Production Readiness

Supplier / Part Information

Date
Supplier Name
Supplier Mfg. Code
Part Name
Part Number / Drawing Number
Prior Capacity Verification Date

Volume Increase Possible : (details on open capacity)

General Capacity Information

How many shifts are planned for initial R@R 1
How many days per week 5 Days typical, OT as needed
How many shifts are planned to reach fully quoted capacity 15 shifts per week
How many days per week at full capacity 5
Does supplier have enough capacity to meet production plan Yes
at Launch? Yes
6 months after launch
12 months after launch
Future expansion opportunities?

Does supplier have expansion capabilities?

How quickly could you add

25% additional volume
50% additional volume
100% additiona volume
How many days of IFA stock are you planning to have on hand at any given time
please add detail: Minimum of 1 week

ZF F-Division - Capacity Verification ONE Operation Page 1 of 3

 Production Readiness
Are Conditions Met? Yes No
Place an "X" in Box
PPAP Requirements
Did you perform your machine capability studies and do the results provide evidence that the process will be in
control (meets the dimensional requirements outlined by the print / QV) X

PPAP requirements have been agreed with customer DATE completed: X

Tier 2 Readiness
Have you ensured that your subtier suppliers are prepared for production?
Are subcomponent PPAP's, PV information and R@R information available and confirmed? X

Production Representation
Is the product being manufactured at the production site in the production environment? (I.e. using the production
tooling, gaging, process, materials, operators, environment, and performed at the required production speed) X

Does the actual process flow agree with the process flow diagram? Ensure it represents the entire process from
receiving through shipping. X

Quality Systems
Is all in-process documentation, such as SPC and work instructions in place? X
Has the process been 'fail-safed' by operation to prevent defective product from moving to the next operation?
X

Is Non Conforming product controlled so it can not move to the next operation/ rework procedures? X
Does the actual process conform with the process control plan? X
Are permanent production operators trained to perform the production operation, part checks and statistical
monitoring as outlined on the process control plan? X

Are customer approved accept / reject master samples available? X

Is the incoming / outgoing material qualification / certification plan in place and sufficient? X
Are preventative maintenance plans (with planned downtime) in place? X
Are repair and maintenance parts available or readily obtainable so as not to present a risk to production (e.g. key
equipment spare parts)? X

Are all production checking fixtures complete, with acceptable measurement system studies (i.e. gage R&R)
performed? X

Have any PV tests been performed and if so did they meet the requirements? n/a
Are all processes conforming to the production control plan specifications? X

Full Speed Production Readiness

Has a packaging trial (with customer plant approval) been completed / Is series packaging available X
Do the parts produced meet print and special Specifications and do individual cavities have acceptable
dimensional capability? X

Is the production acceleration plan sufficient to meet requirements? X

If any of the above questions are answered "No"
then indicate "Not Ready for Capacity Verification," Ready for Capacity Verification Not Ready for Capacity Verification
otherwise indicate "Ready for Capacity
Verification."
x

ZF F-Division - Capacity Verification ONE Operation Page 2 of 3

Run-at-Rate Verification
Annual Capacity Planning
(1) Part Number (2) Part Description/Program 4 Run@Rate Date 28-Jan-2024
Volume (pcs/year)
400-2001-497-008 ABC 2ITR01-4 566,000 5 Supplier Name ABC Company
6 Supplier Address 123 Anywhere Street
7 City/State/ZIP Code Warren. Ohio 44481
8 Supplier Country USA
(3) TOTAL CPV (pcs/year) 566000 9 Supplier Code 19-Jul-4032

Process Step EXAMPLE Operation 1 Operation 2 Operation 3 Operation 4 Operation 5

Process Description Automated Feeder CNC Machining OP10 CNC Machining OP20 Washer & Rp Application Automated Pack
Number of Operators
0 0.5 0.5 0 0
Equipment size
Feedall B-2500 Feeder Fuji FS4 CNC Fuji FS4 CNC Ransohoff System Ultra-Tech System
Units
12 Working hours / shift (8 hours is standard) hours 8.00 8.00 8.00 8.00 8.00
I - Supplier Working Standards

12a Lunch&Meals / shift hours 0.00 0.00 0.00 0.00 0.00

12b Scheduled Preventive Maintenance / shift hours 0.17 0.17 0.17 0.17 0.17

12c Tooling Change Over / shift hours 0.00 0.75 0.75 0.00 0.00

13 Shifts / day (3 shifts is standard) shifts 3.00 3.00 3.00 3.00 3.00

14 Days / week (5 days is standard) days 5.00 5.00 5.00 5.00 5.00

15 Weeks / year (48 weeks is standard) weeks 48.00 48.00 48.00 48.00 48.00

16 Number of lines, presses, etc. units 1.00 1.00 1.00 1.00 1.00

17 Total hours/year ((12-12a-12b-12c)*13*14*15*16) hours 5637.60 5097.60 5097.60 5637.60 5637.60

18 % of line for XYZ Customer parts (Allocation %) % 100% 100% 100% 100% 100%
19 Quoted Production Rate pcs/hour 225.0 155.0 140.0 275.0 140.0
II - Supplier Quoted Capacity Data

19a Cycle time (for informational purposes only) seconds 8.0 23.0 14.0 12.0 11.0

19b Cavities (for informational purposes only) # per tool 1.0 1.0 1.0 1.0 1.0

20 Quoted % scrap % 0.0% 0.3% 0.3% 0.0% 0.0%

21 Quoted process efficiency % 92.00% 92.00% 92.00% 92.00% 92.00%
22 Adjusted production rate (19*(1-20)*21) pcs/hour 207 142 128 253 129
23 Available capacity ((19*21*(1-20)*17*18)) pcs/year 1,166,983 725,100 654,929 1,426,313 726,123
24 Utilization % (3/23) % 49% 78% 86% 40% 78%
25 Quoted Status (28) % Acceptable Acceptable Caution Acceptable Acceptable
26 Bottleneck operation X X

27 Trial run duration (8hrs is default) hours 8.00 8.00 8.00 8.00 8.00
28 Total parts produced pcs 955 955 955 955 955
III - RUN at RATE Results

29 Number of bad parts pcs 2 1 1 3 1

30 First time capability % ((28 - 29)/28) % 99.79% 99.90% 99.90% 99.68% 99.90%
31 Number of good parts (28-29) pcs 953 954 954 952 954
32 Net output (31/27) pcs/ hour 119 119 119 119 119
33 Takt Time Rate (Target) (3/(17*18)) pcs/ hour 100.40 111.03 111.03 100.40 100.40
34 Downtime hours

35 Reason text

Comments

Supplier representative name printed Supplier representative signature Date