GP-9 Training

Definition

定义

The definition of Run @rate is Physical verification that the production process is capable of producing quality products at the daily contracted capacity rate.

Run @ Rate 是对生产过程是否能以“每天合同生产能力”生产出合格产品的现场实际验证。

Note :It is expected that the daily contracted capacity is equal to or greater than the daily LCR/MCR.

注:前提为每天合同供货能力应等于或大于LCR/MCR。

PURPOSE / 目的

---To verify that a supplier’s actual manufacturing process, while operating under normal operating conditions, and under total customer requ irement, is:在正常生产操作条件下,满足顾客的所有要求,供应商的实际生产能力达到下述要求:

(A) Capable of producing quality components/ systems/ modules

生产PPAP质量要求的零件/系统/模块

(B) Capable of meeting or exceeding the “daily contracted capacity,on a sustained

产能持续达到或超过“每天的合同能力”

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PURPOSE(CON’)

目的(续)

Additionally, other elements of systems readiness may be reviewed and noted to ensure that potential start of production problems are identified and addressed

另外,系统中的其他准备因素都得到评审和记录,以保证生产开始时的潜在问题被识别和记录。

Lean Capacity Rate(LCR) 正常生产能力

Maximum Capacity Rate(MCR)最大生产能力

LCR is a daily rate that represents the straight time level of c apacity required to support vehicle assembly operations on a daily basis.

正常生产能力是指满足总装厂每天在正常工作时间内运转所需的生产能力MCR is the Planned maximum daily requirements for vehicle assemb ly plants that could be required.

最大生产能力是指总装厂计划的、可能要求的最大日产量

Generally speaking, MCR is 12 -20% greater than the LCR

通常,MCR=(1.12--1.20)* LCR

All suppliers shall meet SMCV LCR requirement with one pr oduction day 供应商只能用一天的生产安排来满足SMCV LCR 要求(或者说供应商必须用5天的生产安排满足客户5天LCR的要求); 或者用一周的生产安排来满足客户5

天MCR的要求。

SCOPE / 使用范围

Unless exempted by the SQE and approved by the Supplier Quality and Purchasing Directors of the Procuring Division,the procedure applies to all manufacturing and assembly processes contracted to SAICMOTOR Commercial Vehicle to:

除非供应商质量工程师认为可以免除并且得到采购部门供应商质量和采购负责人的批准, 此过程用于SMCV所有制造和装配过程的分供方:

Produce new components/systems or modules 生产新零件/系统或模块Increase existing capacity on previously contracted volume

在原合同产能上增加能力

Tool and equipment moving 工装、设备异地

Changes to existing processes where it is deemed that the capaci ty

and or capacity of the system have been altered

现存过程的改变影响产能

TYPE OF RUN@ RATE

RUN@RATE 类型

●Two type of Run@Rate 两种类型

----Customer Monitored 顾客监督

----Supplier Monitored 供应商监督

●SQE notify the supplier of the type as early in APQP Process as

possible

SQE 应在APQP的早期通知供应商RUN@RATE的类型

DURATION OF RUN @ RATE

GP-9验证期限

The duration of the Run @ Rate will be sufficient to verify that the process can meet the contracted capacity while producing the Total Customer Requirement.

GP-9验证期限必须能足以说明制造过程能力达到合同规定的顾客需求

The default length : the daily contracted hours. For example, if 3 shifts are scheduled for production, 3 shifts should run to complete GP-9

一般要求供应商运行合同答应的每天安排生产时间.例如,如供应商计划用三班生产来满足SMCV要求,GP-9则必须运行三班.

DURATION OF RUN @ RATE(CON’)

GP-9验证期限(续)

SQE have the right to deviate from the default duration aft er taking into consideration the following factors:

根据下列情况,SQE可以进行必要更改:

?Product Complexity 产品复杂度

?Shelf Life 产品库存期

?Storage & Packaging 存储和包装形式

?Cost 成本

?Production Day Length 生产时间长短

TIMING OF RUN @ RATE

GP-9的时间

To perform RUN@ RATE when 什么时候运行GP-9

----after an an interim or fully PPAP approval and

PPAP 临时或正式批准后

----no later than eight weeks prior to start of regular production, or notice from SMCV.

SMCV SORP 加速前8周进行,或根据SMCV的通知

To consider this following factors:

具体时间应由SQE和供应商提前共同确定,可考虑下列因素:----design/process stability 设计/过程稳定性

----subassembly complexity 分零件复杂程度

The exact date should be predetermined by the procuring division and the supplier

具体时间应由采购部门SQE和供应商决定。

SUPPLIER PREPARATION FOR A CUSTOMER

MONITORED RUN @ RATE

供应商准备“顾客监督”型RUN@RATE

Supplier should conduct a practice Run @ Rate and/or production simulations, as well as complete as much of the Run @ Rate Worksheet Attachment(Attachment A),

供应商应模拟运行一次,并完成GP-9附表(附表A)

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SUPPLIER PREPARATION FOR A CUSTOMER

MONITORED RUN @ RATE (con’)

供应商准备“顾客监督”型RUN@RATE(续)

Requests for changes to the Run@Rate schedule must be submitted to the authorized Customer Representative (SQE) at lea st two weeks prior to the Run@Rate

如Run @ Rate 日期发生改变,供应商应在二周前通知SQE

REQUIRED PARTICIPATION AND COVERAGE

形式选择

Customer Monitored 顾客监控–

----The lead SMCV representative typically will be the Supplier Qua lity Engineer, with participation of the Buyer and/or Release Enginee r upon request.

SMCV代表通常是SQE , 可邀请采购员/或产品工程师

----SQE should be present for the entire Run @ Rate

SQE 应在生产现场监督整个GP-9过程,不得缺少任一过程。

----However, where it is clearly evident that the systems capacity is well above the contracted requirement, the authorized Customer Repres entative (SQE) may accept the results of a portion of the Run@Rate withou t being present.

----除非生产线的某个生产环节远大于合同能力,SQE可以不在现场但可接受这部分的GP-9 运行结果

REQUIRED PARTICIPATION(con’)

形式选择(续)

Supplier Monitored –

供应商监控-

----The lead supplier representative(Project manager) or their desig nate must be present during the entire Run@Rate.

供应商代表(项目负责人)或其指定代表必须现场监督GP-9的运行

----The Run@Rate is performed as detailed in this GP-9 procedure.

供应商代表负责按此GP-9程序完成GP-9

----To complete the Run @Rate Summary sheet within 24 hours of com pleting the formal Run@Rate and all attachments , and Submit them to SQE

GP-9运行后24个小时内完成GP-9 总结报告及其附表,并向SQE 提交

Note: If the supplier monitored Run @ Rate results in a fail, an other Run @ Rate must be scheduled with a customer representative present

注:如果供应商监督的GP-9失败,再次运行必须由顾客监督.

REQUIRED PARTICIPATION(con’)

形式选择(续)

Whether the type “Customer Monitored “or the type “supplier Monitored is chosen, Equipment suppliers and /or subcontractors may be asked to participate in Run@Rate running.

如需要,可邀请设备供应商和/或分供方参加GP-9 运行审核

SUBCONTACTOR REQUIREMENT

分供方要求

Supplier are required to ensure the reliability of their supplie rs.

一级供应商对其分供方负责

Written confirmation of daily contracted requirements ,as well a s , actual systems performance for quality, capacity and delivery must be p rovided to SQE prior to the Run@Rate.

在GP-9运行前,供应商以书面形式向SMCV SQE提交分供方的每日合同能力、分供方的实际质量表现、产能及发运包装要求

As for sub-module or critical parts, , The Run@Rate of sub-supplier is suggested to performed as detailed in this GP-9 procedure.

建议按此GP-9程序完成分总成或关键分零件的GP-9.

INVENTORY

库存

If parts are produced ahead of production schedules, the supplie r will hold all parts produced until authorized to ship. The suppl ier will ensure that sufficient production containers and packaging are available to prevent part damage.

一般GP-9在SMCV正式生产前进行,在被授权发运前,供应商应保证生产的产品进行合适地包装和储存,以防零件损坏。

The results of a Run@ Rate

Run@ Rate 结论

Upon completion of the Run @ Rate and a formal review of the completed worksheets, and all attachments. The Run @ Rate can have one of five results:pass; staged; customer fail; pending PPAP or fail.

GP-9必须完成工作表评审及其附件,同时评判GP-9的运行结论。有五种结论:通过、分阶段通过、顾客原因失败、因PPAP待定、失败。

The results of a Run@ Rate (Run@ Rate 结论) A) Pass 通过

----All requirements were met.

所有的GP-9要求均达到

----Quality net output is greater than contracted capacity/MCR

生产能力符合SMCV质量要求和报价能力。

?meet Cpk/Ppk requirements CPK/Ppk满足要求

?GP-12 requirements were met 满足GP-12要求

?Actual manufacturing process agreed with the

manufacturing and quality plan 实际生产过程和所计划的一致

?Quality systems were documented and practiced.

?质量体系文件化并运行有效

?Subcontractors abilities to meet the capacity and quality

requirements have been confirmed in writing by the supplier

and all parts produced 分供方达到产能和质量要求。

The results of a Run@ Rate (con’)

Run@ Rate 结论(续)

B) Staged 分阶段通过

The supplier is meeting the approved Plan for the gradual

introduction of tooling, machinery, and/or shifts required to

meet the full contracted capacity.

分阶段通过表示供应商符合已批准的阶段性计划:阶段性增加工装、机器和/或班次达到报价能力。

The results of a Run@ Rate (con’)

Run@ Rate 结论(续)

C) CUSTOMER FAIL 顾客原因失败

Supplier passed all Run @ Rate requirements based on the contracted capacity or agreed to staged implementation plan, how ever, customer requirements (MCR) or Customer acceleration plan excee d contracted capacity.

供应商GP-9符合报价能力,但顾客要求(MCR)或顾客加速计划超过了供应商报价能力。

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