Production Readiness / Run@Rate Checklist for Purchased Parts

Supplier: ? Supplier no.: ? Run@Rate Date: ?

M+H plant: ?
Project: ? M+H Part Name: ? M+H Part Number: ?

Reason for Process Release / New product Date/index of M+H drawing: ?

Run@Rate: Product change
Process change
Relocation of product / process
Quality Issues

Max. annual need: ? pc. Working weeks / year: ? Defined amount of parts for the R@R: ? pc.
+20% #VALUE! pc. Start in week: ? Duration: ? hours
Max. weekly need: #VALUE! pc.
+20% #VALUE! pc.

Dept. Name Phone: Email:

Project Resp. Supplier: ? ? ? ?
Quality Resp. M+H: ? ? ? ?
Purchasing Resp. M+H: ? ? ? ?

1. Introduction
1.1 Target:
Evaluation and approval of the manufacturing processes for on-time deliveries of quality-conforming parts in peak production quantities.

1.2 Preparation:
The template Production Readiness / Run@Rate for Purchased Parts is given to the supplier in advance. The supplier shall do a self-assessment as a preparation for the
Run@Rate done together with MANN+HUMMEL.

1.3 Evaluation:
GREEN: Targets or deadlines achieved. No indication of deviations from what was seen during the Process Release / Run@Rate.

YELLOW: Targets or deadlines partly not met. Additional actions (see action plan) and follow-up are required.

RED: Critical targets or deadlines not achieved. Additional actions urgently required. SOP at risk. No serial delivery approval. Approval for limited quantity only
(written concession from M+H required). Run@Rate must be repeated.
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MHG-PU-F-0014
 Critical targets or deadlines not achieved. Additional actions urgently required. SOP at risk. No serial delivery approval. Approval for limited quantity only
(written concession from M+H required). Run@Rate must be repeated.

2. Preliminary check Documentation

GREEN YELLOW RED Comments
2.1 Approved drawing(s) with latest change level (index) (customer and production drawings) and current
BOM (bill of materials) available? offen offen offen

2.2 All documents listed in the drawing(s) and PRFPP (standards, etc.) available with latest level and
implemented/considered in own documents? offen offen offen

2.3 If supplier is design responsible: Updated Design FMEA available, measures implemented and
effectiveness confimed (new evaluation done), Special Characteristics according to PRFPP? Experience offen offen offen
from previous projects / Leassons learned considered?
2,4 If supplier is design responsible: Design FMEA used to develop Process FMEA (RPN, corrective actions,
etc.)? offen offen offen

2.5 Updated Process FMEA available (RPN acceptable, measures implemented, effectiveness confirmed by
new evaluation, special characteristics accord. PRFPP, team members,date,etc.)? offen offen offen

2.6 Updated Process flow chart and Control Plan available (incl. receiving, rework, scrap, inspection,
shipping, labeling, finished goods, shipping areas and plant layout) and linked to PFMEA? offen offen offen

2.7 Product related instructions (e.g. inspection, set-up, working, packaging instruction) available, at work
station and based on Control Plan? offen offen offen

2.8 Procedure available to authorize the Start of Production (e.g. process parameters incl. tolerances
recorded and under control, traceability of first OK parts, flow of OK and nOK parts, etc. ("First-off" offen offen offen
procedure))?
2.9 Are samples sizes and check frequency for each operation reasonable and min. according the PRFPP
(comparison of quality data/failures found and sample sizes and frequency)? offen offen offen

2.10 Rework instructions completed and agreed with M+H, marking of part defined?
offen offen offen

2.11 Maintenance plan and instructions available (assembly lines, tools etc.)?
offen offen offen

2.12 Capability of test and control equipment confirmed (according VDA Volume 5 or MSA) and R&R < 10%?
offen offen offen

2.13 Machine capability (Cmk) and preliminary capability (Ppk) study for special characteristics accomplished
with Cmk/Ppk ≥1,67 (≥2,0 if specified)? offen offen offen

2.14 Process capability study for special characteristics installed? => at the latest 3 months after SOP proven.
offen offen offen

2.15 Complete initial sample report according to VDA Volume 2 or PPAP with supporting documents
(product/process) available, all items from PRFPP (if applicable) adressed? offen offen offen

2.16 Evidence of qualification and training for employees for all shifts (qualification matrix, training plan,
training evidence) incl. Personel Employment Plan available? offen offen offen

2.17 For D-part (parts where documentation is mandatory): work stations and documents identified
accordingly and necessary documentation available? offen offen offen

2.18 Bottleneck process identified?

offen offen offen
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MHG-PU-F-0014
 Bottleneck process identified?
offen offen offen

2.19 If Component Cleanliness Management (CCM) requirements are applicable: all documents
(requirements, instructions for cleaning, measurement, documentation, etc.) available? offen offen offen

2.20 IT-safety and electricity safety (back-up system, data safe, fire wall installed, video survaillance, etc.)
offen offen offen

2.21 Is there a preparation / systematic for Requalification, Product and Process Audit for running serial
offen offen offen
production available?
2.22 Procedure available for customer shipping?
offen offen offen

2.23 Data for tooling / equipment / gauges send to M+H (applicable only for tools/equipment/gauges payed
by M+H)? offen offen offen

2.24 Are changes to the product or process in the course of serial production tracked and documented?
offen offen offen

3. Preliminary check Pre-requisites for prove of serial readiness

GREEN YELLOW RED Comments
3.1 Machines arranged according to production layout?
offen offen offen

3.2 Manufacturing under serial conditions (e.g. with machines, tools, process flow, operators, etc.)?
offen offen offen

3.3 Serial testing facilities and serial inspection equipment available, used and calibrated / calibration
planned? offen offen offen

3.4 Trained operators available for all shifts (certificates, qualification matrix, asking of operatores, etc.)?
offen offen

3.5 Traceability assured to an acceptable level (e.g. lot control)?

offen offen offen

3.6 Dispach container labeling according to M+H requirements?

offen offen offen

offen offen offen

4. Preliminary check Sub-Suppliers

GREEN YELLOW RED Comments
4.1 Procedure for incoming inspection incl. testing procedure and inspection equipment for purchased parts
defined (at sub-suppliers, incoming inspection, etc.) and equipment calibrated? offen offen offen

4.2 Special characteristics for purchased parts defined and proof of capability available ?
offen offen offen

4.3 Complete Initial Sample Inspection Reports (ISIR/EMPB/PPAP/PPA) available and approved for all
purchased parts ? offen offen offen

4.4 Sufficient sub-supplier capacity confirmed for all purchased components and materials ? Sub-suppliers
informed about the current ramp-up plan ? offen offen offen

Production Readiness / Run@Rate Checklist for Purchased Parts

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 Sufficient sub-supplier capacity confirmed for all purchased components and materials ? Sub-suppliers
informed about the current ramp-up plan ? offen offen offen

4.5 Process Release/Run@Rates performed at sub-suppliers for important parts/processes, where

specified? offen offen offen

4.6 Appropriate packaging agreed with sub-suppliers for all parts?

offen offen offen

4.7 Purchase orders with specific requirements (orders with latest index, etc.) available?
offen offen offen

4.8 Are only approved/released and quality-capable suppliers selected (release process appropriate)?
offen offen offen

4.9 Procedure for identification, traceability, FIFO (e.g. expiration dates rubber compound) of material
batches/products available and do labels of products refer to the supplier production order? offen offen offen

4.10 Are only approved/released and quality-capable suppliers selected (release process appropriate)?

5. Execution Production
GREEN YELLOW RED Comments
5.1 Manufacturing according to production plan and process flow-chart?
offen offen offen

5.2 Machines / equipment set-up according to set-up instructions (e.g. process paramters) and also
documented? offen offen offen

5.3 Inspections done according to control plan and control instructions (for incoming materials and also
production process), also after set-up processes or tool changes and are adequate aids available offen offen offen
(pictures/parts OK/nOK, working place appropriate, etc.)?
5.4 Boundery samples / Master Parts available to operatores and in use?
offen offen offen

5.5 Master Parts available for error proving devices (e.g. Poka-Yoke, leakage testing)?
offen offen offen

5.6 Maintenance according to maintenance plan / schedule (including preventive maintenance) for tools and
equipment and are suficient spare parts available? offen offen offen

5.7 Tools and gauges properly identified (incl. identification tag "Property of M+H", if the case)?
offen offen offen

5.8 Special product and process requirements controlled by inspection charts, process control charts, etc.
and data properly recorded? offen offen offen

5.9 Where SPC is requried: are data properly recorded, out of control points noted with corrective actions
taken and manufacturing processes demonstrating required capability or performance? offen offen offen

5.10 Pre-series capability for special characteristics (Ppk ≥1,67 (≥2,0 if specified)) confirmed with parts from
internal performance test? offen offen offen

5.11 Root cause analysis systematic implemented to define corrective actions for n.O.K. parts (e.g. FIST-
PASS-Yield, 8D-method)? offen offen offen

5.12 Ergonomic, safety and environmental requirements fulfilled?

offen offen offen
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 Ergonomic, safety and environmental requirements fulfilled?
offen offen offen

5.13 General housekeeping and cleanliness - specially in case of Component Cleanliness Mgmt. (CCM) requirements:
- at workplace / test location?
- in manufacturing / surroundings? offen offen offen
- packaging and packaging area?

5.14 Deterioration of quality incl. mixing of products prevented by:

- sufficient and appropriate in-house packaging?
- internal transport and storage?
offen offen offen
- packaging (according to packaging instruction)?
- storage (parts, tools, devices)?
5.15 n.O.K. and rework parts handling incl. setting parts:
- rejection/separation according process plan, instruction for rework?
- clear marking, separation ensured?
offen offen offen
- re-inspection after rework process (evidence)?

5.16 Warehousing: FIFO, logistic rules in shipping warehouse / identification before delivery to the customer
available? offen offen offen

5.17 Procedure for identification of quality status during production (e.g. AWAITING DECISION, ACCEPTED,
REJECTED, REWORKED) available? offen offen offen

5.18 Safety concept: fire prevention, quality emergency plan, work environment safety, dangerous
substances? offen offen offen

offen offen offen

6. Execution Qualitative Evaluation

Comments
6.1 Amount of parts manufactured during the Run@Rate ? pc.

6.2 Amount of n.O.K. parts ###

- n.O.K. - visual check not according to drawing / border ? pc. ### %

samples
- n.O.K. - dimensional / material not according to drawing ? pc. ### %

- n.O.K. - function not according to drawing / process ? pc. ### %

verifification plan

6.3 Actual scrap ### pc. ### % GREEN YELLOW RED

offen offen offen

Production Readiness / Run@Rate Checklist for Purchased Parts
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 offen offen offen
6.4 Estimated scrap ### pc. ? %
(estimated by supplier)
6.5 Amount of rework parts ? ### %

6.6 First Time Quality (FTQ) ### pc. ### %

(Amount of O.K. parts without rework)

7. Execution Quantitative Evaluation (for Bottleneck process)

Data from original Capacity Planning (from PRFPP) Production capacity found during R@R
Bottleneck Process: ? Current shift model (as planned in serial production):
? x ? = #VALUE!
Peak production: #VALUE! pc./week expected to start in week: ? shifts / week hours / shift min. / week
( +20% #VALUE! ) Data for actual performance calculation:
Planned shift model: Produced good parts: ? pc.
? x ? = #VALUE! Produced scrap: ? pc.
shifts / week hours / shift min. / week Production time without down times: ? min.
Down times: ? min.

Set-up time: ? min. Lot size: ? pc. Set-up time, actual: ? min. Lot size: ? pc.
(e.g. process stop/tool removal/setup/process start up - last good parts until first good parts)

Production time, calculated: ? sec./ pc. Production time, actual: #VALUE! sec./ pc.
(amount of cavities to be considered) (amount of cavities to be considered)

Set-up rate: #VALUE! sec./ pc. Set-up rate, actual: #VALUE! sec./ pc.

Total time per piece: #VALUE! sec./ pc. Total time per piece: #VALUE! sec./ pc.

Scrap rate: ? % Scrap rate, actual: #VALUE! %

Equipment availability: ? % Equipment availability, actual: ? %

(e.g. 100% if machine only

Reserved Capacity for MANN+HUMMEL: ? % used for M+H. 100% is max.) Reserved Capacity for ? %
MANN+HUMMEL:
# of same machines used in parallel: ? (> 1 only if more than 1 machine will be
operating at the same time)

Estimated quantities Calculated quantities (based on Run@Rate result)

#VALUE! max. pc./shift calculated #VALUE! max. pc./shift estipolated
? # of working days per week #VALUE! pc./shift calculated at reserved capacity #VALUE! pc / shift at reserved capacity

Production Readiness / Run@Rate Checklist for Purchased Parts

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 #VALUE! pc. / day calculated at reserved capacity #VALUE! pc. / day at reserved capacity
? # of working days per year #VALUE! pc. / week calculated at reserved capacity #VALUE! pc. / week at reserved capacity
#VALUE! pc. / year calculated at reserved capacity #VALUE! pc. / year at reserved capacity
Remarks:
The amount of parts to be produced during the Run@Rate is specified by the MANN+HUMMEL Project Team depending on actual shift model, recruitment situation, quantity needed for
ramp-up, etc. If peak production level cannot be met with the current shift model, measures must be defined by the supplier (e.g. increase of capacity with timing, reduction of scrap or
rework rate, reduction of product cycle time, etc).

8. Result of Process Release / Run@Rate

Done on: ? Responsible MANN+HUMMEL: ? Department: ?

offen GREEN, successful => Approval for Serial Production (if ISIR/PPAP/PPA was also released !)

offen YELLOW, measures required => Approval of Serial Release after verification of the measures by MANN+HUMMEL

offen RED, without success => Evidence of Mass Production Readiness not given, measures and repetition of Process Release / Run@Rate required

Repetition of Process Release / Run@Rate planned for: ?

Comments

Production Readiness / Run@Rate Checklist for Purchased Parts

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Signatures:

Supplier Quality Responsible MANN+HUMMEL Purchasing Responsible MANN+HUMMEL

Production Readiness / Run@Rate Checklist for Purchased Parts

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MHG-PU-F-0014
Supplier ?

Project: ? Distribution list

M+H Part Number:
Open Issue List (OIL)
?

M+H Part Name: ?

Issue Date ?
Review date ?

Approved
Activities
by M+H
No. Decription of problem Root cause
Action Responsible Date Status Date Yes/No

10

11

12

13

14

15

Production Readiness / Run@Rate Checklist for Purchased Parts Rev.: 12/2013 Page 9 of 10
Template: MHG-SP-F-0017
 Pictures of Tools, Machines and Equipment
Supplier: ? Supplier no.: ? Run@Rate Date: ?

M+H plant: ?
Project: ? M+H Part Name: ? M+H Part Number: ?

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Production Readiness / Run@Rate Checklist for Purchased Parts Rev.: 12/2013

Template: MHG-SP-F-0017