Owens Corning Global Fitness For Use

r CompositesGlobal

Fitness For Use

Overview Manual

OwensCorning

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Global Fitness For Use

"v \Table of

Contents

Introduction

Historical ViewFuture ViewBenefit iiiMethodology (Deployment Chart) vDocument Flow vi


Stage 1 Identification and Specification of Critical Customer and Supplying PartnerBase

Map 1 Identifying and Specifying Customer Base 2

Stage 2 Determination of Customer and Supplying Partner CriteriaMap 2 Understanding Customer Criteria 4Map 3 Understanding Supplying Partner Criteria 8

Stage 3 Assessment of CriteriaMap 4 Assessing Capability of Meeting Needs 12Map 5 Evaluating Options and Developing Action Plan 14Map 6 Communicating No Action to Customer 16Map 7 Modifying Customer Process 18

Stage 4 DefinitionMap 8 Modifying or Inventing Product or Process 20Map 9 Specifying Product Characteristics 30Map 10 Specifying Process Variables 36Map 11 Specifying Machine Characteristics 40

August 1, 1995


Appendix AFitness For Use Forms

Appendix B...Synopsis

Appendix C ..Statistics

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Table ofContents

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49

53

Glossary 59

Deployment Chart 64

August 1, 1995

V \


A

Prologue

Owens-Coming's products and services will be capableofmeeting:

1. Critical Customer Criteria2. Supplying Partner (manufacturing) Criteria

The Fitness For Use process has been developed to accomplish this mission.

The following training manual has been developed to explain and to teach the Owens-Corning Global Fitness For Use Process to Owens-Corning employees. The trainingmanual is an overview of the critical process elements of Fitness For Use and how theprocess fits into the business structure. The training manual is organized such that itmay be used with a variety of audiences.

Depending upon one's role, different levels of understanding may be required for one tomeet the business objectives. For example, if you are concerned with only an overviewand a quick explanation, the introduction section may be all that is necessary. If a general explanation of each map is needed, then you need to look also at the first pages ofthe individual maps. Finally, if you need detailed explanations, some maps include further information..


Historical View

MISSION./ Owens-Coming's products and services/ will be capable of meeting critical customer and

supplying partner criteria.

V

Introduction

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Results• Well accepted philosophy and

"core" process, but...• Procedural gridlock and

dissatisfaction among users• Unclear accountabilities• Unclear responsibilities• Owens-Coming Formal proce

dures

• Mysterious labyrinth• Non-Global

Ausust 1, 1995

jfp^ Global Fitness For Use

Future View

^V A

Introduction

-AMISSIONOwens-Corning products and services will becapable of meeting critical customer and supplying partner criteria.

ResultsDelighted customers andsatisfaction among users

August 1, 1995

Global FFU is a simple, but comprehensive system used for establishing customer needs, defining product/process/machines andassuring that products and processes are in-control and capable.The five stages are listed below with a short explanation:

1. Identification and Specification ofCritical Customer andSupplying Partner BaseThe critical customer and supplying partner base is established by theGlobal Product Team.

2. Determination ofCustomer and Supplying Partner CriteriaThe LPT with assistance from Sales and Manufacturing develops andcommunicates criteria in the format of Need, Measurement Systemand Goal.

3. Assessment ofCriteriaAn assessment is made to compare the customer criteria and supplyingpartner criteria to Owens-Corning's capability to meet the needs.Gaps are identified and an action plan is developed to bridge thesegaps.

4. DefinitionProcesses and procedures are modified or invented and thus specifiedusing a global documentation system. There is an emphasis on specifications that link machine, process and product characteristics withthe customer's criteria. There is an emphasis on vendor (PAS) andcustomer (PPS) documents. There is an emphasis on products andprocesses being in-control and capable.

5. ImplementationOperator control plans are written in the format ofmanufacturing workinstructions. Work instructions are the documents that provide a process operator with the detailed directions on how a job/task is to beperformed.

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Global Fitness For UseBenefits

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Introduction

Standardized Methodology

• Establishes a structured way to do business between supplier and customer

• Develops a systematic method for establishing^customer needsrdefiningproduct/process/machines/ andjdetermining if products and processes are incontrol and capable (2/

• Provides guiding principles which can be applied to new products, modifiedproducts and product transfers

• Creates customer-driven environment in Manufacturing and Science &Technology

Improved Communication

• Provides documented understanding of a product/service so that itmay bealtered or modified in a controlled manner if change is needed

• Provides clarification of roles in the process, therefore eliminating duplicationof efforts

• Develops a common product and process machine language

in August 1, 1995

Y xGlobal Fitness For Use T , .^ r. IntroductionBenefits

X

Improved Understanding

• Encourages understanding of fundamental relationships between CustomerNeeds, Product Characteristics, Process Variables, and Machine Specifications

• Encourages understanding of fundamental relationships between SupplyingPartner (manufacturing) Needs, Product Characteristics, Process Variablesand Machine Specifications

Documented Linkages

• Provides linkages to other systems necessary to support this activity:

Purchase Acceptance StandardsTest and Measurement MethodsManufacturing Operating PlansManufacturing Maintenance PlansDocuments Provided to CustomersPackaging InstructionsGlobal Product Team - Local Product Team Relationships

August 1, 1995

Product Specification

Purchase Acceptance StandardsStatistical TermsSupplying Partner Criteria

Supplying Partner

Work Team Charter

August 1, 1995

a document output in the Definition Stage (4)which defines the nominal values and controlranges for critical product characteristics.

- documents which describe the requirements forpurchase of an item or service by OC.see Appendix C for definitions of statistical terms

- a document which summarizes the informationabout the internal requirements which must besatisfied for Supplying Partners who will producethe product. This is an output of Stage 2, Deter-mining Customer Criteria.a facility which produces a product, usually a manufacturing location, but sometimes a toll manufacturer.

- a document output in the Definition Stage (4) ofthe FFU process which gives instructions to aproject team developing a new or modified prod-uct or process.

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jp\

Measurement system

Mimic Test

Process Model

Process Specification Index

Product Model

a technique or system used to quantify the degreeto which a goal is met. (or) a test method usedto measure a process or product characteristic.

a test method internal to OC which can be used topredict how well a product will satisify a definedcustomer need.a document output of the Definition Stage (4) ofthe FFU process which links critical product characteristics to critical process variables.a document output in the Definition Stage (4) ofthe FFU process which links the product/ process model to the process specifications used tospecify how the product is to be produced inmanufacturing.a document output of the Definition Stage (4)which links customer needs to critical productcharacteristics.

Product Profile Sheet - an output document in the Definition Stage (4) ofthe FFU process which describes the informationabout the product which can be transmitted to thecustomer.

Product Engineer - a jobfunction whomanages the interface betweencustomer and OC for a product line. This is thejob function which has primary responsibility forassuring that the FFU process is properly oper-ated for a given product line.

Product FFU Criteria Sheet - the consolidated customer criteria (needs) which aproduct needs to meet when developed.

62 August 1, 1995

Fitness for Use (FFU)

Gap

Global Product Team (GPT)

Goal

Implementation Stage

Local Product Team (LPT)

Machine Specifications

Maps

August 1, 1995

a term used to describe the process which definescustomer needs and links them to how the productis manufactured to satisfy the need.a term used to describe that a difference existsbetween a needed attribute (such as a customerneed or a supplying partner need) and the abilityto meet that need (or) the difference between thedesired performance and the actual performance.a multi-functional team comprised of the BusinessManager for a product line, an S&T representative, a sales representative and others who man-age the strategy for a product line.a target for achievement. Also a label on the criteria forms. The level the customer wants to meetfor a particular need.Stage 5 in the FFU process which provides working instructions which link the product/ processmodel to actual instructions to manufacturingabout how the product will be produced.a multi-functional team comprised of the ProductEngineer, a manufacturing representative, a salesrepresentative, and sometimes others who manage the strategies established by the GPT at agiven location.

- as related to the FFU process, this is the list ofrequirements which must be defined by Engineering to accompany a new piece of equipment putinto the manufacturing operation.

- a term used in the Fitness for Use Overview Manual to group common topics or sections. (Info-mapped format)

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Assessment

Critical Customer CriteriaSheet

Critical Customer

Critical Product Characteristics

Critical Process Variables

Critical Customer Base

Definition Stage

Design Review

FFU Criteria

60

GLOSSARY

the step in the FFU process which defines whetheror not the customer need is met or not met.the document used to summarize information thata critical customer tells OC about what a producthas to do when the customer uses it. This document is an output of Stage 2, Determining Customer Criteria.a customer, selected from the entire customerbase which will help to determine the fitness foruse of OC products.

- those product attributes which are critical to making the product satisfy the customer needs, forexample; yardage, solids, etc.

- those process items which control the ability tomake critical product characteristics.- the list of customers for whom Customer CriteriaSheets will be completed.

- Stage 4 in the FFU process which includes thesteps and document outputs necessary to definehow the product characteristics and critical pro-cess variables are linked to customer needs.

- a meeting inwhich the chartering team (LPT orGPT) reviews the progress of product or processdevelopment activities in the Definition Stage (4)of the FFU process.

- the needs defined by the customer regarding prod-ucts, logistics, service, or support.

August 1, 1995

August 1, 1995

Fitness For UseGlossary

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Special Causes - A source of variation that is intermittent, unpredictable, unstable; sometimes called an assignable cause. It is signaled by a point beyond the control limits or arun or other non-random pattern of points within the control limits.

Stability - The absence of special causes of variation; the property of being in statisticalcontrol.

Stable Process - A process that is in statistical control.

Standard Deviation - A measure of the spread of a process output or the spread of asampling statistic from the process (e.g., of subgroup averages); denoted by the Greekletter (sigma).

Statistical Control - The condition of describing a process from which all special causesof variation have been eliminated and only common cause remain; evidenced on a control chart by the absence of points beyond the control limits and be the absence of non-random patterns of trends within the control limits.

Statistical Process Control - The use of statistical techniques such as control charts toanalyze a process or its outputs so as to take appropriate actions to achieve and maintain a state of statistical control and to improve the process capability.

August 1, 1995 57

Common Cause - A source of variation that affects all the individual values of the process output being studied: in control chart analysis it appears as part of the random process variation.

Control Chart - A graphic representation of a characteristic of a process, showing plottedvalues of some statistic gathered from that characteristic, a central line, and one or twocontrol limits. It has two basic uses: as a judgement to determine if a process has beenoperating in statistical control, and as an operation to aid in maintaining statistical control.

Control Limit - A line (or lines) on a control chart used as a basis forjudging the significance of the variation from subgroup to subgroup. Variation beyond a control limit is evidence that special causes are affecting the process. Control limits are calculated fromprocess data and are not to be confused with engineering tolerances.

Individual - A single unit, or a single measurement of characteristics.

Mean - The average of values in a group of measurements.

Process - The combination of people, equipment, materials, methods, and environmentthat produce output - a given product or service. A key tool for managing processes isstatistical process control.

Process Average - The locating of the distribution of measure values of a particular pro-f^ cess characteristic, usually designated as an overall average, X.

Process Capability Study - A procedure for determining the control and capability of aprocess by means of control charts. Typically run as a project.

Randomness - A condition in which individual values are not predictable, although theymay come from a definable distribution.

Run - A consecutive number of points consistently increasing or decreasing, or above orbelow the central line. Can be evidence of the existence of special causes of variation.

Run Chart - A simple graphic representation of a characteristic of a process, showingplottedvalues of some statistic gathered from the process (often individual values) and acentral line (Often the median of the values), which can be analyzed for runs, (see alsocontrol Chart.)

Sample - In process control applications, a synonym with Subgroup; this use is totally different from the purpose of providing an estimate of a larger group of people, items, etc.

Sigma - The greek letter used to designate a standard deviation.

56 August 1, 1995

f. During a New Product Design Review the chartering team and the project team(LPT and Product Development Team) may decide to accept a process that is not in- ^%control and capable.

II. What does capable mean?

A CPC or CPV is said to be capable if the Cpk is equal to or greater than 1.00.Cpk's can only be calculated if the characteristic is in statistical control.

Cpk=Zmin =Minimum of USL-X (or) - (LSL - X)3s 3s 3s

USL&LSLare the upper and lowerengineering tolerances, X is the process average,and "s" is the process standard deviation. (RE: Continuing Process Control andProcessCapability Improvement, Copyright 1983, by the FordMotor Company, Inc.).

III. This methodology is applicable for both assessments of standard products (Map 05)and modifying or inventing productor process (Map 09) in design reviews.

Glossary of Statistical Terms

Advanced Statistical Methods - More sophisticated and less widely applicable techniques of statistical process analysis and control than included in Basic Statistical Methods; this can include more advanced control chart techniques, regression analysis,design of experiments, advanced problem-solving techniques, etc.

Average - The sum of values divided by the number (sample size) of values; designatedby a bar over the symbolfor the values being averaged: e.g., X (X Bar) is the average ofthe Xvalues within a subgroup; X (X double bar) is the average of subgroup averages; X(X tilde bar) is the average of subgroup medians; p (p bar is the average of p's from allthe subgroups. (See also Mean.)

Basic Statistical Methods - Applies the theory of variation through use of basic problem-solving techniques and statisticalprocess control; includes control chart construction andinterpretation (forboth variables and attributes data) and capability analysis.

Capability - (can be determined only after the process is in statistical control.)When the process average plus and minus the 3-sigma spread of the distribution of individuals (X+3 sigma) is contained within the specification tolerance (variables data), orwhen at least 99.73% of individuals are within specification (attributes data), a process issaid to be capable.

Characteristic - A distinguishing feature of a process or its output on which variables orattributes data can be collected.

August 1, 1995 55

APPENDIX C

Control and Capability Methodology

I. What does statistically in-control mean?

The condition describing a process from which all special causes of variation have been eliminated and only common causes remain. Training in statisticalprocess control is necessary to make this assessment.

a. A statistical control chart is a good graphical tool for showing control.

b. Control can be evidenced on a control chart by the absence of points beyondthe control limits and by the absence of runs.

c. A practical rule for the evaluation of points is to consider more than 1 out of 35,or 2 out of 100 points outside control limits as evidence of control.(RE: ANSI Standard Z1.3-1958, Revised 1975).

d. The best tool for gathering control and capability data is a process capabilitystudy. (RE: Statistical Quality Control Handbook, Section II, Part A. AT&TTechnologies, Copyright 1956, Western Electric Co., Inc.).

/f^ e. Guidelines for amount of data required for a process capability study.

X and R Charts*A suitable amount of data to start with would be as follows:

First period 30 measurementsSecond period 30 measurements (optional)Third period 30 measurements (optional)

p-Charts*A suitable amount of data would consist of 20 to 25 samples for each one of theseperiods. Each sample should represent about 50 or 100 units checked.

Charts for individual measurements with control limits based on the movingrange. *In this type of study we are ordinarily limited to very little data It is permissible touse as few as 10 consecutive numbers, provided these numbers cover a representative period of time.

'Multiple studies may be necessary to study the effects of process cycles, lots of materials, operators orother variables. While the rules given above are safe rules to follow, do not hesitate to use larger or

smaller amounts of data ifthis is necessary. Ifmore data are readily available, by all means use them. Ifvery little data can be taken, it is still possible to obtain answers to many problems by using these data in a

a capability study.

54 August 1, 1995

"VAppendix C

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Control and CapabilityMethodology

August 1, 1995

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52 August 1,1995

stsgeDefinition

Map owner «„; JtftqpSiSS-; Dosctipftofr;

8S&T Managing Projects to

Modify or InventProducts and Pro

cesses

One of the action plans can be to charterawork team. The Project Leader leads ateam to fulfill the charter followingFFU sub-procedures.The Design Review is an integral partof the development process.Creating Definition documents is anintegral part of the development process.

9-11S&T Specifying Modified

or New Products and

Processes

Specifying documents contain the nom-inals and tolerances for product andprocess variables.

ImplementationMfg.

Creating OperatingPlans

Work Procedures, Work Instructionsand supporting documents are created.Work Instructions are the documents

that provide a process operator with thedetailed directions on how a job/task isto be performed.

S&TCreating ExternalDocuments

Documents referenced in Definitionsare created by owners of proceduresoutside the Fitness For Use Procedure.

Examples would be Purchase Acceptance Standards, Test Methods andProduct Profile Sheets.

GPT Approving FinalProject

A formal project completion DesignReview is held with the GPT.

August 1, 1995 51

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j^SA macro-view of the Fitness For Use Process is provided in this table. The variousprocedures supporting the main stages are summarized. Each section is a map of aFFU Process. The map numbers refer to elements in the flowchart as well as toindividual maps in the Overview Manual.

Stage Map Owner

Process Description

Identification andSpecification ofCritical Customerand Supplying Partner Base

GPT Developing ProductLine Strategy

The product line strategy is developed. Businesses, channels andmarkets are part of the strategy.

1 GPT Identifying andSpecifying Customer and Supplying Partner Base

Customers and Supplying Partners that will drive Global Fitness-For-Use are communicated.

Determination ofCustomer and Supplying Parmer Criteria

2 LPT Understanding Customer Criteria

Needs, measurement systems andgoals for customer criteria areunderstood and communicated.

3 LPT Understanding Supplying Partner Criteria

Needs, measurement systems andgoals for supplying partner criteria are understood and communicated.

Assessment of Criteria

4 LPT Assessing Capability ofMeetingNeeds

The capability to meet criteria isassessed. The gaps between criteria and capability are identified.Gaps are issues to be resolved.

5 LPT Evaluating Optionsand DevelopingAction Plans

The LPT's work with the GPT todevelop an action plan based onthe assessment.

6 Sales

CommunicatingNO Action to Customer

One of the action plans may be tonot meet a criteria. An action planmay not be needed if the criteria isalready satisfied.

7 S&T Modifying Customer Process

One of the action plans may be tocharter a work team. The ProjectLeader leads a team to fullfil theexpectations of the charter.

50 August 1, 1995

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Appendix B

Fitness For UseSynopsis

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prodspec.sam

PRODUCT SPECIFICATION

Number

Characteristics Test MethodCalibrationMethod Nominal Tolerance

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profilea.sam

PRODUCT PROFILE SHEET

Product Family: Product/Process Model:

Prepared By: Document Number:

Date:

A. Products Available

B. Expected ProductCharacteristics

C. Expected End-UsePerformance

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niodels.sani

PROCESSMODEL

PRODUCTCONSOLIDATEDFFUDOCUMENT

CUSTOMER(S)DATEPREPAREDBY

DOCUMENT

CRITICALPRODUCTCHARACTERISTICS

PROCESSVARIABLEMACHINETESTMETHOD

models,sam

PRODUCTMODEL

PRODUCTCONSOLIDATEDFFUDOCUMENT

CUSTOMER(S)DATEPREPAREDBY

DOCUMENTit

CUSTOMERFFUCRITERIAPRODUCTCHARACTERISTICTESTMETHOD

0

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Charter, sam

WORK TEAM CHARTER

Original Date

Amended Date

Chartering Team

Project Title

TEAM GOAL

LEVEL OFAUTHORITY

CONSTRAINTS

EXPECTEDACTIVITIES

RESOURCESAVAILABLE

EXPECTEDRESULTS

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spcrit.sam

SupplyingPartnerCriteria

Facility:Project:

Factory:PreparationDate:

Operation:ValidationDate:

Process:Preparedby:

USECRITERIARANKMEASUREMENTSYSTEMGOALASSESSMENTOCPROGRAM

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custcrit.sam

Customer Criteria

Customer: OC Product:

Customer Process: Preparation Date:

Customer Product: Validation Date:

End Use: Prepared by:

USE CRITERIA RANK MEASUREMENT SYSTEM GOAL ASSESSMENT OC PROGRAM

48 August 1,1995

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Appendix A

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Fitness For UseForms

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46 August 1, 1995

Summary of Course

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1. Identification and Specification ofCritical Customer and SupplyingPartner Base

• Critical Customer List li

• Supplying Partner List

2. Determination of Customer andj Supplying Partner Criteria

• Customer Criteria Sheet |• Supplying Partner Sheet

3. Assessment of Criteria and Development of Action Plans

• No Action Decision

• Customer ModificationPlan

• Modification or Inventionof Product or Process

4. Definition

•

• Product FFU

• Work Team Charter

• Product Model

• Process Model

• Product Profile Sheet

• Product SpecificationsProcess Specifications• Machine Specifications

5. Implementation • Work Instructions

August 1, 1995

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44

The FFU systems to satisfy customer needs inthe area of service, logistics and support arecurrently under development by a projectteam.

Work instructions currently generated by manufacturing and maintenance areas have beendesigned to satisfy ISO 9002 requirements. TheFFU process is complete when work instructions describe how to produce a Product/Process Model.

August 1, 1995

Map 11Specifying MachineCharacteristics

Machine Document

1.02.03.04.05.06.07.08.09.010.011.0

Machine Document

PurposeOperating InstructionsPreventative MaintenanceMaintenance and TroubleshootingRecommended Equipment SparesDrawing ListsVendor InformationPurchase OrdersEngineering ContactsLubrication Schedule and InformationAlignment and Vibrations

12.0 Critical Process Specifications13.0 Miscellaneous14.0 Adjustments

Machine Adjustment

r Stage 4

Definition

Items 1 -13 are traditionally provided by Engineering as part of amachine "package"

~\

Machine Adjustment Table and Machine Adjustment "Expanded View" are critical for linking the variables in a machine to unique process set-ups.

The method referencedfor changing the variable1 Calibration method

for test method

Variable S AdjustmentMethod

Machine AdjustmentMachine Code

Adjustment MeasurementMethod

Item that can be adjusted tocreate a "unique" set-up

August 1, 1995

CalibrationMethod

OperatingRange

The test method forassuring the

variable is correct r.


Machine Document

42

Machine Document

1.0 Purpose2.0 Operating Instructions3.0 Preventative Maintenance4.0 Maintenance and Troubleshooting5.0 Recommended Equipment Spares6.0 Drawing Lists7.0 Vendor Information8.0 Purchase Orders9.0 Engineering Contacts10.0 Lubrication Schedule and Information11.0 Alignment and Vibrations12.0 Critical Process Specifications13.0 Miscellaneous

14.0 Adjustments

Stage 4

Definition

August 1, 1995

Scope


Stage 4

Definition

This map describes the general process steps that lead to creating the body ofdocumentation that Science and Technology is accountable to provide to Manufacturingwhen machines are developed or modified.

The Definition Documents are created when machines are developed or modified. TheDefinition Documents are modified when products or processes are modified. The Definition Documents are validated periodically against current customer and supplying partner documents.

A system is not considered to be defined until all appropriate definitions are completed.Amachine is a device which when set up in a unique way is configured into a uniqueprocess for making a unique product.

Accountability

The following members of the Science and Technology group are responsible for creating Definition Documents and presenting them for approval:

Project Leader for new, modified or transferred machinesProject Leader for new, modified or transferred productsProduct Engineer for on-going validation and review

Deliverables

Winning is the Machine Definition Documents being approved for inclusion in theGlobal FFU Document.

August 1, 1995 41

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GlobalProductTeam

LocalProductTeam

Scienceand

Technology

40


1.02.03.04.05.06.07.08.09.010.011.0

Machine Document

PurposeOperating InstructionsPreventative MaintenanceMaintenance and TroubleshootingRecommended Equipment SparesDrawing ListsVendor InformationPurchase OrdersEngineering ContactsLubrication Schedule and InformationAlignment and Vibrations

12.0 Critical Process Specifications13.0 Miscellaneous14.0 Adjustments

Stage 4 ^

Definition

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Specification

Map 10Specifying Process

Variables

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X

Stage 4 A

Definition

Specifying the process consists of providing process variable information as well as references to the other process related topics.

Specification Index

SpecialInstructions

PurchasingDocument(PAS)

GlassSpecification

SizingSpecification fit

PackagingSpecification

MachineSpecification

*** '

Fabrication Specification

Forming Specification

Product Mociel

Melting SProduct Code

IpecificationProduct Use Document

Variable Machine # Test Method Calibration Method Nominal Tolerance

August 1, 1995 39

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Variables

Specification Index

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>>

Stage 4~\

Definition

The Specification Index is a master "look-up" table that cross references the groups ofdocuments that specify how a product at the "code" level is "manufactured." The Specification index also provides linkage to the various Criteria Documents and Definition Documents that are related to the product referenced.

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SPECIFICATION INDEXProduct

Special InstructionsProduct FFU CriteriaProduct/Process ModelProduct Profile SheetProduct SpecificationGlass SpecificationSizing SpecificationMelting SpecificationForming SpecificationFabrication SpecificationMachine SpecificationPackaging Specification

August 1, 1995

Scope


Variables

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A

Stage 4 "\

Definition

This map describes the general process steps that lead to creating the body of documentation that Science and Technology is accountable to provide to Manufacturing when processes are developed or modified.

The Definition Documents are validated periodically against current customer and supplying partner criteria.

A process is a machine setup in a unique way to produce a unique product. A processis not considered to be defined until all appropriate specifications are completed.

Accountability

The following members of the Science and Technology group are responsible for creating definition documents and presenting them for approval:

• Project Leader for new, modified or transferred products• Product Engineer for on-going validation and review

Deliverables

Winning is the generation of theProcess Specifications which tellManufacturing how to operate theprocess to produce the product.

August 1, 1995

Global ProcessFFU Documents

sf37

4^

GlobalProductTeam

LocalProductTeam

Manufacturing

Scienceand

Technology

36


Variables



9-14, 20SpecifyingProduct/Process

~V~Stage 4

Definition

A

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August 1, 1995

The following maps (processes) are being further developed by project teams. Additionalinformation will be forthcoming when theseteams have completed their work.

Included will be:

Process Specification Index which links theProduct/Process Model to manufacturing workinstructions

Engineering specifications for machinecharacteristics

Implementation of Product/Profile Sheet vs.Customer Acceptance Specifications (CAS)

Development of additional process maps forlogistics, service and support

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Map 9Specifying ProductCharacteristics

Product Specification

"V

X

Stage 4 "\

Definition

Specifying the product characteristics consists of providing product characteristic informationwhich allows the criteria in the Product FFU Criteria document to be met.

Specifjcation Index

ProductFFU CriteriaSupplying Partner

Criteria

Product / ProcessModel

Product ProfileSheetProduct

Specification

Product SpecificationNumber

Characteristics Test Method Calibration Method Nominal Tolerance

August 1, 1995 33

#^

#^


Specification Index

^V

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Stage 4

Definition

The Specification Index is a master "look-up" table that cross references the groups ofdocuments that specify how a product at the "code" level is "manufactured." The Specification Index also provides linkage to the various Criteria Documents and Definition Documents that are related to the product referenced.

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August 1, 1995

Scope


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A

Stage 4

Definition

This map describes the general process steps that lead to creating the body of documentation that Science and Technology is accountable to provide to Manufacturing whenproducts or processes are developed or modified.

The Definition Documents are validated periodically against current customer and supplying partner criteria.

A product is the output of a machine(s) set up in a unique manner (process). A productis not considered to be defined until all appropriate specifications are completed.

Accountability

The following members of the Science and Technology group are responsible for creating definition documents and presenting them for approval:

• Project Leader for new, modified or transferred products• Product Engineer for ongoing validation and review

Deliverables

Winning is the generation of a ProductSpecification Document for the ProductDefinition Documents which are approvedfor inclusion in the Global FFU Document

August 1, 1995

Global ProductFFU Documents

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0^

GlobalProductTeam

Manufacturing

Scienceand

Technology

30




9-14, 20SpecifyingProduct/Process

^rStage 4 A

Definition

>s

August 1, 1995

Map 08Modifying or InventingProduct or Process

Design Review - Product Profile Sheet

V^

>s

Stage 4

Definition

Part of defining a product is the creation of a Product Profile Sheet. The Product ProfileSheet is the document that contains information that satisfies the need for providinginformation to customers. Some organizations may use the information in lieu of the current CAS. Others can use this information to create Product Data Sheets.


PRODUCT FAMILY

A. PRODUCTS AVAILABLE

B. EXPECTED PRODUCT CHARACTERISTICS

C. EXPECTED END-USE PERFORMANCE

August 1,1995

Describes items available to thecustomer within the product lineand their limits, such as the various weights, widths, lengths,yields, packaging, etc. that are

offered. An entry here implies thatthe product is included within thescope described in the product/

process model.

^>

Describes the critical productcharacteristics and their

expected ranges.

Describes end-use attributes that can beexpected from the product.

Describes limits of use and other information that a customer would find relevant

about the use of the product.^

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Stage 4

Definition

Design Review - Process Model

One process model will exist for each common productmodel. The product and processmodels actually form a document set.

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Critical process variablesthat govern the level of a

critical product characteristicCritical product characteristics from product model

PROCESS MODEL

PRODUCT PRODUCT FFU CRITERIA DOCUMENT

CUSTOMER(S) DATE PREPARED BY DOCUMENT*

Critical Product Characteristics -^

Critical ProcessVariable

Machinek

CPC1 CPC2 CPC3 CPC4 CPCXTest Method

k A-l

\ V A-2

—\- \

The machine codeis referenced here.In some situationsmore than onemachine may be

specified to define aprocess. This willresult in a unique

product.

The attachment in each blockreferences support documentation that "proves" to the chartering team that linkage exists.Support documentation may be:• Design of Experiments• Correlation Analysis• Graph• Report• "Expert Testimony"• Other

S.

The testmethod usedto measurethe criticalprocess vari

able.

August 1, 1995


Design Review - Product Model

>^~

X

Stage 4 ~\

Definition

One product (process) model will exist for each Product Fitness For Use Criteria Sheet.

Critical productcharacteristics that controlwhether the customer use

criteria will be met

Customer fitness for usecriteria from Product FFUCriteria Sheet that links to

this product family

^ \

r

PRODUCT MODEL

PRODUCT PRODUCT FFU CRITERIA DOCUMENT

CUSTOMER(S) DATE PREPARED BY DOCUMENT*

"

Customer FFU Criteria ^

CriticalProduct

Characteristic

Customer

Criteria#1

Customer

Criteria#2

Customer

Criteria#3

Customer

Criteria#4

Customer

Criteria#5

Test

Method

A-l

i A-3 A-4

A-2 J| Mimic \

i.

The mimic is OC'smethod for simulating, correlatingor reproducingcustomer's measurement method.

The attachment number (A-#) in eachblock references support documentationthat "proves" to the chartering team thatlinkage exists.Support documentation included with theProduct Model may be:

Design of ExperimentsCorrelation AnalysisGraphReport"Expert Testimony"Other

\

SAugust 1,1995

Indicate thetest methodused to measure the critical productcharacteris

tics.

27


~^

/s

Stage 4

Definition

Design Review - Fitness-For-Use Criteria

26

/This column is "checked off" to showthat the need has been met. Eachcriteria must be reconciled duringthe design review process. A majorcriteria group in every SupplyingPartner Criteria Sheet is that all critical product characteristics and allcritical process variables (from theproduct/process models) are in-control and capable. Please referencethe glossary for definitions of in-control and capable.

\

Product Fitness-For-Use Criteria

customer:

"Cusi:omex

FFU

CRITEI

u<_ rroauct:

t*iy»ngrafinn I ram-

Supplying Partner Fitness-For-Use Criteria

facility:Factory:

operation:Process:

Project:preparation uate:vaiiaation Date:

Prepared oy:

/''input in the column is Yes or No.

Yes is based onLPTs consensusthat need is metafter review of

appropriate data.

August 1, 1995

f 7T7Z, v—-—Stage 4Map 08

Modifying or InventingProduct or Process Definition

Design Review

The Design Review is an essential element of the Global Fitness For Use Process. Thedesign review is conducted between the chartering team and the project team, for example, a Local Product Team and a Product Development Team.

The purpose of the design review is to:Insure communicationsInsure that evidence is generated to assure that the Product FFU criteria hasbeen metInsure that evidence is generated to assure that the Supplying Partner Criteriahas been met

Create an environment where realistic changes in target criteria can be madebased on information during the development processInsure that the definition of critical product characteristics and critical process ^variables are documentedInsure that the range of product use is defined and all necessary customer communication documents are created

/*%

August 1,1995 25

r


Work Team Charter

~V

>S

Stage 4

Definition

A work team is commissioned by the Local Product Team to resolve gaps. The work charter consistsof the following elements:

Team Goal

Work Team Charter

/Clear understanding and commitment to achieve team goals.If the goal is development of anew or modified product, thegoal must reference the Prod

uct Criteria Sheet.Level of Authority

The scope and limitsof authority withinwhich the team isallowed to act (whatdecisions it may ormay not make, andany spending limita

tions)

Constraints f Identify cost restrictions, gross marginrequirements, etc.

Expected Activities

Expected Results

24

Identify results expected of the team, suchas improvements, savings, gains, and benefits. If the goal is development of a newproduct, expected results will include product/process model documents, a product pro

file sheet, and process specifications.

Describe key activities the teamis expected to undertake, including specific objectives, strategies,recommendations, and analysis tobe performed. This may require awork plan, charts, reports, andpresentations to the LPT.

Identify the resources available to the team, includingthe team adviser, subject matter expert, or LPT leader.

August 1, 1995


Product FFU Criteria Sheet

~V

>>

Stage 4

Definition

The requirements that must be met by the new product are given in a Product FFU CriteriaSheet. It includes consolidated criteria from individual customer criteria sheets.

/r" Product Fitness-For-Use Criteria

Facility: Project:Factory: Preparation Date:

Operation: Validation Date:

Process: Prepared by:

FFUCRITERIA

RANKMEASUREMENT

SYSTEMGOAL ASSESSMENT

OC

PROGRAM

August 1,1995

Consolidated FFU Criteria.

This is the consolidated list ofcustomer criteria.

The input data comes fromthe Critical Customer CriteriaSheets.

s

23

'"^1


Chartering a Work Team

V"

>^

Sta°e4

Definition

If the assessment step results in a need to modify an existing product or to develop anew product, a Product FFU Criteria Sheet must be developed. The Product FFU Criteria sheet contains the consolidated critical customer criteria and the consolidated criticalsupplying partner criteria which the new or modified product must meet.

The Product FFU Criteria Sheet and the Work Team Charter are used to give direction tothe project team responsible for developing or modifying the product.

Accountability

The LPT or chartering team is responsible for generating the requirements to be met bythe project work team.

Deliverables

Winning is the- development and publication of a Product FFU Criteria Sheet- development and publication of a Work Team Charter- defining and chartering a project team

22 August 1, 1995

Scope


V~

>>

Stage 4

Definition

This map describes the process that a chartered work-team would follow to modify or inventproducts, processes, machines, logistics, services, support to meet the customer and supplying partner criteria.

Accountability

The Local Product Team or the Global Product Team charters "teams" to resolve gaps foundduring the assessment stage. The leader of the chartered work-team is responsible for ensuring that appropriate definition documents are created and that the results are presentedto the Local Product Team for approval during the design review phase.

Deliverables

Winning isHaving the LPT:- define the consolidated needs of the critical customers in a Product FFU Criteriadocument

- communicate Supplying Partner(s)- develop a work team charter to define the activity needed to achieve a needs metassessment

- conduct design reviews to assure success of the project

And having the Work Team:- publish the Product and Process models- publish the Product Profile Sheet- publish the Product Specification- publish the Process Specification Index

August 1,1995

U

21

GlobalProductTeam

Scienceand

Technology

20


Design Review

09Modifying orinventingProduct orProcess

A^Stage 4

Definition

>^

'roduct Profile SheetProduct/ Process ModelSupplying Partner FFU Criteria

Product FFU Criteria

Work Team Charter

August 1, 1995

Scope

Map 07Modifying Customer Process

^v^

>.

Stage 3

Assessmentof Criteria

~\

This map describes the process that a work team would follow to provide support to acustomer.

This support would allow customer criteria to be satisfied by modifying a customer's process instead of modifying Owens-Coming's product.

Accountability

The Local Product Team charters "teams" to resolve gaps. The leader of the projectteam is responsible for documenting the actions taken, along with the results obtained,and submitting them to the Local Product Team. The LPT approves these during the design review process.

Deliverables

Winning is a Satisfied Customer andan Updated Global Fitness-For-UseDocument.

August 1, 1995 19

/*^%

f^

GlobalProductTeam

LocalProductTeam

Manufacturing

Scienceand

Technology

18

Map 07Modifying Customer Process

^

>^

Customer Fitness-For-Use Criteria

Stage 3



Customer Process: Preparation Date:Customer Product: Validation Date:


USE

CRITERIARANK

MEASUREMENTSYSTEM GOAL ASSESSMENT

OCPROGRAM

A

August 1, 1995

Scope

Map 06Communicate No Action

to Customer

~V

>>

Stage 3


"\

This map describes the process that takes place when no action is to be taken as a result of an assessment process

• A No Action response could be made if it is decided that a customer'scriteria will not be met.

• A No Action decision could be made if the current condition satisfiescriteria.

Accountability

The Customer Sales Representative, with the assistance of the LPT if necessary, communicates to the customer what action Owens-Corning will take.

Deliverables

Winning is communicatingOwens-Corning's action decision to the customer.

All action decisions are communicated by the sales representative - not just No Action.

August 1, 1995 17

/^%

r

GlobalProductTeam

Sales

LocalProductTeam

Manufacturing

Scienceand

Technology

16

Map 06Communicating No Action

to Customer

06CommunicateeNo Action

ToCustomer


Stage 3





USE

CRITERIARANK

MEASUREMENTSYSTEM GOAL ASSESSMENT OC

PROGRAM

August 1, 1995

Map 05Evaluating Options and Developing

Action Plans

Scope

Stage 3

Assessment

of Criteria

This map describes the process for evaluating who will take action to satisfy gaps foundduring the assessment process. It also describes the requirements for chartering projectteams to develop new or modify existing products or processes.

Accountability

The Local Product Team is responsible for developing action plans to address gapsidentified during assessment of capability. The LPT may charter a project team to closethe gap. The criteria to be met by the project team is included in a team charter. If theaction required is a development of a new or modified product, the LPT must also complete a Product FFU Criteria Sheet along with the work team charter.

The Local Product Team has three choices of action:• If no action is taken, then Sales and Manufacturing must be notified.• If the action needed is within LPT's scope, then a work team is chartered.• If the action needed is not within LPT's scope, the Global Product Team is notified. The LPT will charter the team if the GPT is in agreement.

Deliverables

August l, 1995

Appropriate Team is chartered to address thecustomer and supplying partner criteria.

ot Q

LPT Work Team

15

Map 05Evaluating Options and Developing

Action Plans

Stage 3


Scienceand

Technology

14


Supplying Paitner Fitness-For-Use Criteria

hacility Projecthactory Preparation Date

Operation Validation Date

Process Prepared by

FFUCRITERIA

RANKMEASUREMENT

SYSTEMGOAL

OCASSESSMENT B.J1;.,,[ PROORAM|

11August 1, 1995

Scope

Map 04Assessing Capability of

Meeting Needs

T Stage 3 *


This map defines the procedure used to:• determine our current capability to provide products/services that meet thecritical customer and supplying partner criteria documents

• generate a list of options based on our capability

Accountability

The Local Product Team is responsible for updating the Assessment Column of the Customer Criteria and Supplying Partner Criteria Documents. Assessments for existing /^products occur at regular intervals. Assessments of new products occur during the de- Jvelopment process (Map 8).

Deliverables

The assessment thus assures that products are in-control and capable of meetingcritical customer and supplying partner needs. Although some assessment may bequalitative, assessments of critical product characteristics (CPC's) and critical process variables (CPU's) must be quantitative.

In-control means that special causes of variation have been eliminated and that onlycommon causes of variation remain. Statistical analysis techniques should be usedto determine that the variable is in-control. Some examples of the statistical analysismethods are included in the appendix C.

After the process is determined to be in-control, an assessment of capability shouldbe made. Capability is usually expressed as a process capability index (CpK). (Seethe appendix C for an explanation of capability.)

Typically, Owens-Corning desires in-control CPC's ad CPU's to have a CpK of at| least 1.33 However, the acceptable CpK level is to be determined by the LPT ^%

August 1, 1995 13

GlobalProductTeam

LocalSpijo|gef£Tearn .1

Scienceand

Technology

12

Map 04Assessing Capability of

Meeting Needs

04AssessCapabilityerf MeetingNeeds

Stage 3

Assessment

of Criteria

Supplying Partner Fitness For Use CriteriaCustomer Fitness For Use Criteria

Customer: UC Product:


hnd Use: Prepared by:

FFUCRITERIA

RANKMEASUREMENT


OCPROGRAM

August 1, 1995

Map 03Understanding Supplying

Partner Criteria

Stage 2

Determination of Customerand SupplyingPartner Criteria


Facility:Factory:

Operation:

PFUCRITERIA

Process:

RANK

FFU Criteriaare grouped:

Outputs• Safety• Health• Environment• Cost/Productivity• Training• Communication• Quality• Vendor Require

ments

Process FlowReceiving/StorageSupplied MaterialPreparationMelting ProcessForming processIntermediateProcessFabricationPackaging Warehouse

August 1, 1995

Project:Preparation Date:Validation Date:

Prepared by:

MEASUREMENT


OCPROGRAM

FFU Criteriaare given a relative importance rankingbased on supplying partnerfeedback.

Measurement systems are the meth

ods that asupplying partner

uses to

determine if criteria has been met

The Goal is thelevel of performance thatmust beachieved againstthe measure

ment system thatrepresents satisfactory perfor

mance.

~\

^*%

11


Partner Criteria

~V

>s

Stage 2


Supplying Partner Criteria

10


Facility: Project:Factory: Preparation Date:

Operation: Validation Date:

FFU—CRITERIA

Process:

RANK

i

MEaSURKMKNTSYSTEM

I

Prepared by:

GOAL ASSESSMENT

These columns are completed for eachcritical supplying partner (manufacturingsite) when determining or revising FFU

criteria in this stage.

/'"This column is updated when an assessment is made of how Owens-Corning isdoing versus the criteria. This step is performed during the assessment stage.

/This column is used to communicate Owens-Coming's action to fill a "gap" between

desired and actual performance. It is completed during the "evaluate options and

develop action stage."

OCPROGRAM

August 1, 1995

Scope


Partner Criteria

^V Stage 2


^\

This process step will allow us to understand and communicate a prioritized list of supplying partner needs and expectations.

Supplying Partner needs and expectations fall into the following areas:• Outputs

• Safety• Health•Training •Communication• Vendor Requirements • Quality

• Environmental• Cost/Productivity

• Process Flow• Receiving/Storage *• Supplied material preparations «• Melting Process «• Forming Processes «

Manufacturing is the principle supplying partner.

Accountability

Fabrication ProcessesPackagingWarehousingPackaging Warehouse

The Local Product Team, working with the appropriate manufacturing engineers at specific sites, is responsible for ensuring that the Supplying Partner (i.e. manufacturing) Criteria is obtained and that the Criteria Sheets are filled out and updated.

Deliverables

Winning is the publication of the Supplying Partner Criteria Documents.

August 1, 1995

/^%

LocalProductTeam

Scienceand

Technology


Partner Criteria

03

UnderstandingSupplyingPartnerCriteria

Stage 2

Determination of Customer

and SupplyingParmer Criteria

The Supplying PartnerFitness-For-Use Criteria Form isexplained later in this section.

Auaust 1, 1995

Map 02UnderstandingCustomer Criteria

Customer Criteria

V Stage 2



Customer: UC Product:

Customer Process: ^reparation Date:Customer Product: validation Date:

End Use: trepared by:

FFUCRITERIA

RANKMEASUREMENT

SYSTEMGOAL ASSESSENT

OC

PROGRAM

FFU Criteriaare grouped by• Product

• Service

• Logistics• Support

FFU Criteriaare expressed in thecustomer's languageand do not state whatthe "Product" is, butwhat it must "Do"

when used.

August 1, 1995

FFU Criteria aregiven a relativeimportanceranking basedon customer

feedback.

Measurement Systemsare the methods that acustomer uses to determine if criteria has

been met

The Goal is the levelof performance thatmust be achievedagainst the measurement system thatrepresents satisfactory performance.

/^%[

Map 02Understanding

Customer Criteria

Customer Criteria

>^ Stage 2

>>



Customer:

Customer Process:

Customer Product:

fcnd Use:

OC ProductPreparation Datevalidation Date

Prepared by

August 1, 1995

Scope

Map 02UnderstandingCustomer Criteria

^V Stage 2


This process step will allow us to understand and communicate a list of customer andsupplying partner needs and expectations that fall into these four areas:

• Product

• Logistics• Service• Support

These needs and expectations are prioritized by the customer.

This procedure is an on-going process:• Customer Criteria Sheets are updated when customer criteria changes• Customer Criteria Sheets are updated when "need met" or "action"changes

Accountability

The Local Product Team, working with the customer sales representative, is responsiblefor ensuring that the Customer Criteria is obtained and the Criteria Sheets are completedand updated.

Deliverables

August 1, 1995

Winning is publication of all Customer Specific CriteriaDocuments for the key customers that drive the GlobalFFU.

/*^k

Scienceand

Technology

Map 02Understanding

Customer Criteria

"V Stage 2


The CustomerFitness-For-Use Criteria form isexplained later in this section.

August 1, 1995

^

Scope

Map 01Identifying and Specifying

Customer Base

>^~ Stage 1

Identification and Specification of Critical Customerand Supplying Partner Base

>s

This map defines the procedure that establishes the Critical Customer Base and the Critical Supplying Partner Base List.

The Critical Customer Base List is defined as the key external customers that driveestablishment of Global Fitness For Use Criteria.

The Critical Supplying Partner Base List is defined as potential manufacturing sites(internal or external) where:

* a new product will be produced* an existing product design will be modified

The Critical Customer Base List is selected from the entire customer base by the globalproduct team at the direction of the Business Manager for the product area involved.

Those customers not on the Critical Customer Base List do not drive FFU.

Accountability

The Business Manager for the product line involved is responsible for ensuring that theCritical Customer Base List and the Critical Supplying Partner Base List have been communicated to the Local Product Team.

Deliverables

Winning for this procedure is the communication of the Critical CustomerBase List and the Critical SupplyingPartner Base List to the Local ProductTeam.

August 1, 1995

/^l

GlobalProductTeam

Manufacturing

Scienceand

Technology

Map 01Identifying and Specifying

Customer Base

^ Stage 1

Identification and Specification of Critical Customerand Supplying Partner Base

identifying &SpecifyingCustomerBase

J^

Inputs Process Outputs

CriticalCustomer Base

-Products

" Markets

" Accounts

" ManufacturingSites

Critical SupplyingPartner Base

1 Identify \/andSpecify \/ Customer \/ Base \

CriticalCustomerBase

CriticalSupplyingPartner

Base

August 1, 1995

Global Fitness For UseMaps

This section of the training guide deals with an overviewof the tactical process elementsthat comprise the Global FFU System. The overview training information used in conjunction with a specific process map in the procedures will enable a user to operate thesystem.

This symbol will be found throughout this trainingdocument. The symbol indicates that there is training information which goes into greater depth onthis topic other than the summary page. The additional information is found on the followingpage(s). If you do not have the need for furtherinformation, please advance to the next map.

Various topics in the manual are divided into sectionsor maps. This is the headeryou will find distinguishing

these maps.

A landscape version of the previously mentioned deployment chart can be found in theback of this manual. A fold-out of the deployment chart may also be found in the back ofthis manual for your use as you go through the manual. This is included to aid you inseeing what steps surround the process step that you are in.

August 1, 1995

Science

& Technology

Stage 1Identification andSpecification ofCritical Customer

and SupplyingPartner

01

Identifying &SpecifyingCustomerBase

August 1, 1995

Stage 2Determination ofCustomer and

Supplying PartnerCriteria

02

DeterminingCustomerCrileria

03DeterminingSupplying

Partner Criteria

IGlobal Fitness For UseDeployment Chart

Stage 3Assessment of Criteria

Stage 4Definition

06

CommunicatingNo ActionTo Customer

07

MotlifyingCustomer

Process

08

ModifyingInvent

ProductProcess

9-14.20

SpecifyingProduct/Process

Stage 5Implementation

15-19

CreatingOperatingProcedures

64

3

O

oo

^ ^

Stage 1 Stage 2 Stage 3 Stage 4 Stage 5

Critical Customer Updated Assessment andOC Pro Consolidated FFU Criteria Manufacturing Work InstrucCustomer Criteria gram Column on criteria sheets tions

Base List Sheets Work Team Charter

Maintenance Work Instruc

Supplying Supplying Product FFU Criteria tions

Partner Partner

Base List Criteria

Sheets

Product Model

Process Model

Product Profile

Specification Index andsupporting documentation

PAS

Machine Document

Logistics Work Instructions

Service Work Instructions

Support Work Instructions

Logistics Definitions

Service Definitions

Support Definitions

August 1, 1995 65

• Owens-CorningGlobal

Fitness For Use

Workbook

Name

Date

Instructor

Phone Number

k-

LQ_Ll_LJ_L_l_i..-..J..J...1L

f^OC NOTEBOOK

NAME: Steve SimsDATE:

f^* KEY LEARNINGS

THIS PAGE ALLOWS YOU TO LIST THE KEY LEARNINGS WHICH YOU HAVE GAINEDFROM THIS SECTION OF THE FFU OVERVIEW COURSE.

Section of the FFU Process:Establishing the Customer List

List the Key Learnings in your workbook for this Section:

Write down specific ideas on how this section applies to your job:(If this section is not your job responsibility, think of how the results, right or wrong, would affectyour job.)

D


Customer: RoofCore OC Produci:Customer Process: Preparation Date:Customer Product: Validation Date:End Use: Prepared by:

USE CRITERIA RANK MEASUREMENTSYSTEM GOAL ASSESSMENT OC PROGRAM


Customer: RoofCore OC Product:Customer Process: Preparation Date:Customer Product: Validation Date:End Use: Prepared by:


1


Customer: RoofCore OC Product:Customer Process: Preparation Date:Customer Product: Validation Date:End Use: Prepared by:


f~ KEY LEARNINGS

THIS PAGE ALLOWS YOU TO LIST THE KEY LEARNINGS WHICH YOU HAVEGAINED FROM THIS SECTION OF THE FFU OVERVIEW COURSE.

Section of the FFU Process: Understanding Customer Criteria


Write down specific ideas on how this section applies to your job:(If this section is not your job responsibility, think of how the results, right or wrong, wouldaffect your job.)

Facility:Factory:Operation:Process:

1

Anderson


Project:Preparation Date:Validation Date:Prepared by:


No Urethane size ingredients

Good running process Conversion Efficiency >95%

Low Labor Manhours/100 lbs. <1.00

Available raw materials Purchasing Department Only existingmaterials

Safe Lost Time Accidents/year <25

Fit For Use % Control of all Variables

CpK Index for all Characteristics

>95%

>1.33

/^

KEY T/EARNTNGS


Section of the FFU Process: Understanding Supplying Partner Criteria

list the Key Learnings in your workbook for this Section:


(O

~)Customer Fitness-For-Use Criteria

Customer:Customer Process:Customer Product:

RoofCoreWet Formed Mat Process

OC Product:Preparation Date:Validation Date:

685-M-l"4/18/954/28/95

End Use:

Shingle/Roofing MatRoofing Shingles and Roll Roofing Prepared by: Steve Sims

USE CRITERIAA. PRODUCT1.Good consistent mat compositestrength (1.8# mat)

2. Able to disperse fiber at 750 fpm linespeed

3. Need to use boxes to "meter" glassinto slurry

4. Need to insure that our productsmeet regulatory standards

B. LOGISTICS1. Effective logistics.

2Want "HighTech" communications

RANK

1-a

1-b

2.00

MEASUREMENTSYSTEM

ISO 828

ISO 828

Visual inspection by line operator ofa sample produced at 750 fpm

Box Weight

UL5

Inventory in receiving area

Percent of transactions that are electronic

GOAL

MD Tensile 100

lb. minimumCMD Tensile 50

lb. minimum

< 1.0% rejectedrolls because of

non-dispersedfiber

1000 # +/-.!#

100% pass

less than 2 daysupplymore than 1 daysupply.

>90%

1

ASSESSMENT OC PROGRAM


Customer: Little Rock OC Product: 685-M-l"

Customer Process: Wet Formed Mat Process Preparation Date: 4/18/95

Customer Product: Shinele/Roofing Mat Validation Date: 4/26/95

End Use: Roofing Shingles and Roll Roofing Prepared by: Steve Sims

USE CRITERIAA. PRODUCT1. Good consistent mat compositestrength at 600 fpm line speed (1.8 lbs.mat)

2. Obtain budget efficiency at budgetline speed

3. No contamination or strings in mat


2 Want "High Tech" communications

C. SUPPORT1. Need to minimize advertising budget

RANK MEASUREMENTSYSTEM

1-a ISO 828forMD tensile

1-b ISO 828for CMD tensile

1-c ISO 828

for Permeability

2 Daily production record of JobEfficiency

Visual inspection by line operator


Percent of transactions that are elec

tronic

Consumer Survey Reports

GOAL

115 lbs. minimum

55 lbs. minimum

755-855

>93%

< 1.5% roll rejectrale

less than 2 daysupply>90%

30% of sales generated by advertising other thannative. Sales are a

result of pull-thruby supplier.

ASSESSMENT OC PROGRAM


Customer:Customer Process:Customer Product:End Use:

PaperTechWet Formed Mat ProcessShingle/Roofing MatRoofing Shingles and Roll Roofing

OC Product:Preparation Date:Validation Date:Prepared by:

685-M-l"4/18/955/1/95Steve Sims


A. PRODUCT1.Consistent mat composite strengthat 800 fpm line speed (1.8 lbs. mat)

1-a

1-b

1-c

ISO 828

for MD tensileISO 828for CMD tensileISO 828forMD wet tensile

175 lbs. minimum

60 lbs. minimum

60 lbs. minimum

2. Good productivity 2 Count of wet breaks on shift production sheet adjusted to breaks per5000 rolls.

<100

3. High thruput is maintained 3 Average operating line speed 800 fpm

4. Good dispersion 4 Visual inspection of samples takenon each roll, at 800 FPM linespeed

No undisperscdbundles


2Want "High Tech" communications


Percent of transactions that are electronic

less than 2 daymore

than 1 day supply>90%

C. SUPPORT1. Need to minimize advertising budget Consumer Survey Reports 30% of sales gen-

crated by advertising other thannative. Sales are a

result of pull-thruby supplier.

0^^

INFORMATTON AVAILABLE FROM DATA COTXECTED AT ROOFCORE

•Mat tensile strength over the past 60 days at Roofcore ranges from a low of 115 lbs in themachine direction to a high of 130 lbs. Cross machine direction tensile ranged from 52 lbs as alow to 81 lbs. as a high. The line speed during this period was 750 fpm.

•Roll rejection rate is .82%

•No customer information is available on box weight. Plant data indicates box weights vary from996 lbs to 1002 lbs over the past 90 days based on OC obtained data.

•No complaints have been received from the customer on inventory issues.

•Harry, the purchasing agent at Roofcore, reports that the internet linkage is meeting his expectations regarding electronic transmitted data.

•No instances have been noted by Roofcore regarding UL5 failure during the past 6 months.

•OC Marketing's new advertising program for glass reinforced shingles has allowed Roofcore todiscontinue advertising in 3 periodicals, down from an original 9 magazines.

•Budget efficiency at Roofcore is 94% on the Beta equipment process.

12

J^N

INFORMATION AVAILABLE FROM DATA COLLECTED AT LITTLE ROCK

•Mat tensiles range from a low of 110lbs. to a high of 150 lbs. in themachine direction (MD)over the past 45 days and 58 to65 lbs. in the cross machine direction (CMD). DiscussionswithLittleRockpersonnel indicate the 110 lb. matwasproducedduringan ovenmalfunction.No other measurements of machine direction tensile were below 115 lbs. Line speed over theperiod is 650 fpm.

•Budget efficiency at Little Rock is at 90% on Alphaequipment.

•Roll reject rate at Little Rock is <1% during the last quarter.

•The customer is delighted with the new electronic information linkage.

•Reductions in advertising are planned based on a successful OC marketing program which isgenerating 40% of Little Rock sales.

• No complaints on inventory have been received.

INFORMATION AVAILABLE FROM DATA COLLECTED AT PAPERTECH

•Mat tensile is an average of 160 lbs (MD) and 60 lbs. dry cross machine direction over the past45 days. However, wet tensile averaged just 55 lbs.

•Wet breaks/ shift at Papertech are an average of 93 per 5000 rolls of mat produced over the pastmonth while operating at 800 fpm.

•The customer reports no rejects due to mat dispersion.

•No inventory, regulatory, or advertising issues are known to exist at this account.

•Budget efficiency of 95% was achieved using Beta equipment.*

* Note: Beta equipment uses "sigma" blades. Alpha equipment has no "sigma" blades.

13

KEY LEARNINGS


Section of the FFU Process:Assessing Capability of Meeting Needs


Write down specific ideas on how this section applies to your job:(If this section is not your job responsibility, think of how the results, right or wrong, would aftect yourjob.)

14

Customer Criteria

Customer: Product FFU Criteria OC Product: TBD - Product to be developedCustomer Process: Wet Formed Mat Process Preparation Date:Customer Product: Shingle/ Roofing Mat Validation Date:End Use: Roofing Shingles and Roll Roofing Prepared by:


A. PRODUCTConsistent mat tensile sir.

- machine direction

- cross mach. direction

- permeability

By ISO 828Roofcore

Little Rock

Papertech

Roofcore

Little Rock

Papertech

by ISO 853Roofcore

Little Rock

Papertech

^%

Customer Criteria

Customer: Product FFU Criteria OC Product: TBD - Product to be developedCustomer Process: Wet Formed Mat Process Preparation Date:Customer Product: Shingle/ Roofing Mat Validation Date:

End Use: Roofing Shingles and Roll Roofing Prepared by:


A. PRODUCTObtain budget efficiency atbudgeted line speed

Good dispersion at line speed

Roofcore

Little Rock

Papertech

Roofcore

Little Rock

Papertech

^^

f*

WORK TEAM CHARTER

Original Date 5/1/95Amended Date 5/15/95Chartering Team WUCSGPTProiect Title New Generation WUCS Product

TEAM GOAL Develop a new product for use in Wet Formed Mat Lines that achieves a "needs met" status for the attached consolidated customer and supplying partner criteria documents.

LEVEL OF

AUTHORITY

The TEAM is empowered to act without checking with the chartering team unlessresources are projected to exceed the resources allocated by 25% or Customer/SupplyingPartner Criteria will not be met.

No decision can result in the violation of a environmental or safety regulatory requirement.CONSTRAINTS The Team is restricted to the use of chemicals which meet the approved vendor list.

The 1995-2000 sales plan must be achieved utilizing existing melting capacity.

Capital for implementation is restricted to SIMM.EXPECTED

ACTIVITIES

1. There must be thorough understanding and validation of Customer/Supplying PartnerCriteria Sheets referenced by the charter.2. Outside resources should be employed in the design phase to ensure diverse thinking.3. Amilestone plan must be published and agreed to in the 1st design review. Themilestone plan should be updated and published quarterly.4. A design review will be held twice per year.

RESOURCES

AVAILABLE

Manpower 5 man-years of OC resources1 man-year of contracted resources20% of NA and Europe Product Engineers

Expenses S200M

Capital $50MEXPECTED

RESULTS

All elements of Charter satisfied.Product FFU Criteria and Supplying Partner(s) Criteria met as stated as of the finalDesign Review.Definition documents are complete: Product Model, Process Model and Product ProfileSheet

Specification Documents are complete.

Gross Margin at 1995 selling price [adjusted for inflation] will be 40%.NPV for proiect will be greater than or equal to S20MM.

17

CRITERIA EXERCISE

The purpose of this exercise is to reinforce the differences between the different types of information gathered when conducting Customer and Supplying Partner surveys.

Please select a code from the following list and identify each statement with the correct code.

CR CriteriaMS Measurement SystemGO GoalPC Critical Product CharacteristicPV Critical Process Variable

CODE STATEMENTOC Chopper Speed1/4 inch Fiber Chop Length500 PSIGood DispersablityISO 828 Machine Direction Tensile StrengthDaily Production Report for Job EfficiencyPre-Pad Spray Volume in OC ProcessSelling Price of Chop Fiber = $.20Just-in-Time DeliveryMatWet Tensile Strength -Customer ASTM Test T064685% Job Efficiency.5% Strand SolidsJohn's Opinion of Dispersability of Fibers in White WaterGlass Dielectric Constant of 6.61000 Pound Containers15 % Moisture in GlassNo Interference with Production RatesApplicator Speed of OC's Roll ApplicatorsBushing ThruputPermeability of Mat Testing Device PM8888

18

#**^

KEY LEARNINGS


Section of the FFU ProcessiDefinition Stage



19

WORK TEAM CHARTER

Original Date 5/1/95Amended Date 5/15/95Chartering Team String GPT/LPTProiect Title F.A.M.E.

TEAM GOAL Solve the "needs not met" issues associated with the attached customer and SupplyingPartner criteria sheets by developing a new product. The current product offering 999 isno longer fit for use.

LEVEL OF

AUTHORITY

The TEAM is empowered to act without checking with the chartering team unlessresources are projected to exceed the resources allocated by 20% or Customer/SupplyingPartner Criteria will not be met.

CONSTRAINTS The Team is restricted to the use of raw materials sold by Preferred Suppliers.The 1995-2000 sales plan must be achieved utilizing existing melting capacity.Capital for implementation is restricted to S500M

EXPECTED

ACTIVITIES

1. There must be thorough understanding and validation of Customer/SupplyingPartner Criteria Sheets referenced by the charter.2. Outside resources should be employed in the design phase to ensure diverse thinking.3. A milestone plan must be published and agreed to in the 1st design review. The milestone plan should be updated and published quarterly.4. A design review will be held twice per year.5. The FFU protocol will be followed

RESOURCES

AVAILABLE

Manpower 5 man-years of OC resources1 man-year of contracted resources20 % of NA and Europe Product Engineers

Expenses S300MCapital S50M

EXPECTED

RESULTS

A new product for commercialization.All elements of Charter satisfied.

Product FFU Criteria and Supplying Partner(s) Criteria met as stated as of the finalDesign Review.Definition documents are complete: Product Model, Process Model and Product ProfileSheet

Specification Documents are complete.No proliferation of the product line.

20

^

Product FFU Criteria

Customer: Product FFU for Stringstar Product Line OC Product:Customer Process: Filament Winding Preparation Date: 5/1/95Customer Product: Pipe Validation Date: 6/1/95End Use: Drain Field Prepared by: Kay Scenario

USE CRITERIA RANK MEASUREMENTSYSTEM GOAL ASSESS

MENT

OC PRO

GRAMA. Product1.) When we reinforce our proprietaryresin system we get real strong parts.

ISO 888 for Tensile

ISO 999 for Burst Strength

ISO 111 for Solvent Resistance

50M pounds at 50% glass content

100M PSI at 50%

glass content

80% Retention

Not Met

Not Met

Not Mel2.) Our production rate is significantlyhigher.

Line speed of APEX 100 equipmentwith a turbo option drive.

200 FPM Not Met

3.) Our environmental stewardship isimproved.

% of scrap recycled 85%

4.) Finished laminate cost is muchlower.

Laminate cost schedule. 20% reduction over 1994 Not Met

5.) Need to insure that our productsmeet regulatory standards

UL5 100% Pass Met

B. LOGISTICS1. Effective logistics. Inventory in receiving area less than 2 day supply

more than 1 day supply.Met

C. SUPPORT1. Need to minimize advertising budget Consumer Survey Reports 30% of sales generated by

advertising other than native.Sales are a result of pull-thru bysupplier.

Met

to

^


Facility: Anderson Project: AnyFactory: All Preparation Date: 5/1/95Operation: All Validation Date: 5/15/95Process: All Prepared by: Carl Osbirn


I. Systems and Sub-Systems MeetGeneral Operational NeedsA. Do Not Pat People At Risk1. Regulatory Requirementsa. Process free of chemicals or materi

als that creates undue health hazards to

employees.

OSHA 1910- Subpart Z In compliance with OSHAregulated chemicals, i.e.permissible exposure levels

Not Met

b. Process meets OSHA and Corporatemachine guarding specifications.

OSHA 1910-Subpart 0Corp Spec 05585

In compliance Met

c. Pre Start up inspection indicates thatprocess is safe

Plant Inspection AN-333 In Compliance Met

2. People Feedback to Process Owner Plant Nurse, Safety Leader, PlantManager

No complaints on impact toeye, ear complaints, stressstrain, or other ergonomicimpact.

Not Met

B. Do Not Put Environment at Risk1. Regulatory Requirementsa. Materials do not contain chemicals

which have the potential to generateVOC's greater than current permit rale.

ASTM 2639 VOC's within permit Not Met

b. Air quality is not put at risk Title V Permit Review indicates an in

compliance status.Met

c. Water quality is not affected •Water treatment toxicity test•Water treatment biological lest•Water treatment sludge test

•No neg. impact•No neg. impact•No neg. impact

Not Met

^Supplying Partner Criteria

Facility: Anderson Project: AnyFactory: All Preparation Date: 5/1/95Operation: All Validation Date: 5/15/95

Process: All Prepared by: Carl Osbirn

USE CRITERIA RANK MEASUREMENT SYSTEM GOAL ASSESSMENT OC PROGRAMC. Do Not Put Business at Risk Process is Dependable-

Conversion Efficiency (in-the-box)82% Met

Process is Predictable-

•Critical Product Characteristics

and Critical Process Variables

are in-control


and Critical Process Variables

are capable.

% in-conlrol >90%

CpK index > 1.00

Not Met

Not Met

II. System and Sub-Systems MeetSpecific Operational Requirements

Process Owner Need Met

A. Procurement

Good vendors utilized

% preferred vendors used100%

Met

B. Input Storage Process Owner Need Met Met

C. Preparation (mixing, batching) Process Owner Need Met Not Met

D. Converting (forming, fabrication) Process Owner Need Mel Not Met

E. Packaging Process Owner Need Met Met

F.Warehousing/Shipping Process Owner Need Met Met

G. Maintenance Process Owner Need Met Met

H. Environmental Process Owner Need Met Met

•Minimum materials wasted Application Efficiency >80% Not Met

I. Safety/Wellness Process Owner Need Met Met

Abbreviations for TermsAppearing on

Supplying Partner Criteria Sheet

TAPs- Toxic Air Pollutants

112(g) MACT -Maximum Achievable Control Technology

NOx - Nitrogen Oxides

PSD - Prevention ofSignificant Deterioration ofAir Quality

NAAQS - National AmbientAirQuality Standard

SOx-Sulfur Oxides

ASTM - American Standards for Testing Materials

VOC - Volatile Organic Compounds

LAER - Lowest Achievable Emission Rate

TSCA - Toxic Substance Control Act

SARA 313 - Superfund Amendment and Reauthorization Act

NSR - New Source Review (for glass melting furnaces)

CENT - Composites Environmental Network Team

DHEC -Department ofHealth and Environmental Control (South Carolina)

EAD - Environmental Affairs Department

RL - Regulatory Law

WWTP - Waste Water Treatment Plant

24

a^ Global Fitness For Use

^=s

^

Summary of Course

Review of Course Objectives

1. Know what steps exist in the FFU process and who is responsiblefor performing them.

2. Understand why proper execution of the FFU process is importantto OC Composites.

3. Know what outputs (documents) are generated during each processstep.

4. Become familiar with good practices in conducting design review.

5. Be aware of how the process satisfies customer needs.

6. Learn the specific tasks outlined for your job function on the following pages.

25

1.

Global Fitness For UseV

List 5 course expectations:

26


GOALS FOR FFU TRAINING FOR FIELD SALES REPRESENTATIVES

A: BASTC KNOWLEDGE IS EXPECTED TN THF FOLLOWING AREAS-

•THE PURPOSE OF FFU

•THE 5 BASIC STAGES OF THE PROCESS AND WHAT THEY INCLUDE.•WHICH JOB FUNCTIONS ARE RESPONSIBLE FOR EACH STEP IN THE PROCESS.•HOW THE PROCESS GENERATES THE CRITERIA FOR PRODUCT DEVELOPMENT.•THE COMMUNICATION OPTIONS WHICH EXIST IN THE PROCESS WITHREGARD TO CUSTOMER FEEDBACK.

•TECHNIQUES TO USE IN GATHERING AND ORGANIZING CUSTOMERNEEDS AND EXPECTATIONS FOR CRITICAL CUSTOMERS.

B. FIELD SALES REPS COMPLETING THE TRAINING SHOULD BE ABLETO PERFORM THE FOLLOWING TASKS:

•GATHER AND ORGANIZE NEEDS AND EXPECTATIONS FROM CRITICALCUSTOMERS AND GENERATE AN INDIVIDUAL CRITICAL CUSTOMERCRITERIA SHEET

•TRANSMIT INFORMATION TO CUSTOMERS REGARDING DECISIONSRESULTING FROM DESIGN REVIEWS.•KNOW HOW TO USE A PRODUCT PROFILE SHEET TO COMMUNICATE

PRODUCT INFORMATION TO CUSTOMERS.

•KNOW THE RESPONSIBILITIES OF SALES PERSONNEL IN THE FFU PROCESS.

27

/^^

#^


GOALS FOR FFU TRATNING FOR SALES REPRESENTATIVES ON LPT'S

A: BASTC KNOWLEDGE TS EXPECTED TN THE FOLLOWING AREAS:

•THE PURPOSE OF FFU

•THE 5 BASIC STAGES OF THE PROCESS ANDWHAT THEY INCLUDE.JOB FUNCTIONS ARE RESPONSIBLE FOR EACH STEP IN THE PROCESS.

•HOW THE PROCESS GENERATES THE CRITERIA FOR PRODUCT DEVELOPMENT.•THE COMMUNICATION OPTIONS WHICH EXIST IN THE PROCESS WITH REGARD TOCUSTOMER FEEDBACK.

•TECHNIQUES TO USE IN GATHERING AND ORGANIZING CUSTOMER NEEDS ANDEXPECTATIONS FOR CRITICAL CUSTOMERS.

•HOW DESIGN REVIEWS ARE USED TO GENERATE KEY DECISIONS IN THE FFUPROCESS.

B. SALES REPS ON LPT'S COMPLETING THE TRAINING SHOULD BE ABLE TOPERFORM THE FOLLOWING TASKS:

•GATHER AND ORGANIZE NEEDS AND EXPECTATIONS FROM CRITICAL CUSTOMERSAND GENERATE AN INDIVIDUAL CRITICAL CUSTOMER CRITERIA SHEET

•TRANSMIT INFORMATION TO CUSTOMERS REGARDING DECISIONS RESULTINGFROM DESIGN REVIEWS.

•KNOW HOW TO USE A PRODUCT PROFILE SHEET TO COMMUNICATE PRODUCTINFORMATION TO CUSTOMERS.

THE RESPONSIBILITIES OF SALES PERSONNEL IN THE FFU PROCESS.•BE ABLE TO FUNCTION AS A MEMBER OF LPT IN DECISION MAKING IN DESIGNREVIEWS.

28

#f*PN'

/0^*^

#"*S


FFU TRAINING GOATS FOR PRODUCT ENGINEERS

A: BASTC KNOWLEDGE TS EXPECTED TN THE FOLLOWING AREAS:

•THE PURPOSE OF FFU•THE 5 BASIC STAGES OF THE PROCESS AND WHAT THEY INCLUDE•WHICH JOB FUNCTIONS ARE RESPONSIBLE FOR EACH STEP IN THE PROCESS.•THE BASIC OUTPUT DOCUMENTS AND HOW THEY RELATE•HOW THE PROCESS GENERATES THE CRITERIA FOR PRODUCT DEVELOPMENT.•HOW THE PROCESS GENERATES ACTIONS WITHIN DESIGN REVIEWS•WAYS TO FACILITATE ACTIONS AND REMOVE ROADBLOCKS.•THEIR ROLE IN MAKING THE PROCESS OPERATE.

B. PRODUCT ENGINEERS COMPLETING THE TRAINING SHOULD BE ABLE TOPERFORM THE FOT J .OWTNG TASKS:

•ASSIST SALES IN GATHERING AND ORGANIZING NEEDS AND EXPECTTONS FROMCRITICAL CUSTOMERS TO GENERATE AN INDIVIDUAL CRITICAL CUSTOMERCRITERIA SHEET

•ASSIST MANUFACTURING IN OBTAINING THE INFORMATION NECESSARY TOCOMPLETE A SUPPLYING PARTNER CRITERIA SHEET.•ASSIST THE LPT IN GENERATING PRODUCT FFU CRITERIA SHEETS.•EVALUATE OPTIONS AND DEVELOP ACTION PLANS WHICH RESULT IN:

a. Projects to Modify Customer Operationsb. Projects to Develop New or Modified Productsc. Customer Communications which Describe Intent to Not Meet Expectations.

•BE ABLE TO LEAD A DESIGN REVIEW.•TRANSLATE CRITICAL CUSTOMER NEEDS AND EXPECTATIONS BY COMPLETING.PRODUCTMODEL DOCUMENTS. INCLUDING PROPER USE OF "SUPPORTINGDOCUMENTATION".•COMPLETE A PROCESS MODEL DOCUMENT. INCLUDING PROPER TRANSLATION OFCRITICAL PRODUCTCHARACTERISTICS (CPC's)INTO CRITICAL PROCESS VARIABLES(CPV's).

•COMPLETE THE 3 KEY SECTIONS OF A PRODUCTPROFILE SHEET•GENERATE A PRODUCTSPECIFICATION INDEX FOR EACH PRODUCT FORWHICHTHEY ARE RESPONSIBLE.

•BE ABLE TO USEMACHINE DOCUMENTS IN PROCESS DEFINITION

29


GOALS FOR FFU TRAINING FOR MANUFACTURING REPRESENTATIVES

A: BASTC KNOWTEDGE TS EXPECTED TN THE FOLLOWING AREAS:

•THE PURPOSE OF FFU•THE 5 BASIC STAGES OF THE PROCESS AND WHAT THEY INCLUDE.•WHICH JOB FUNCTIONS ARE RESPONSIBLE FOR EACH STEP IN THE PROCESS.•HOW THE PROCESS GENERATES THE CRITERIA FOR PRODUCT DEVELOPMENT.•THE COMMUNICATION OPTIONS WHICH EXIST IN THE PROCESS WITH REGARDTO CUSTOMER FEEDBACK.

•TECHNIQUES TO USE IN GATHERING AND ORGANIZING NEEDS AND EXPECTATIONSFOR SUPPLYING PARTNERS.

•HOW DESIGN REVIEWS ARE USED TO GENERATE KEY DECISIONS IN THE FFU

PROCESS.•HOW TO IDENTIFY GAPS BETWEEN SUPPLYING PARTNER NEEDS AND ACTUALPERFORMANCE.

B. MANUFACTURING REPS COMPLETING THE TRAINING SHOULD BE ABLE TOPERFORM THF FOT J .OWTNG TASKS:

•GATHER AND ORGANIZE NEEDS AND EXPECTATIONS FROM SUPPLYING PARTNERSAND GENERATE A SUPPLYING PARTNER CRITERIA SHEET

•COMMUNICATEWITH VARIOUS AREAS OF MANUFACTURING TO DEVELOP ANDCOMPLETE A GAP ANALYSIS BETWEEN THE SUPPLYING PARTNER CRITERIA SHEET

NEEDS AND EXPECTATIONS AND ACTUAL PERFORMANCE.•KNOW HOW TO DEFINE PRODUCTS IN TERMS OF PRODUCT/PROCESS MODELS.•BE ABLE TO TRANSLATE INFORMATION FROM PRODUCT SPECIFICATIONS ANDPROCESS MODELS INTO MANUFACTURING WORK INSTRUCTIONS.•KNOW HOW TO CONTRIBUTE TO SUCCESSFUL DESIGN REVIEWS.

30


GOALS FOR FFU TRATNTNG FOR PRODUCT/ PROCESS DEVELOPERS

A: BASTC KNOWTEDGE TS EXPECTED TN THE FOLLOWING AREAS:

•THE PURPOSE OF FFU•THE 5 BASIC STAGES OF THE PROCESS AND WHAT THEY INCLUDE.•WHICH JOB FUNCTIONS ARE RESPONSIBLE FOR EACH STEP IN THE PROCESS.•HOW THE PROCESS GENERATES THE CRITERIA FOR PRODUCT DEVELOPMENT.•UNDERSTAND HOW NEEDS ARE CONSOLIDATED INTO AN FFU PRODUCT CRITERIASHEET TO DEFINE THE GOALS FOR A NEW PRODUCT/ PROCESS•KNOW THE ELEMENTS REQUIRED IN A WORK TEAM CHARTER.•UNDERSTAND THE REQUIREMENTS FOR COMPLETING ALL THE ELEMENTS OFTHE PRODUCT DEFINITION STEP.•THE PURPOSE OF DESIGN REVIEWS

B. PRODUCT DEVELOPERS COMPLETING THE TRAINING SHOULD BE ABLE TOPERFORM THE FOT TOWTNG TASKS:

•HOW TO COMPLETE A PRODUCTMODEL.•HOW TO COMPLETE A PROCESS MODEL.•HOW TO GAIN AGREEMENT ON ATTAINABLE GOALS IN DESIGN REVIEWS.•HOW TO COMPLETE A PRODUCT SPECIFICATION.•HOW TO DEFINE THE ELEMENTS IN ADDITION TO THE PRODUCT SPECIFICATIONAND THE PROCESS MODELWHICH MANUFACTURING NEEDS TO OPERATE THEPRO CESS (PROCESS SPECIFICATION INDEX AND ASSOCIATED SPECIFICATIONS).

31

rOC NOTEBOOK

name: Steve SimsDATE: 07/15/95

T h e c O n V e r s a t i 0 n w i t hC I a u d e I i s t e d t h e

f O I I O w i n K c u s t 0 m e r s

a s b e i n /? c r i t i c a I t 0 F F U •

R O O f c O r e

L i t t I e R O c kP a P e r t e c

S u P P I y i n 8 P a r t n e r s :

A n d e r s O n

B i r k e I a n d

A- 1

"t


Customer: RoofCore OC Product: 685-M-l"Customer Process: Wet Formed Mat Process Preparation Date: 1/1/95Customer Product: Shingle/Roofing mat Validation Dale: 1/1/95End Use: Roofing Shingles and Roll Rooting Prepared by: Stephen Beli

USIi CRITERIA RANK MEASUREMENTSYSTEM GOAL ASSESSMENT OC PROGRAMGood Quality

Low Cost

On-Time Delivery

cost/pound $.10

>•

N3


Customer: RoofCore OC Product: 685-M-l"Customer Process: Wet Formed Mat Process Preparation Date: 3/1/95Customer Product: Shingle/Roofing mat Validation Date: 3/1/95End Use: Roofing Shingles and Roll Roofing Prepared by: Stephen Bell

USE CRITERIA RANK MEASUREMENTSYSTEM GOAL ASSESSMENT OC PROGRAMA. PRODUCTDisperses Well

Good tear Strength

No Contamination

Musi Meet regulatory requirements

B. LOGISTICSMinimum Inventory

Visual Inspection

Amount of material in the receivingarea.

>


Customer: RoofCore OC Product: 685-M-l"


Customer Product: Shingle/Roofing Mat Validation Dale: 4/28/95



A. PRODUCT1.Good consistent mat compositestrength (1.8# mat)

1-a

1-b

ISO 828

ISO 828

MD Tensile 100

lb. minimumCMD Tensile 50

lb. minimum

2. Able to disperse fiber at 750 fpmline speed

2.00 Visual inspection by line operatorof a sample produced at 750 fpm

< 1.0% rejectedrolls because of

non-dispersedfiber


Box Weight 1000 U +/-MI

4. Need to insure that our productsmeet regulatory standards

UL 5 rating 100% Pass

K. LOGISTICS1. Effective logistics. Inventory in receiving area Less than 2 day

supplyMore than 1daysupply

2 Want "High Tech" communications Percent of transactions that are

electronic

>90%

>I


Facility:Factory:Operation:'rocess:

Anderson

All

AllAll

Project:Preparation Date:Validation Date:Prepared by:

Any5/1/955/15/95Carl Osbirn

USE CRITERIA RANK MEASUREMENTSYSTEM GOAL ASSESSMENT OC PROGRAMI.SystemsandSiih-SystemsMeetGen-eral Operational NeedsA. Do Not Put People At Risk1. Regulatory Requirementsa. Process free of chemicals or materialsthat create undue health hazards to

employees

OSHA I91U- Subpart Z In compliance withOSHAregulatedchemi-cals, i.e. permissibleexposure levels

b. Process meets OSHA and Corporatemachine guarding specifications.

OSHA 1910-Subpart OCorp Spec 05585

In compliance

c. Pre Start up inspection indicates thatprocess is safe

Plant Inspection AN-333 In compliance

2. People Feedback to Process Owner Plant Nurse, Safety Leader, PlantManager

No complaints onimpact to eye, earnose, throat or skin.No complaints onstress strain or other

ergonomic impactJi. Do Not Put Environment at Risk1. Regulatory Requirementsa. Materials do not contain chemicals

which have the potential to generateVOC's greater than current permit rate

AS I'M 2639 VOL s within permit

b. Air quality is not put at risk Title V Permit Review indicates an in

compliance status



Anderson

AllAllAll

to jccl:Preparation Date:Validation Dale:Prepared by:

Any5/1/955/15/95Carl Osbirn

c. Water quality is not affected •Water treatment toxicity test•Water treatment biological lest•Water treatment sludge test

•No neg. impact

•No neg. impact•No neg. impact

2.Community"feedbaek"toprocessowner Reports to Environmental Leader on•odor

•water taste

•crop damage

•none

•none

•none

C. Do not Put Property at RiskProcess free of chemicals or materialsthat create a fire or explosion hazard

OSHA 1910-Subpart H In-Compliance

D. Do Not Put Business at Risk Process is Dependable-Conversion Efficiency (in-lhe-box)

82%

Process is Prcdictable-

•Critical Product Characteristicsand Critical Process Vari ables are

in-control


and Critical Process Variables are

capable

% in-control >90%

CpK index > 1.00

E. Customer Needs are Met Customer Criteria Sheets (FFU) All Needs Met

F.Definition of systemis adequate tocreate work instructions for operators

FFU Protocol Complete

>I

en


Anderson

AllAllAll


Project: AnyPreparation Date:Validation Date:

5/1/955/15/95

Prepared by: Carl Osbirn


11. System and Suh-Systems MeetSpecific Operational Requirements

Process Owner (Need Met

A. Procurement

•Good vendors utilized % preferred vendors used 100%

B.Input Storage Process Owner Need Met

C. Preparation (mixing, batching) Process Owner Need MetD. Converting (lorming, tabncation) Process Owner Need Met

E. Packaging Process Owner Need Met

F. Warehousing/Shipping Process Owner Need Met

G. Maintenance Process Owner Need Met

H. Environmental Process Owner Need Mel

•Minimum materials wasted Application Efficiency >80%

l.SaletyAVellness Process Owner Need Met

>I

-4



RoofCoreWet Formed Mat ProcessShingle/Rooting MatRoofing Shingles and Roll Roofing

OC Product:Preparation Dale:Validation Date:Prepared by:

685-M-l"4/18/954/28/95

Steve Sims


A. PRODUCT1. Good consistent mat compositestrength (1.8# mat)

1-a

1-b

ISO 828

ISO 828

MD Tensile 100

lb. minimumCMD Tensile 50lb. minimum

yes

yes

2. Able to disperse fiber at 750 fpm linespeed

2.00 Visual inspection by line operatorofa sample produced at 750 fpm

< 1.0% rejectedrolls because ofnon-dispersalfiber

yes


Box Weight 1000 ft +/-.1 tt no No plans at this time tochange packaging tolerances.

4. Need to insure that our products UL5 100% pass yes

meet regulatorystandards

B. LOGISTICS1. Effective logistics. Inventory in receiving area less than 2 day

supplymore than 1 daysupply.

Need More Data Seek more data on

inventory levels in daysupply

2Want"High Tech" communicalions Percent of transactions that arc elec

tronic

>90% Need More Data Seek more data on %


Customer: Little Rock OC Product: 685-M-l"


Customer Product: Shingle/Roofing Mat Validation Date: 4/26/95


USE CRITERIA RANK MEASUREMENTSYSTEM GOAL ASSESS

MENT

OC PROGRAM

A. PRODUCT1. Good consistent mat compositestrength at 600 fpm line speed (1.8 lbs.mat)

2. Obtain budget efficiency at budgetline speed

3. No contamination or strings in mat

l-a

1-b

1-c

2.00

3.00

ISO 828

forMD tensile

ISo 828

for CMD tensileISO 828

for Permeability

Daily production record of Job Efficiency

Visual inspection by line operator

115 lbs. minimum

55 lbs. minimum

755-855

>93%

< 1.5% roll rejectrale

yes

yes

Need More

Data

no

-line is at

90%

yes

Seek data on test results

Provide lechnieal support to cus-tonier to improve performance oftheir operation.(Help install signia blades in mixlank.)

R. LOGISTICS1. Effective logistics.

2 Want "High Tech" communications


Percent of transactions that are elec

tronic

less than 2 daysupply

>90%

Need more

data

Need more

data

Seek more data on inventorylevels in day supply

Seek more data on %

C. SUPPORT1. Need to minimize advertising budget Consumer Survey Reports 30% of sales gener

ated by advertisingother than native.

Sales are a result of

pull-thru by supplier.

yes

>

CD



PaperTechWet Formed Mat ProcessShingle/Roofing MatRoofing Shingles and Roll Roofing

OC Product:Preparation Date:Validation Date:Prepared by:

685-M-l"4/18/955/1/95Steve Sims

USE CRITERIA RANK | MEASUREMENT SYSTEM GOAL ASSESSMENT OC PROGRAM

A. PRODUCT1. Consistent mat composite strengthat 800 fpm line speed (1.8 lbs. mat)

1-a

1-b

ISO 828for MD tensile

ISO 828

175 lbs. minimum

60 lbs. minimum

no

yes

"Besl-in-Class" si/.e

development for newproduct *

1-c

for CMD tensileISO 828for MD wet tensile

60 lbs. minimum no *

2. Good productivity 2.00 Count of web breaks on shift production sheet adjusted to breaks per5000 rolls.

< 100 yes

3. High thrupul is maintained 3.00 Average operating line speed 800 fpm yes

4. Ciood dispersion 4.00 Visual inspection of samples takenon each roll, at 800 FPM linespeed

No undispersedbundles

yes

IJ. LOGISTICS1. Effective logistics. Inventory in receiving area less than 2 day

more

Need more data Seek more data on inventory levels in day supply

2 Want "High Tech" communications Percent of transactions that are elec

tronic

than 1 day supply>90% Need more data Seek more data on %

C. SUPPORT1. Need to minimize advertising budget Consumer Survey Reports 30% of sales gen

erated by advertising other thannative. Sales are aresult of pull-thruby supplier.

Need more data Seek more data

>

o


Customer: Product FFU Criteria OC Product: TBD - Product to be developed


Customer Product:End Use:

Shiimle/Roofing MatRoofing Shingles and Roll Roofing

Validation Date:Prepared by:

4/26/95Stephen Heli


A. PRODUCT

1. Need to insure that our product 1 UL 5 Rating 100% Pass

meets regulatory standards.2. Consistent mat composilestrength at800 fpm line speed (1.8 lbs. mat)produced onLittle Rocktypemachine

1-a

1-b

ISO 828forMD tensile

ISO 828 for CMD tensile

175 lbs. minimum

60 lbs. minimum

3. Obtain budget efficiency at budget

1-c

1-d

2.00

ISO 828 for MD wet tensileISO 828 for Permeability- Daily production record of Job

60 lbs. minimum755-855>93%

line speed (800FPM) on a LittleRockType machine

4. Obtain a homogeneous mat on a Little Rock type machine at 800 FPM

3.00

Efficiency- Web Breaks per Shift (adjusted tobreaks per 5,000 rolls)Visual inspection by line operator forundispersed fiber

<100

<1.5% roll rejectrate

B. LOGISTICS1. Effective logistics. Inventory in receiving area less than 2 day

supplymore than 1 day

2 Want "High Tech" communications Percent of transactions that are electronic

supply>90%

C. SUPPORT1. Need to minimize advertising budget Consumer Survey Reports 30% of sales gen

erated by advertising other thannative. Sales are aresult of pull-thruby supplier.

WORK TEAM CHARTER

Original Date 5/1/95Amended Date 5/15/95Chartering Team WUCS GPTProject Title New Generation WUCS Product

TEAM GOAL

LEVEL OF

AUTHORITY

CONSTRAINTS

EXPECTEDACTIVITIES

RESURCES

AVAILABLE

EXPECTED

RESULTS

Develop anewproduct for use inWet FormedMatLines that achieves a "needsmet" status forthe attached consolidated customer and supplying partner criteria documents.The TEAM is empowered to act without checking with the chartering teamunless resources are projected to exceed the resources allocated by 25% or Customer/Supplying Partner Criteria will not be met.

No decision can result in the violation of a environmental or safety regulatory requirement.

The Team is restricted to the use of chemicals which meet the approved vendor list.the environmental and safety requirements of the supplying partners.

The 1995-2000 sales plan must be achieved utilizing existing melting capacity.

Capital for implementation is restricted to SIMM1.There must be thorough understanding and validation of Customer/SupplyingPartner Criteria Sheets referenced by the charter.2. 200 lbs tensile on sheet former trials must be achieved.3. Outside resources should be employed in the design phase to ensure diverse thinking.4. Amilestoneplanmust bepublished and agreed to in the 1stdesignreview.Themilestone plan should be updated andpublished quarterly.5. A design review will be held twice per year.Manpower 5 man-years of OC resources

1 man-year of contracted resources20 %of NA and Europe Product Engineers

Expenses S200MCapital S50MAll elements of Charter satisfied.Product FFU Criteria and Supplying Partner(s) Criteria met as stated as of the finalDesign Review.Definitiondocumentsare complete: Product Model, ProcessModel and Product ProfileSheetSpecification Documents are complete.GrossMargin at 1995selling price [adjusted for inflation] will be 40%.Manufacturing costs of new product to be no higher than current product.NPV for project will be greater than or equal to S20MM .

A-12

CRITERIA EXERCISE

The purpose of this exercise is toreinforce the differences between the different types ofinformation gathered when conductingCustomer and Supplying Partner surveys.

Please select a code from the following list and identify each statement with the correct code.

CR Criteria

MS Measurement SystemGO GoalPC Critical Product CharacteristicPV Critical Frocess Variable

CODEPVPCGO or MSCRMS"

MSPVPCCRMSGOPCMSPCPCPCCRPVPVMS

STATEMENTOC Chopper Speed1/4 inch Fiber Chop Length500 PSIGood DispersablityISO 828 Machine Direction Tensile StrengthDaily Production Report for Job EfficiencyPre-Pad Spray Volume in OC ProcessSelling Price of Chop Fiber = $.20Just-in-Time DeliveryMat Wet Tensile Strength -Customer ASTM Test 064685% Job Efficiency.5% Strand SolidsJohn's opinion ot DispersaDiiity ot HDers in wmte wateTGlass Dielectric Constant of 6.61000 Pound ContainersID °/c Moisture in Ulass

No Interference with Production RatesApplicator Speed of PC's Roll ApplicatorsBushing ThruputPermeability of Mat Testing Device PM8888

A-13

>

PRODUCT MODEL

PRODUCT PRODUCT

FFU DOCUMFNT

CUSTOMER(S) DATE PREPARED BY DOCUMENT #

999.00 ANI00-A

CUSTOMER FFU CRITERIA

I

PRODUCTCHARACTERISTIC MDIcn-

sile

CMIEbn-

sile

MDWet

Tensile

Perm %LineEfficiency

Web Breaks UndispensedFiber

TEST METHOD

% Strand Solids A-3 A-3 A-3 A-3 A-2 OC-W-05-FB% Moisture A-2 OC-W-05-FB

Filament Diameter A-1 A-l A-l OC-D-02CAmount ol Long Chop A-2 A-2 OC-L-OUContamination A-2 OC-CM-01

Fiber Length A-l A-l A-i OC-Sk-12

Surface Chemistry A-4 A-4 A-4 A-4 A-4 A-4 A-4 OC-GCH-WX

Mimic Sheet

Former

Sheet

Former

Sheet

Former

Sheet

Former

Customer

Machine

Customer

Machine

SheetFormer

>

Product Model Data Index

PRODUCT PRODUCT

FFU DOCUMENT

CUSTOMER(S) DATE PREPARED BY DOCUMENT#

999.00 S. Smith AN 100-A

Reference SummaryA-l Graph of mat tensile vs. fiber diameter and fiber length.

Data collected in March 1995 in Anderson, South Carolina as part of Tesl Request And-1255

A-2 Paper written by Charles Wilier and presented as part of the Product Training School.This paper summarizes the industry experience of this consultant and discusses industry process experience.

A-3 Graph and data analysis of mat tensile vs. strand solids and feed rale and cureData collected in February of 1995 in Anderson, South Carolina as part of Test request And-1240

A-4 Memo Report number A-4000 issues May 10, 199.4) by Steve Alexis999 WUCS Surface Size Chcmistiy Ratios Vs. Mechanical Properties of Wet Formed Non-Woven Matsand Veil

I

>

-A

I

PROCESS MODEL

PRODUCT PRODUCT

FFU DOCUMENT

CUSTOMER(S) DATE PREPARED

BY

DOCUMENT#

AN100-B

CRITICAL PRODUCT CHARACTERISTICS

PROCESS VARIABLE MACIl

INE%

StrandSolids

%

Mois

ture

Fila

ment

Diame

ter

LongChop

Con

tami

nation

Fiber

LengthSurface

ChemistryTEST METHOD

Bushing Thrupul B-l B-l OC-B-09Pre-Pad Pressure B-2 B-l OC-P-03Applicator Speed B-2 B-2 B-l B-l OC-A-06Size Temperature B-2 OC-T-031Size Mix Solids B-I OC-S-97Chopper Speed B-l B-l OC-C-37Cot/Cutter Pressure C-l OC-H-94Col/Cutler Alignment C-l OC-AL-39Position Alignment C-l OC-AL-30Concentrate Solids D-l OC-CS-01Preact Valve #2 Timing D-l OC-MX-01Preact Valve #1 Timing D-l OC-MX-01

PRODUCT

999.00

ReferenceB-l

B-2

C-l

D-l

PRODUCT

FFU DOCUMENT

Summary

Process Model Data Index

CUSTOMER(S) DATE PREPARED

BYS. Smith

DOCUMENT*

AN 100-A

WUCS DOE run on 4/18/91A 6 variable experiment with 4 responsesThe variables were: Applicator Speed, Prepad Spray Pressure, Bushing Thruput, Tray temperature, Chopper Speed andBinder Flow.The responses were: Fiber Diameter, Wet Moisture, Strand Solids and Chop Length.WUCS DOE run on 5/3/93A 5 variable experiment with 2 responsesThe variables were: Graphite Shoe Position, Binder Temperature, Applicator Speed, Prepad Spray pressure and Binderfray Flow. The responses were: Solids and Moisture.Letter from Steve Sims to James Mills establishing the relationships between "long chop" and a) Cot/Cutter pressureb) Position of S Alignments c) Col/ Cutter Alignments .An engineering assessment study. ANDENG-1230[The study ascertained the critical variables in size mixing affecting the variance from spccilication.


Product Family: 999.00 Product/Process Model: AN100

Prepared By: S. Smith Document Number: ANPPS100Date: 5/15/95

A. Products Available Nominal Fiber Length 3/4. T. 1 1/4"

Nominal Strand Solids .10%. .20%

Nominal Strand Moisture .18%

Packaging 3.000 lbs. Bulk Carton

B. Expected Product Characteristic Tolerance Test Method

Characteristics

Fiber Diameter +/- 1.1 Micron OC-D-02C

Chop Length +/- 1/8 " OC-SR-12

% Strand Solids +/- .06% OC-W-05-FB

% Strand Moisture +/- 4% OC-W-05-FB

Surface Chemistry Between Curves OC-GCH-WX

C. Expected End-UsePerformance

For Optimum Performance•Use an anionic polyaciylamide type viscositymodifier.•Low amounts of dispersants should be considered.•Whitewater Ph range of 6.0 - 8.0.

999 Attributes

•Increased tensile strength of wet-formed non-woven mats and veils.•Reduced "Fiber Cling" to the wet former wire.•Improved uniformity of fiber dispersion.

A- 18

PRODUCT SPECIFICATION

Number: 999

Characteristics Test Method

Calibration

Method Nominal Tolerance

% Strand Solids OC-W-05-FB CAL-X05 .35% LSL=.20%USL=.50%

% Moisture OC-W-05-FB CAL-X05 15.5% LSL=10%USL=21%

Filament Diameter OC-D-02C CAL-X02C 18 micron (microns)LSL=15USL=21

Amount of Long Chop OC-L01J CAL-X01J 50 grams (grams)LSL=N/AUSL=200

Contamination OC-CM-01 CAL-X01 5 grams (grams)LSL=N/AUSL=10

Fiber Length OC-SR-12 CAL-XSR12 1 inch (inches)LSL=7/8USL=1 1/8

Surface Chemistry OC-GCH-WX CAL-WX93 curve D234 LSL=curve

D210

USL=curve

D285

A-19

Global Fitness-For-Use Training EvaluationName: (Optional)

Date:

Instructor:

Scale: 1 - 5(Strongly Disagree -- Strongly Agree)

General:

1. This Global Fitness-For-Use training workshop has addressed most 12 3 4 5ofmyNEEDS and has better equipped me to use the FFUtools.

2. I was comfortable with the tasksin the workshop andwas able to 12 3 4 5complete the exercises and activities with relative ease.

3. I will use this training to improve myworkperformance. 12 3 4 5

Content/Methods:

1. The Global FFUvideowas a useful learning tool. 12 3 4 5

2. Completing the Global FFU forms was a valuable exercise. 12 3 4 5

3. Theglobal FFU Deployment Chart is a valuable tool thatclearly 12 3 4 5defines responsibility andhelps me understand the total process.

4. Theworkbook was wellprepared and valuable inmy learning. 12 3 4 5

5. The "keylearnings'section helped me capture new ideasand 12 3 4 5enhanced my learning.

Instructor/ Facilitator:

1. The instructor clearly communicated the objectives of the course. 12 3 4 5

2. The instructor was well prepared. 12 3 4 5

3. The instructor heldmy interest. 12 3 4 5

FFU Evaluation Page # 1

4' ^ej^:t°r1comP,eteIy ^ ftorougUy covered the Global FFU 12 3 4 5course material.

5. The instructor thoroughly summarized the training and clearly 1 2 1 4 «communicated how it is linked to Owens Coming's corporate'goalsand strategies.

Comments:

1. My most valuable experience during the day and ahalfsession was:

2. My least valuable experience during the session was:

FFU Evaluation Page # 2

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