Part #'s in family or group 3Any "Non Saleable"parts in the group NoLess Finish Part Number (if applicable)Does Mfg plan exceed 235 days/year or 5 days/wk? YesWas a copy of the Process Flow Diagram provided? YesDate Run at Rate Scheduled 23.03.2010

Section 2: CONSTRAINT IDENTIFICATION

Capability Requirement Constraint

Rubber Mixing 16 3 8 1 1440 20 15 10 10 1254 131 4 1 0.5% 1955 5.0% 1118 57%Deagreasing 12 3 8 2 2880 20 15 10 10 2750 75 3 1 0.5% 1696 6.5% 1136 67%

Gritblastic 6 3 8 3 3600 60 15 10 15 3400 100 4 1 0.5% 1442 6.0% 1130 78% ConstraintCoating 39 3 8 6 8640 60 15 10 10 7465 1080 11 1 1.0% 5702 5.0% 1118 20%

Moulding 10 3 8 3 4320 15 103 99 15 0 4088 78 1 1.0% 3103 4.0% 1106 36%Assembly 0 3 8 3 4320 60 10 10 30 1068 3142 30 1 3.0% 6095 1.0% 1073 18%Inspection 6 3 8 3 4320 60 60 0 0 1708 2492 48 1 1.0% 3084 0.0% 1062 34% Final

Section 3: RESULTS

Final Operation Constraint Operation Additional Questions ( If "No" please comment. )10 Duration (Hrs) 2 Duration (Hrs) Yes Were all scheduled change-overs, breaks, lunches, and maintenance performed and found to be consistent with their forecasted times?726 Good Parts Produced 1500 Good Parts Produced Yes Have the times allocated to other components been reviewed and found to be reasonable?0 Scrap Parts Produced 0 Scrap Parts Produced Yes Was unscheduled downtime within forecasted daily expectations?

3015 Project Daily Good Parts 1250 Project Daily Good Parts Yes Did the parts produced during the Run at Rate meet PPAP requirements? 1062 Required Good Parts 1130 Required Good Parts Yes Was the line staffed by the operators who will work during normal production?

Yes Did the Tier 1 have all subcontractors confirm in writing their ability to meet capacity, quality and delivery requirements? Run @ Rate Result

Pass Result Comments:March 23, 2010 Date Run @ Rate was Performed Operators are considered for all 3 shifts and all duplicate stations.

Reschedule or Follow Up Date No of mould are being considered for calculating R&R for Moulding.One Operator is responsible for Moulding and assembly

Electronic Signature Electronic Signature InstructionsSave this file to your computerDouble click the signature line and signClose file by "X" in the upper right cornerAttach saved file to email and send

Run @ Rate Goal

Operation

List each separate / discrete

operation

Operators

Number of operators

Shifts

Total Shifts per Day

(3 max)

Hours

Hours per Shift

(hours)

Duplicate

Number of duplicate

machines or operations

Gross Minutes

Total MinutesAvailable per day

(minutes / day)

Lunch

Scheduled Breaks, Lunch,

Mtgs etc.

(minutes / day)

Changeovers

Changeovers or Tool Changes

(minutes / day)

Maintenance

Planned Maintenance

(minutes / day)

Downtime

Estimated Unscheduled

Downtime

(minutes / day)

Other

Time allocated for other

components - GM & Non GM

(minutes / day)

Net Minutes

Net Minutes Available per day for Run

at Rate Parts

(minutes / day)

Cycle Time

Cycle Time Estimate

(seconds)

Parts Per Cycle

Parts Per Cycle (ie # Cavities)

(1 minimum)

Scrap Rate

Scrap Rate Percentage

( % )

Capability

# of good parts capable of

being produce on the

operation in one day

Downstream Scrap

Sum all down stream

operations scrap rate %s

Requirement

# of good parts required to be

produced at this operation to

allow the final operation to produce the contracted capacity

Utilization

Requirement / Capability

Constraint Operation

Select Constraint &

Final operation

X

J4

List all part numbers in the family or group. If more lines are required add a separate tab to this workbook.

M4

Lean Capacity Rate Reference GQTS. If not available contact your GM representative.

N4

Reference GQTS. If not available contact your GM representative.

N5

If the LCR > Daily Contracted Capacity for any part number the SQE Manager approval is required for a Pass status.

O5

Hours should be the same for each part in the group or family.

S7

Insert the total contracted capacity for the group or family. It may be the sum of the contract capacities but it depends on how contracts were written.

T7

Insert the contracted hours for the run at rate. It will not be the sum of all the hours.

F12

Insert Customer or Supplier

R12

Insert Yes if parts are being exempted from Run@Rate. GM Managers must approve all exempts with an electronic signature.

F14

This number is automatically generated by GQTS when a Run at Rate group is created by the SQE.

F16

Yes or No If any part in the family/group is "non-saleable" then a SQE Manager approval is required.

B18

The RFQ states.... • Your tooling capacity must be configured based on a 5- day work week, 16 hours per day, and 235 production days per year. Note: Actual contracts may vary….

F18

Yes or No

F19

Yes or No

B25

Insert more lines in this section if required to accommodate more operations.

D25

List total number of shifts that the supplier is working.

F25

If an operation has parallel lines producing the same end product list the total number of parallel lines. Default is 1. If 2 or more is entered ensure Lunch, Changeovers,Maintenance, Downtime, and Other take into account mulitple lines.

G25

Automatically Calculated: Gross Minutes Available per day = Shifts per day x Hours per Shift X # of Duplicate Operations X 60 minutes per hour

I25

Insert the time required to change tools. Ensure time is adjusted to cover the "other customer parts" that are manufactured on days other than the Run @ Rate day.

L25

Insert how many minutes the operation is scheduled to produce other customer part numbers. This should also include the time allocated for other GM part numbers that are not covered in this Run@Rate. Ensure time is adjusted to cover the "other customer parts" that are manufactured on days other than the Run @ Rate day.

M25

Automatically Calculated Net Minutes = Gross Minutes Available per day less Column G - K

P25

Insert the % Scrap for the specific operation. If there are duplicate operations with different scrap rates then determine the combined scrap rate percentage.

Q25

Automatically Calculated Capability=Net Available Minutes per day Study Parts X Cavities X (1-Scrap Rate) / (Cycle Time/60)

R25

Downstrean Scrap is the accumulation (summation) of all downstream (subsequent) processes scrap rate %s. Do Not include current operations scrap rate in this number.

S25

Automatically Calculated: Requirement = Contract / (1-Total Scrap)

T25

What % of this operations Capability is required to produce the final contracted capacity

U25

Must select only one operation as the constraint. It usually is the operation that has the highest utilization. If two or more operations have the same utilization then choose the operation with the higher risk based on your knowledge. Do NOT choose the final operation as the constraint.

J45

Enter Yes or No

J46

Enter Yes or No

J47

Enter Yes or No

J48

Enter Yes or No

J49

Enter Yes or No

J50

Enter Yes or No

B51

GM Managers must approve a Pass with an electronic signature when: The duration is less than 4 hours The duration is greater than 4 hrs and the Run at Rate was stopped prior to meeting contract requirements A part in the group is Non Saleable GM Managers & Commodity Managers must approve a Pass when: A customer fail (Contract <LCR) exists within the group The manufacturing plan exceeds 235 days / year or 5 days / week. GM Managers must approve a ALL Conditional Passes with an electronic signature. GM Managers must confirm the plan and the reschedule date prior to approving.

B52

Pass Fail Conditional Pass Pass Definition: The supplier’s process (while operating under normal operating conditions and under total customer requirement) is capable of producing GMs contracted capacity requirement of PPAP approved (full or interim) components. Fail Definition: The supplier’s process (while operating under normal operating conditions and under total customer requirement) is NOT capable of producing GMs contracted capacity requirement of PPAP approved (full or interim) components. Conditional Pass Definition: The Run@Rate Passed GM’s fixed production volume requirements as indicated by the Program Team but did NOT pass the maximum contracted capacity and the plan (including re-scheduled date) to meet the increase in production volume requirements was approved by the GM Manager.

D52

NOTE: The question... "Did the Tier 1 have all subcontractors confirm in writing their ability to the to meet capacity, quality and delivery requirements?" must be answered "Yes" before a Pass status can be given.

D54

Fail and Conditional Pass status require a Reschedule or Follow Up Date. This date must be added in GQTS.

B56

GM Managers must approve a Pass with an electronic signature when: The duration is less than 4 hours The duration is greater than 4 hrs and the Run at Rate was stopped prior to meeting contract requirements A customer fail (Contract <LCR) exists within the group A part in the group is Non Saleable The manufacturing plan exceeds 235 days / year or 5 days / week. Managers must approve All Exempts Managers must approve All Conditional Pass

Supplier: 0 Part Name: 0 Part Number(s) __

R@R Date: Constraint Run Time Final Run TimeTotal R@R GROSS Time in Minutes Total R@R GROSS Time in Minutes

AM / PM LESS Planned Downtimes: LESS Planned Downtimes:Time for Breaks/Lunch/Meetings: Time for Breaks/Lunch/Meetings:

AM / PM ime for Tool Changes & Changeovers: Time for Tool Changes & Changeovers:Time Required for Other Customers: Time Required for Other Customers:

0 0

Enter Data in White cells only

Operation Name: #N/A Operation Name: #N/A Buffer 1 Buffer 2

Hour Starting Constraint Station or Operation Final Line or Operation Beginning BeginningProduction for the Hour Production for the Hour of the hour of the hour

6 A.M.7 A.M.8 A.M.9 A.M.10 A.M.11 A.M.12 A.M.1 P.M.2 P.M.3 P.M.4 P.M.5 P.M.6 P.M.7 P.M.8 P.M.9 P.M.10 P.M.11 P.M.

12 A.M. +1 day1 A.M.2 A.M.3 A.M.4 A.M.5 A.M.

6 A.M. STOP STOP STOP STOP STOP STOP

Total 0 0 0 0 0 0 0 0

SQE / Supplier Instructions:1) Supplier to record exact start time (cell C5), finish time (cell C8), and total run time of the run at rate for both the constraint (cell G4) and the final operation (cell J4).

R@R Exact Start Time:

Time for "Planned" Maintenance Events: Time for "Planned" Maintenance Events:R@R Exact End Time:

Time Available to Produce R@R Study Parts - Constraint

Time Available to Produce R@R Study Parts - Final Op

Hourly Good Parts

Hourly Scrap Parts

Un-Planned Downtime Minutes

Hourly Good Parts

Hourly Scrap Parts

Un-Planned Downtime Minutes

2) For both constraint and final operation, Supplier to record all planned downtimes including breaks, lunches, meetings (cells G6 / J6); planned maintenance (cells G7 / J7); changeovers, tool and/or material changes (cells G8 / J8); and time allocated for other customers (cells G9 / J9) that concur with the C2 and the SQE/Supplier Run-at-Rate design/plan;3) For both constraint and final operation, Supplier to record hourly data for good parts, scrap parts, all unplanned downtime, and all downtime greater than allowed for lunches, breaks, meetings; planned maintenance; changeovers / tools changes; time allocated for other customers; than as stated on the C2.4) OPTIONAL (SQE Decision): Buffers are to be recorded at the start of the Run at Rate, every four hours, and at the end. Please note: Reduction of buffers (quantities) from start to finish indicates a potential capacity shortage.

J42

Record Buffer at end of Hour starting 5 AM here.

Supplier Name: Date: 03/23/10Supplier / DUNS No.: 918432084 Part name: MOUNT ASM

INDIA Part number(s): 20859367Program: GMX 353 Drawing Date: 4-Mar-09Model Year: 2010 Eng. Change Level: 1

Daily Contracted Run at Rate Results

Capacity Hours Final Op. Constraint Duration Full Saleable

0 1062 1062 22 726 7500 10.0 Yes

Total:

Use additional pages if required.

Supplier Monitored Yes Customer Monitored Yes No

Do the parts produced meet customer’s quality requirements as stated in PPAP?

Comments:

Follow up scheduled:Yes No

Follow up Date:

Supplier Signature Print Name Phone Number Date

SQE Signature Print Name Phone Number Date

SIGMA VIBRACOUSTIC INDIA PVT.LTD

Plant Location Country:

Part Number

Daily MMDB LCR

PPAP Status

Has the Process Control Plan Audit (Attachment GM1927-16) and "Process Specific" Control Plan, when applicable, passed and is it (are they) attached?

Has the Capacity Workbook, GM1927-35 (Flow Diagram (C1), Shared Capacity (CS), System Capacity (C2), R@R Hourly Count, Summary Sheet) passed and is it attached?

Has the ability of all subcontractors to the Tier 1 to meet the capacity, quality and delivery requirements been confirmed in writing by the Tier 1 prior to the Run at Rate?

PASS - Supplier has met the Daily Contracted Capacity in one production day.

CONDITIONAL PASS – The Run@Rate Passed GM’s fixed production volume requirements as indicated by the Program Team but did NOT pass the maximum contracted capacity and the plan (including re-scheduled date) to meet the increase in production volume requirements was approved by the GM Manager.

FAIL – The supplier’s process (while operating under normal operating conditions and under total customer requirement) is NOT capable of producing GMs contracted capacity requirement of PPAP approved (full or interim) components.

R@R Passed

mailto:R@R%20Passed

D4

NOTE: Highlighted Cells are linked to Information Cells on R@R Summary & Information Sheet

Documents

GM 1927-35 Run at Rate Form_121049_01032010151508