ALLOCATION WORKSHEET

Time (Enter as
# of Working hours/shift
Factor fraction of an Total 8.90
Occurrences (8 hrs max. is standard)
hour)
Shifts/ day
Shift Length (hrs)10 1.00 10.00 1.00
10 (Standard is 3)
Days/ week
Short Breaks (hrs) 1 0.50 0.30 5.00
(Standard is 5)
Weeks/ year
Meal Break (hrs) 1 0.50 0.30 48.00
(Standard is 48)

Down Time per Shift (hrs) 0.50 Number of Lines 2.00

WORKING HOURS PER SHIFT 8.90 Available hours per year 4272.00

Available Hours per month 356.00

A B C D E F G H I
Formula A B C D 3600/D A/E + B*C F*12 G/Total of G Total Part Number
Reqmnts G/ Total
TRW Reqmnts G
Part Number Monthly Number of Setup Adjusted Production Total monthly Total Allocation as Allocation as a % of
Volume Setups per time/run Cycle Time Rate in pcs/hr working hrs Annual a % of TRW Total Hours
month (hrs) (seconds) required working hrs Hours Available
required
TRW Part Numbers

Date: 24 Jan 2008 766046210.xls; Allocation % Worksheet Process Owner / Department:

Rev: E R. Spariosu / Supplier Development
Doc No: D_020_4_12 Approved by:
Page 1 of 9 R. Blanchette / Global Director, SDE
ALLOCATION WORKSHEET
Time (Enter as
# of Working hours/shift
Factor fraction of an Total 8.90
Occurrences (8 hrs max. is standard)
hour)
Shifts/ day
Shift Length (hrs)10 1.00 10.00 1.00
10 (Standard is 3)
Days/ week
Short Breaks (hrs) 1 0.50 0.30 5.00
(Standard is 5)
Weeks/ year
Meal Break (hrs) 1 0.50 0.30 48.00
(Standard is 48)

Down Time per Shift (hrs) 0.50 Number of Lines 2.00

WORKING HOURS PER SHIFT 8.90 Available hours per year 4272.00

Available Hours per month 356.00

A B C D E F G H I
Formula A B C D 3600/D A/E + B*C F*12 G/Total of G Total Part Number
Reqmnts G/ Total
TRW Reqmnts G
Part Number Monthly Number of Setup Adjusted Production Total monthly Total Allocation as Allocation as a % of
TRW Part Numbers

Volume Setups per time/run Cycle Time Rate in pcs/hr working hrs Annual a % of TRW Total Hours
month (hrs) (seconds) required working hrs Hours Available
required

0 0 0.00 0.00 0 0.00 0.00 0.00% 0.00%

TOTAL

Date: 24 Jan 2008 766046210.xls; Allocation % Worksheet Process Owner / Department:

Rev: E R. Spariosu / Supplier Development
Doc No: D_020_4_12 Approved by:
Page 2 of 9 R. Blanchette / Global Director, SDE
ALLOCATION WORKSHEET
Time (Enter as
# of Working hours/shift
Factor fraction of an Total 8.90
Occurrences (8 hrs max. is standard)
hour)
Shifts/ day
Shift Length (hrs)10 1.00 10.00 1.00
10 (Standard is 3)
Days/ week
Short Breaks (hrs) 1 0.50 0.30 5.00
(Standard is 5)
Weeks/ year
Meal Break (hrs) 1 0.50 0.30 48.00
(Standard is 48)

Down Time per Shift (hrs) 0.50 Number of Lines 2.00

WORKING HOURS PER SHIFT 8.90 Available hours per year 4272.00

Available Hours per month 356.00

A B C D E F G H I
Formula A B C D 3600/D A/E + B*C F*12 G/Total of G Total Part Number
Reqmnts G/ Total
TRW Reqmnts G
Part Number Monthly Number of Setup Adjusted Production Total monthly Total Allocation as Allocation as a % of
Volume Setups per time/run Cycle Time Rate in pcs/hr working hrs Annual a % of TRW Total Hours
month (hrs) (seconds) required working hrs Hours Available
required

TRW Total 0 0 0.00 0.00 0 0.00 0.00 0.00%

Customers
Other

Customer A

Customer B

TOTAL 0 0 0.00 0.00 0 0.00 0.00 0.00%

Overall Utilization 0.00%

Available Time (hours/yr) 4272.00

Date: 24 Jan 2008 766046210.xls; Allocation % Worksheet Process Owner / Department:

Rev: E R. Spariosu / Supplier Development
Doc No: D_020_4_12 Approved by:
Page 3 of 9 R. Blanchette / Global Director, SDE
 Run-at-Rate Verification
(1) Part Number (2) Part Description/Program TRW Annual Capacity Planning 4
Run@Rate Date
Volume (pcs/year)
5 Supplier Name
6 Supplier Address
7 City/State/Postal Code
8 Supplier Country
(3) TOTAL CPV (pcs/year) 0 9 Supplier Vendor Code

10 Process Step STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6

11 Process Description
48 Number of Operators
49 Equipment size
Units
12 Working hours/shift (8 hours is requirement) hours
I - Supplier

Shifts/ day (3 shifts is requirement) shifts

Standards

13
Working

14 Days/ week (5 days is requirement) days

15 Weeks/ year (48 weeks is requirement) weeks
16 Number of lines, presses, etc. units
17 Total hours/year (12*13*14*15*16) hours
18 % of line for TRW parts (Allocation %) %
II - Supplier Quoted

19 Quoted Production Rate pcs/hour

Capacity Data

20 Quoted % scrap %
21 Quoted process efficiency %
22 Adjusted production rate (19*(1-20)*21) pcs/hour
23 Available capacity ((19*21*(1-20)*17*18)) pcs/year
24 Utilization % (3/23) %
25 Quoted Status (28) % Unacceptable Unacceptable Unacceptable Unacceptable Unacceptable Unacceptable
26 Bottleneck operation X
27 Trial run duration (8hrs is default) hours
28 Total parts produced pcs
29 Number of bad parts pcs
30 First time capability % ((28 - 29)/28) %
31 Number of good parts (28-29) pcs
32 Net output (31/27) pcs/ hour
III - RUN at RATE Results

33 Takt Time Rate (Target) (3/(17*18)) pcs/ hour

34 Downtime hours

35 Reason text

36 Availability ((27-34)/27) %
37 Quality (31/28) %
38 Perfomance ((28/27)/19) %
39 Overall OEE (36*37*38) %
40 Run-Off utilization % % 0.00% 0.00% 0.00% 0.00% 0.00% 0.00%
50 Utilization as % of Allocation (40/18) % 0.00% 0.00% 0.00% 0.00% 0.00% 0.00%
41 Bottleneck operation X X X X X X X
42 Net Output-Weeks (32*12*13*14) pcs/week #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE!
43 Net Output-Months ((32*12*13*14*15)/12) pcs/month #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE!
SHADED CELLS ARE CALCULATED 45 44
44 Run at Rate Conducted by: Overall Process TRW Reviewer
Status
Utilization % Name:
Product Line:
0.00% Acceptable
Location:
Comments

46

47
Supplier representative name printed Supplier representative signature Date
Date: 24 Jan 2008 766046210.xls; Run at Rate Form Process Owner / Department:
Rev: E R. Spariosu / Supplier Development
Doc No: D_020_4_12 Approved By:
Page 4 of 9 R. Blanchette / Global Director, SDE
 Run at Rate Exception Form
DATE OF REQUEST: RUN AT RATE DATE:

ORIGINATOR: NUMBER OF LINES:

SUPPLIER: ANNUAL CPV:

SUPPLIER CODE: STANDARD CALCUATION: [3 Shifts; 8 hours; 5 Days (120 hour maximum rate)]

SDE: CALCULATION: Shifts Hours Days

COMMODITY MANAGER: UTILIZATION PERCENTAGE:

PART NUMBER: SUPPLIER PLANNED SCHEDULE:

PROGRAM: CALCULATION: Shifts Hours Days

PART NAME: UTILIZATION PERCENTAGE:

RUN AT RATE CONDUCTED BY: RED/YELLOW/GREEN STATUS:

SDE REASON FOR THIS EXCEPTION:

COMMODITY MANAGER EXPLAIN COST IMPLICATION:

APPROVED: YES NO

PRODUCT LINE PROGRAM MANAGER SIGNATURE: DATE:

PRODUCT LINE PURCHASING SENIOR MANAGER SIGNATURE: DATE:

PRODUCT LINE PURCHASING DIRECTOR APPROVAL SIGNATURE: DATE:

APPROVAL COMMENTS:

Date: 24 Jan 2008 766046210.xls; Exception Form Process Owner / Department:

Rev: E R. Spariosu / Supplier Development
Doc No: D_020_4_12 Approved By:
Page 5 of 9 R. Blanchette / Global Director, SDE
ALLOCATION WORKSHEET
Time (Enter as 7.50
# of Working hours/shift
Factor fraction of an Total
Occurrences (8 hrs max. is standard)
hour)
Shifts/ day 3.00
Shift Length (hrs) 8.00
(Standard is 3)
Days/ week 5.00
Short Breaks (hrs) 0.25 2 0.50
(Standard is 5)
Weeks/ year 48.00
Meal Break (hrs) 0.00
(Standard is 48)
5400.00
Down Time per Shift (hrs) Available hours per year

450.00
WORKING HOURS PER SHIFT 7.50 Available Hours per month

A B C D E F G H I
Formula A B C D 3600/D A/E + B*C F*12 G/Total of G (Total Reqmnts H -
Total Reqmnts I)/
Total Reqmnts H
Monthly Number of Setup Adjusted Production Total monthly Total Required Maximum Addition
Volume Setups per time/run Cycle Time Rate in pcs/hr working hrs Annual Allocation % Allocation %
month (hrs) (seconds) required working hrs available to TRW
required

TRW Part A 25,000 4 0.5 7 514.29 50.61 607.33 27.30%

TRW Part B 25,000 4 0.5 7 514.29 50.61 607.33 27.30%

TRW Part Numbers

Date: 24 Jan 2008 766046210.xls; Allocation % Example Process Owner / Department:

Rev: E R. Spariosu / Supplier Development
Doc No: D_020_4_12 Approved By:
Page 6 of 9 R. Blanchette / Global Director, SDE
ALLOCATION WORKSHEET
Time (Enter as 7.50
# of Working hours/shift
Factor fraction of an Total
Occurrences (8 hrs max. is standard)
hour)
Shifts/ day 3.00
Shift Length (hrs) 8.00
(Standard is 3)
Days/ week 5.00
Short Breaks (hrs) 0.25 2 0.50
(Standard is 5)
Weeks/ year 48.00
Meal Break (hrs) 0.00
(Standard is 48)
5400.00
TRW Part Numbers

Down Time per Shift (hrs) Available hours per year

450.00
WORKING HOURS PER SHIFT 7.50 Available Hours per month

A B C D E F G H I
Formula A B C D 3600/D A/E + B*C F*12 G/Total of G (Total Reqmnts H -
Total Reqmnts I)/
Total Reqmnts H
Monthly Number of Setup Adjusted Production Total monthly Total Required Maximum Addition
Volume Setups per time/run Cycle Time Rate in pcs/hr working hrs Annual Allocation % Allocation %
month (hrs) (seconds) required working hrs available to TRW
required

50,000 8 1.00 14 1028.57 101.22 1214.67 54.60% 81.30%

TOTAL

TRW Total 50,000 8 1.00 14 1028.57 101.22 1214.67 54.60%

Customers

Customer A
All

15,000 3 0.50 10 360.00 43.17 518.00 23.28%

Customer B 12,000 2 0.50 12 300.00 41.00 492.00 22.12%

TOTAL 77,000 13 2.00 36 1688.57 185.39 2224.67 100.00%

Overall Utilization 41.20%
Available Time (hours/yr) 3175.33

Date: 24 Jan 2008 766046210.xls; Allocation % Example Process Owner / Department:

Rev: E R. Spariosu / Supplier Development
Doc No: D_020_4_12 Approved By:
Page 7 of 9 R. Blanchette / Global Director, SDE
 Run-at-Rate Verification
(1) Part Number (2) Part Description/Program TRW Annual Capacity Planning 4
Run@Rate Date 10-Jan-2008
Volume (pcs/year)
31367943B Tube 300000 5 Supplier Name Acme Stamping Company
6 Supplier Address 12345 S. North Blvd.
7 City/State/Postal Code Wayout, ID 56565
8 Supplier Country USA
(3) TOTAL CPV (pcs/year) 300000 9 Supplier Vendor Code 3478548

10 Process Step STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6

11 Process Description Weld Seam Endform Holes Flats Bend Gage/Label/Pack
48 Number of Operators 2 1 1 1 1 2
49 Equipment size Binford 3000 Former Drill Press 75 Ton Press Franklin 240 NA
Units
12 Working hours/shift (8 hours is requirement) hours 7.50 7.50 7.50 7.50 7.50 7.50
3.00 3.00 3.00 3.00 3.00 3.00
I - Supplier

Shifts/ day (3 shifts is requirement) shifts

Standards

13
Working

14 Days/ week (5 days is requirement) days 5.00 5.00 5.00 5.00 5.00 5.00
15 Weeks/ year (48 weeks is requirement) weeks 48.00 48.00 48.00 48.00 48.00 48.00
16 Number of lines, presses, etc. units 1.00 1.00 2.00 2.00 1.00 1.00
17 Total hours/year (12*13*14*15*16) hours 5400.00 5400.00 10800.00 10800.00 5400.00 5400.00
18 % of line for TRW parts (Allocation %) % 50% 35% 50% 50% 100% 100%
II - Supplier Quoted

19 Quoted Production Rate pcs/hour 720.0 500.0 150.0 150.0 120.0 100.0
Capacity Data

20 Quoted % scrap % 0.0% 1.0% 1.0% 1.0% 1.0% 1.0%

21 Quoted process efficiency % 85.00% 90.00% 90.00% 90.00% 90.00% 85.00%
22 Adjusted production rate (19*(1-20)*21) pcs/hour 612 446 134 134 107 84
23 Available capacity ((19*21*(1-20)*17*18)) pcs/year 1,652,400 841,995 721,710 721,710 577,368 454,410
24 Utilization % (3/23) % 18% 36% 42% 42% 52% 66%
25 Quoted Status (28) % Acceptable Acceptable Acceptable Acceptable Acceptable Acceptable
26 Bottleneck operation X X
27 Trial run duration (8hrs is default) hours 10.00 2.00 10.00 10.00 10.00 10.00
28 Total parts produced pcs 5790 1080 1288 1283 855 743
29 Number of bad parts pcs 0 4 5 1 15 10
30 First time capability % ((28 - 29)/28) % 100.00% 99.63% 99.61% 99.92% 98.21% 98.64%
31 Number of good parts (28-29) pcs 5790 1076 1283 1282 840 733
32 Net output (31/27) pcs/ hour 579 538 128 128 84 73
III - RUN at RATE Results

33 Takt Time Rate (Target) (3/(17*18)) pcs/ hour 111.11 158.73 55.56 55.56 55.56 55.56
34 Downtime hours

35 Reason text

36 Availability ((27-34)/27) % 100.00% 100.00% 100.00% 100.00% 100.00% 100.00%

37 Quality (31/28) % 100.00% 99.63% 99.61% 99.92% 98.25% 98.65%
38 Perfomance ((28/27)/19) % 80.42% 100.00% 85.87% 85.53% 71.25% 74.30%
39 Overall OEE (36*37*38) % 80.42% 99.63% 85.53% 85.47% 70.00% 73.30%
40 Run-Off utilization % % 19.19% 29.50% 43.30% 43.34% 66.14% 75.79%
50 Utilization as % of Allocation (40/18) % 38.38% 84.30% 86.60% 86.67% 66.14% 75.79%
41 Bottleneck operation X X
42 Net Output-Weeks (32*12*13*14) pcs/week 8246
43 Net Output-Months ((32*12*13*14*15)/12) pcs/month 32985
SHADED CELLS ARE CALCULATED and protected 45 44
44 Run at Rate Conducted by: Roger Andover Overall Process TRW Reviewer
Status
Utilization % Name: Roger Andover
Product Line: Steering
75.79% Acceptable
Location: Pamplona
Comments

46

47 Runyon Wraitt Runyon Wraitt 10-Jan-2008

Supplier representative name printed Supplier representative signature Date
Date: 24 Jan 2008 766046210.xls; Run at Rate Form Example) Process Owner / Department:
Rev: E R. Spariosu / Supplier Development
Doc No: D_020_4_12 Approved By:
Page 8 of 9 R. Blanchette / Global Director, SDE
 Run at Rate Exception Form
DATE OF REQUEST: 10-Jan-2007 RUN AT RATE DATE: 9-Nov-2006

ORIGINATOR: R. U. Kedding NUMBER OF LINES: 1 Line

SUPPLIER: S. Claus Manufacturing ANNUAL CPV: 5.5 Million Annually

SUPPLIER CODE: 57389 STANDARD CALCUATION:[3 Shifts; 8 hours; 5 Days (120 hour maximum rate)]

SDE: Runyon Wraitt CALCULATION: 3 Shifts 8 Hours 5 Days

COMMODITY MANAGER: Les Kost UTILIZATION PERCENTAGE: 94.80%

PART NUMBER: 42568799B SUPPLIER PLANNED SCHEDULE:

PROGRAM: Various CALCULATION: 3 Shifts 8 Hours 7 Days

PART NAME: Widget UTILIZATION PERCENTAGE: 67.70%

RUN AT RATE CONDUCTED BY: Runyon Wraitt RED/YELLOW/GREEN STATUS: Yellow

SDE REASON FOR THIS EXCEPTION:
Original run at rate was calculated as yellow with 7 days (93.2% utilization) and red with 5 days (130.4% utilization). The supplier improved the process efficiency and has been able to
provide utilization at 94.8% for 5 days. The volume utilized for the run at rate is 5.5 million pieces per year. A second supplier for this component provides TRW with approximately 1.2
million parts per year. TRW Commodity Management will secure a commitment from the second supplier to hold 600K capacity open for TRW to make the run at rate for S. Claus
Manufacturing at 84.5% wich is acceptable (volume calculated would drop to 4.9 million).

COMMODITY MANAGER EXPLAIN COST IMPLICATION:

To add additional capacity at S. Claus Mfg. will cost $250,000 for dedicated capital equipment and tooling that this component requires.

APPROVED: X YES NO

PRODUCT LINE PROGRAM MANAGER SIGNATURE: DATE:

PRODUCT LINE PURCHASING SENIOR MANAGER SIGNATURE: DATE:

PRODUCT LINE PURCHASING DIRECTOR APPROVAL SIGNATURE: DATE:

APPROVAL COMMENTS:

Date: 24 Jan 2008 766046210.xls; Exception Form Example Process Owner / Department:
Rev: E R. Spariosu / Supplier Development
Doc No: D_020_4_12 Approved By:
Page 9 of 9 R. Blanchette / Global Director, SDE