773 Capacity Analysis Report 2m275r
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Capacity Planning
A. New Model Required OEE - DİNAMİK YAY 2014 B460 08455-100 (773) A1) Supplier & Part Information
A2) Capacity Requirements Supplier Name Location/Site Code Part Name Part Number
DİNAMİK YAY DEMİRKAPI/EYÜP/İSTANBUL B460 08455-100 (773)
Source of Capacity Requirements
Supplier to demonstrate APW of Supplier to demonstrate MPW of
A4) Planned Departmental Operating Pattern & Net Available Time
Process 1 APW Plan
Process description (in value stream order) Days / Week Shifts / Day Total Hours / Shift Contractual Planned Downtime - lunch, breaks, etc. (minutes/shift) Allocation Percent (enter 100 for dedicated) Net Available Time (hours / week) [B*C*(D-(E/60))*F] Planned Minutes per Changeover (into this part #) Planned Changeover Frequency / Week (into this part #)
F G G1 G2
A5) Required Good Parts / Week H J
forming & heat treatment
2352
APW
MPW
2350
3000
A3) Key s Name STA Site Engineer Supplier Lead TAYFUN TURGAÇ Ford Buyer
Other (specify in Notes at bottom left)
2350 3000
Process 2
MPW Plan
Phone #
Email
212 4933374
[email protected]
parts per week operating no more than 5 days per week parts per week operating no more than 6 days per week
Process 3
Process 4
Process 5
Process 6
Process 7
Process 8
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
forming & heat treatment
5.5 2 8
7 2 8
0
0
6.2% 5.46
6.2% 6.94
-
-
-
-
-
-
-
-
-
-
-
-
-
-
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
90 0.13 APW Plan
Percent of parts scrapped Req'd Good Parts / Week to Next Process [Process 1 Req'd Parts = Process 2 Req'd Parts / Avg. Weekly Max Weekly (100% - Process 2 Scrap%)] Required Incoming Parts for
Requirements
Date of Study
11-Sep-13
Capacity Requirements
A B C D E
Program Code Model Year
B460 2014
0.1%
2350
3000
-
-
-
-
-
-
-
-
-
-
-
-
-
-
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
6.68 1 1 6.68
6.68 1 1 6.68
-
-
-
-
-
-
-
-
-
-
-
-
-
-
2940
3742
-
-
-
-
-
-
-
-
-
-
-
-
-
-
79.9%
80.2%
-
-
-
-
-
-
-
-
-
-
-
-
-
-
3002
A6) Required OEE K L M N P
Ideal Cycle Time per Tool or Machine (sec/cycle) # of Tools or Machines in parallel # of identical parts produced per Tool or Machine Cycle Net Ideal Cycle Time (sec/part) [K / (L*M)] Theoretical Parts per week at 100% OEE [G x 3600 / N]
Q
Required OEE
R S
Percent of parts reworked (re-run through process) Can process contain its changeover, scrap & rework assumptions? [Is J/(100%-H) + (JxR) + (G1x60xG2/N) <= P]
T
% Remaining for Availability & Performance Efficiency losses {P - [(J/(100%-H)) + (JxR) + (G1x60xG2/N)]} / P
[J / P]
0.0% YES
YES
-
-
-
-
-
-
-
-
-
-
-
-
-
-
16.6%
17.1%
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Enter any other assumptions for clarification
A7) Shared Process - Total Allocation Plan U
forming & heat treatment
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Enter Total % Allocation from "Shared - Loading Plan" Tab
B. Supplier Demonstrated OEE - Surrogate Historical Performance B1) Surrogate Performance (from Surrogate OEE Summary) Process Description V W X Y
forming & heat treatment
Supplier Name Supplier Location Site Code for Surrogate Process Surrogate Customer & Program Reference (~Ford P221) List reference Surrogate Process (~Stamping Press #12) Average Surrogate OEE Enter any other assumptions for clarification (Part Number, Annual Volume, Operating Pattern, etc.)
Z
B2) Process Specific Weekly Part Estimate [P * Z]
Dinamik Yay İstanbul
95.2%
2798
3562
-
-
-
-
-
-
-
-
-
-
-
-
-
-
C. Gap Analysis - Required OEE vs. Demonstrated OEE; Predicted Good Parts / Week Process Description
forming & heat treatment
APW Result
MPW Result
OK
OK
Demonstrated OEE > Required OEE? (Is Z > Q?)
APW Result
MPW Result
Predicted Good Parts / Week
APW Result MPW Result APW Result MPW Result APW Result MPW Result APW Result MPW Result APW Result MPW Result APW Result MPW Result
Req'd OEE at APW
APW
MPW
2976
3790
100% 90%
Req'd OEE at MPW
Surrogate Demonstrated OEE
95%
80% 70%
NOTES OEE %
60% 50% 40% 30% 20% 10% 0%
79.9%
80%
forming & heat treatment
SUPPLIER OPERATION MANAGEMENT APPROVAL
Authorized Representative Name / Title
Signature
Capacity Analysis Report version 4.3
Date
Insert Signatu Email re Image from file
FOR STA USE Version 4.3 Approved Site Engineer
STA LL6 Supervisor
Signature/Date
Signature/Date
Rejected
© 2010 Ford Motor Company Phone Number
Page 1
Date Revised: 8-Oct-10 Date Printed:09/26/2013
Phase 0 PPAP (Run @ Rate)
A. New Model Required OEE - DİNAMİK YAY 2014 B460 08455-100 (773) A1) Supplier & Part Information Supplier Name Location/Site Code Part Name Part Number
DİNAMİK YAY DEMİRKAPI/EYÜP/İSTANBUL B460 08455-100 (773)
Required Incoming Parts for
Date of Study
11-Sep-13
Process 1
forming & heat treatment
2352
MPW
2350
3000
1 Select for Analysis
A3) Key s Name STA Site Engineer Supplier Lead TAYFUN TURGAÇ Ford Buyer
G/MV
2350 3000
Process 2
MPW Plan
Phone #
Email
212 4933374
[email protected]
parts per week operating no more than 5 days per week parts per week operating no more than 6 days per week
Process 3
Process 4
Process 5
Process 6
Process 7
Process 8
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
forming & heat treatment
5.5 2 8
7 2 8
0
0
6.2% 5.46
6.2% 6.94
-
-
-
-
-
-
-
-
-
-
-
-
-
-
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
90 0.13 APW Plan
Percent of parts scrapped Req'd Good Parts / Week to Next Process [Process 1 Req'd Parts = Process 2 Req'd Parts / Avg. Weekly Max Weekly (100% - Process 2 Scrap%)]
3000
APW
Revised Requirements Source of Capacity Requirements
APW Plan
Process description (in value stream order) Days / Week Shifts / Day Total Hours / Shift Contractual Planned Downtime - lunch, breaks, etc. (minutes/shift) Allocation Percent (enter 100 for dedicated) Net Available Time (hours / week) [B*C*(D-(E/60))*F] Planned Minutes per Changeover (into this part #) Planned Changeover Frequency / Week (into this part #)
A5) Required Good Parts / Week H J
2350
Requirements
Supplier to demonstrate APW of Supplier to demonstrate MPW of
A4) Planned Departmental Operating Pattern & Net Available Time
F G G1 G2
Program Code Model Year
B460 2014
Capacity Requirements
A B C D E
1
A2) Capacity Requirements
0.1%
2350
3000
-
-
-
-
-
-
-
-
-
-
-
-
-
-
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
6.68 1 1 6.68
6.68 1 1 6.68
-
-
-
-
-
-
-
-
-
-
-
-
-
-
2940
3742
-
-
-
-
-
-
-
-
-
-
-
-
-
-
79.9%
80.2%
-
-
-
-
-
-
-
-
-
-
-
-
-
-
3002
A6) Required OEE K L M N P
Ideal Cycle Time per Tool or Machine (sec/cycle) # of Tools or Machines in parallel # of identical parts produced per Tool or Machine Cycle Net Ideal Cycle Time (sec/part) [K / (L*M)] Theoretical Parts per week at 100% OEE [G x 3600 / N]
Q
Required OEE
R S
Percent of parts reworked (re-run through process) Can process contain its changeover, scrap & rework assumptions? [Is J/(100%-H) + (JxR) + (G1x60xG2/N) <= P]
T
% Remaining for Availability & Performance Efficiency losses {P - [(J/(100%-H)) + (JxR) + (G1x60xG2/N)]} / P
[J / P]
0.0% YES
YES
-
-
-
-
-
-
-
-
-
-
-
-
-
-
16.6%
17.1%
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Enter any other assumptions for clarification
A7) Shared Process - Total Allocation Plan U
forming & heat treatment
-
-
-
-
-
-
-
-
-
-
-
-
-
-
0 390 NOT REQUIRED
NOT REQUIRED
NOT REQUIRED
NOT REQUIRED
NOT REQUIRED
NOT REQUIRED
NOT REQUIRED
NOT REQUIRED
14
-
-
-
-
-
-
-
Enter Total % Allocation from "Shared - Loading Plan" Tab
B. Supplier Demonstrated OEE - Phase 0 PPAP (Run @ Rate) B1) Equipment Availability V W X Y Z AB AC AD
forming & heat treatment
Total Available Time (ACTUAL changeover NOT included for Shared) (minutes) Planned Downtime - lunches/breaks/mtgs. (minutes) Net Available Time (minutes) [V - W] Shared Equip Changeover Time ACTUAL (minutes) Shared Equip Changeover Time Weekly Scaled (minutes) [(G1 * G2 * X) / (60*G - (G1 * G2))] Observed Unplanned Downtime (minutes) Operating Time (minutes) [X - AB]
390
Equipment Availability [(X - AB) / (X + Z) * 100]
0 390
-
-
-
-
-
-
-
96.6%
-
-
-
-
-
-
-
B2) Performance Efficiency AE AF AG AH
Total Parts Run (Good, Scrapped, & Reworked) Planned Net Ideal Cycle Time (seconds/part) [N or Other]
Performance Efficiency (AE * AF / AC)
3500 6.7
-
-
-
-
-
-
-
99.9%
-
-
-
-
-
-
-
"Availability" and/or "Performance Efficiency" Losses Not Captured (minutes) [AC - (AE * AF)]
0
-
B3) Quality Rate
#
%
AJ AK AL
0 0
-
# Parts Scrapped # Parts Reworked
Quality Rate [(AE - AJ - AK) / AE]
#
%
#
-
100.0%
%
#
-
-
%
#
-
-
%
#
-
-
%
#
-
-
%
#
%
-
-
-
-
-
B4) Overall Equipment Effectiveness (OEE) AM
Phase 0 OEE [AD * AG * AL]
96.5%
B5) Process Specific Weekly Part Estimate [P * AM] B6) Observed Average Cycle Time (sec/cycle)
2837
3611
-
-
-
-
-
-
-
-
-
-
-
-
-
-
C. Gap Analysis - Required OEE vs. Demonstrated OEE; Predicted Good Parts / Week Process Description
forming & heat treatment
APW Result
Demonstrated OEE > Required OEE? (Is AM > Q?)
OK
MPW Result APW Result MPW Result
APW Result MPW Result APW Result MPW Result APW Result MPW Result APW Result MPW Result APW Result MPW Result APW Result MPW Result
OK
Predicted Good Parts / Week
Req'd OEE at APW
APW
MPW
120%
2896
3686
100%
Req'd OEE at MPW
Demonstrated OEE
97%
80% OEE %
NOTES
60% 40% 20% 0%
79.9%
80%
forming & heat treatment
SUPPLIER OPERATION MANAGEMENT APPROVAL
FOR STA USE
Insert Email Signat ure Image from file
Version 4.3 Approved
[email protected]
Authorized Representative Name / Title
A. Tayfun Turgaç
Signature
Capacity Analysis Report version 4.3
6/13/2013
Date
Site Engineer
STA LL6 Supervisor Rejected
0212 493 33 74
© 2010 Ford Motor Company
Phone Number
Signature/Date
Page 1
Signature/Date Date Revised: 8-Oct-10 Date Printed:09/26/2013
Phase 3 PPAP (Capacity Verification)
A. New Model Required OEE - DİNAMİK YAY 2014 B460 08455-100 (773) A1) Supplier & Part Information Supplier Name Location/Site Code Part Name Part Number
DİNAMİK YAY DEMİRKAPI/EYÜP/İSTANBUL B460 08455-100 (773)
Program Code Model Year
B460 2014
Process 1
Process description (in value stream order) Days / Week Shifts / Day Total Hours / Shift Contractual Planned Downtime - lunch, breaks, etc. (minutes/shift) Allocation Percent (enter 100 for dedicated) Net Available Time (hours / week) [B*C*(D-(E/60))*F] Planned Minutes per Changeover (into this part #) Planned Changeover Frequency / Week (into this part #)
2352
3000
MPW
2350
3000
1 Select for Analysis
A3) Key s Name
●
STA Site Engineer Supplier Lead TAYFUN TURGAÇ Ford Buyer
G/MV
2350 3000
Process 2
MPW Plan
Phone #
Email
212 4933374
[email protected]
parts per week operating no more than 5 days per week parts per week operating no more than 6 days per week
Process 3
Process 4
Process 5
Process 6
Process 7
Process 8
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
forming & heat treatment
5.5 2 8
7 2 8
0
0
6.2% 5.46
6.2% 6.94
-
-
-
-
-
-
-
-
-
-
-
-
-
-
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
90 0.13 APW Plan
Percent of parts scrapped Req'd Good Parts / Week to Next Process [Process 1 Req'd Parts = Process 2 Req'd Parts / Avg. Weekly Max Weekly (100% - Process 2 Scrap%)] forming & heat Required Incoming Parts for treatment
0.1%
2350
3000
-
-
-
-
-
-
-
-
-
-
-
-
-
-
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
6.68 1 1 6.68
6.68 1 1 6.68
-
-
-
-
-
-
-
-
-
-
-
-
-
-
2940
3742
-
-
-
-
-
-
-
-
-
-
-
-
-
-
79.9%
80.2%
-
-
-
-
-
-
-
-
-
-
-
-
-
-
3002
A6) Required OEE K L M N P
Ideal Cycle Time per Tool or Machine (sec/cycle) # of Tools or Machines in parallel # of identical parts produced per Tool or Machine Cycle Net Ideal Cycle Time (sec/part) [K / (L*M)] Theoretical Parts per week at 100% OEE [G x 3600 / N]
Q
Required OEE
R S
Percent of parts reworked (re-run through process) Can process contain its changeover, scrap & rework assumptions? [Is J/(100%-H) + (JxR) + (G1x60xG2/N) <= P] % Remaining for Availability & Performance Efficiency losses {P - [(J/(100%-H)) + (JxR) + (G1x60xG2/N)]} / P
T
Date of Study
11-Sep-13
APW Plan
A5) Required Good Parts / Week H J
Requirements
Supplier to demonstrate APW of Supplier to demonstrate MPW of
A4) Planned Departmental Operating Pattern & Net Available Time
F G G1 G2
2350
APW
Revised Requirements Source of Capacity Requirements
Capacity Requirements
A B C D E
1
A2) Capacity Requirements
[J / P]
0.0% YES
YES
-
-
-
-
-
-
-
-
-
-
-
-
-
-
16.6%
17.1%
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Enter any other assumptions for clarification
A7) Shared Process - Total Allocation Plan U
forming & heat treatment
-
-
-
-
-
-
-
-
-
-
-
-
-
-
0 405
-
-
-
-
-
-
-
0
-
-
-
-
-
-
-
Enter Total % Allocation from "Shared - Loading Plan" Tab
B. Supplier Demonstrated OEE - Phase 3 PPAP (Capacity Verification) B1) Equipment Availability V W X Y Z AB AC AD
forming & heat treatment
Total Available Time (Include ACTUAL changeover time for Shared) (minutes) Planned Downtime - lunches/breaks/mtgs. (minutes) Net Available Time (minutes) [V - W] Shared Equip Changeover Time ACTUAL (minutes) Shared Equip Changeover Time Weekly Scaled (minutes) [Y * (X / 60) / (G / G2)] Observed Unplanned Downtime (minutes) Operating Time (minutes) [X - Y - AB]
405
Equipment Availability [(X - Z - AB) / X * 100]
0 405
-
-
-
-
-
-
-
100.0%
-
-
-
-
-
-
-
B2) Performance Efficiency AE AF AG AH
Total Parts Run (Good, Scrapped, & Reworked) Net Ideal Cycle Time (seconds/part) [N]
Performance Efficiency (AE * AF / AC)
3500 6.7
-
-
-
-
-
-
-
96.2%
-
-
-
-
-
-
-
"Availability" and/or "Performance Efficiency" Losses Not Captured (minutes) [AC - (AE * AF)]
15
-
B3) Quality Rate
#
%
AJ AK AL
0 0
-
# Parts Scrapped # Parts Reworked
Quality Rate [(AE - AJ - AK) / AE]
-
#
%
-
#
%
-
100.0%
-
#
%
-
-
#
-
-
%
#
-
-
%
#
-
-
%
#
%
-
-
-
-
-
B4) Overall Equipment Effectiveness (OEE) AM
Phase 3 OEE [AD * AG * AL]
96.2%
B5) Process Specific Weekly Part Estimate [P * AM]
2828
3599
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
B6) Observed Average Cycle Time (sec/cycle)
C. Gap Analysis - Required OEE vs. Demonstrated OEE; Predicted Good Parts / Week Process Description
forming & heat treatment
APW Result
MPW Result
OK
OK
Demonstrated OEE > Required OEE? (Is AM > Q?)
APW Result
MPW Result
Predicted Good Parts / Week
APW Result MPW Result APW Result MPW Result APW Result MPW Result APW Result MPW Result APW Result MPW Result APW Result MPW Result
Req'd OEE at APW
APW
MPW
120%
3128
3982
100%
Req'd OEE at MPW
Demonstrated OEE
96%
80% OEE %
NOTES
60% 40% 20% 0%
79.9%
80%
forming & heat treatment
SUPPLIER OPERATION MANAGEMENT APPROVAL
Authorized Representative Name / Title
Signature
Capacity Analysis Report version 4.3
Date
Insert Signat Email ure Image from file
Rejected
FOR STA USE Version 4.3
Approved Site Engineer
STA LL6 Supervisor Rejected
© 2010 Ford Motor Company Phone Number
Signature/Date
Page 1
Signature/Date
Date Revised: 8-Oct-10 Date Printed:09/26/2013
Surrogate OEE Summary Demonstrated (Surrogate) Performance History
GPP = Good Parts Produced
NICT = Net Ideal Cycle Time (sec/part)
NAT = Net Available Time (hrs/wk)
OEE = Overall Equipment Effectiveness [GPP/(NAT/NPICT)]
forming & heat treatment
WK#
Date (mm/dd/yyyy)
GPP
NICT
NAT
OEE
WK1
6/6/2013 6/7/2013 6/8/2013 6/10/2013 6/11/2013 6/12/2013 6/13/2013
10000 10000 10000 10000 10000 10000 10000
4.9 4.9 4.9 4.0 4.0 4.0 4.0
14.8 14.8 13.5 12.2 11.2 12.2 11.2
91.5%
-
-
-
-
-
-
-
91.5% 100.0% 91.8% 100.0% 91.8% 100.0% 95.2%
-
-
-
-
-
-
-
WK19 WK20 WK21 WK22 WK23 WK24 WK25 AVERAGE SURROGATE OEE
OEE
forming & heat treatment OE E
80%
Surrogate OEE
60% 50% 40% 30%
GPP
NICT
100%
80%
90%
90%
70%
80%
80%
60%
70%
70%
60%
60%
50% 40% 30%
50% 40% 30% 20%
6/6/2013
6/13/ 2013
6/12/2013
6/11/2013
6/10/2013
6/9/2013
6/8/2013
6/7/2013
OEE
OEE OE E
OEE OE E
OE E
100%
90%
90%
90%
90%
80%
80%
80%
80%
70%
70%
70%
70%
60%
60%
60%
60%
30%
Surrogate OEE
100%
Surrogate OEE
100%
Surrogate OEE
100%
40%
50% 40% 30%
50% 40% 30%
Page 1
6/13/2013
6/12/2013
6/11/2013
6/10/2013
6/9/2013
6/8/2013
6/7/2013
6/6/2013
6/13/2013
6/12/2013
6/11/2013
6/10/2013
6/9/2013
6/8/2013
6/ 7/2013
6/6/2013
6/13/2013
0%
6/12/2013
0%
6/11/2013
10%
0%
6/10/2013
10%
6/ 9/ 2013
20%
10%
0% 6/ 8/2013
20%
6/7/2013
20%
10% 6/6/2013
20%
Capacity Analysis Report version 4.3
OEE
20%
6/6/2013
6/13/2013
6/12/2013
6/11/2013
6/10/2013
6/9/2013
6/8/2013
6/ 7/ 2013
6/6/2013
6/13/2013
6/12/2013
6/11/2013
0%
6/10/2013
0%
6/9/2013
0% 6/8/2013
10%
0% 6/7/2013
10%
30%
NAT
30%
10%
50%
NICT
40%
10%
40%
GPP
50%
20%
50%
OEE
OE E
100%
OE E
NAT
OEE
90%
OEE
Surrogate OEE
OEE
20%
6/6/2013
Surrogate OEE
70%
NAT
OE E
Surrogate OEE
90%
NICT
OEE
OE E
100%
100%
GPP
6/13/2013
WK18
OEE
6/ 13/ 2013
WK17
NAT
6/12/2013
WK16
NICT
6/12/2013
WK15
GPP
6/11/2013
WK14
OEE
6/11/2013
WK13
NAT
6/10/2013
WK12
NICT
6/10/2013
WK11
GPP
6/ 9/ 2013
WK9 WK10
OEE
6/9/2013
WK8
NAT
6/8/2013
WK7
NICT
6/8/2013
WK6
GPP
6/7/2013
WK5
OEE
6/7/2013
WK4
NAT
6/6/2013
WK3
NICT
Surrogate OEE
WK2
GPP
Date Revised: 8-Oct-10 Date Printed:09/26/2013
Shared - Loading Plan Shared Process Loading Plan
NICT = Net Ideal Cycle Time (sec/part)
11-Sep-2013
Date of Study
Study Phase Phase 0 PPAP (Run @ Rate)
PROCESS
FORMING AND HEAT TREATMENT
Departmental Operating Pattern for Average Weekly
Departmental Operating Pattern for Max Weekly
5.5 2 8
7 2 8
0
0
Net Available Time (NAT) (hrs/week)
88.00
112.00
Demonstrated OEE: Enter average OEE from most recent production performance data; Surrogate OEE tab may be used for this calculation
95.2%
95.2%
Loading Plan to meet Average Weekly
Loading Plan to meet Max Weekly
Days / Week Shifts / Day Total Hours / Shift Contractual Planned Downtime - lunch, breaks, etc. (minutes/shift)
Part
Ford Part # or "Non-Ford"
17
07772(765) 07773(766) 07791(768) 07972(772) 00352(512),00368(513) 08171(667).08170(668) 08241(538) 08242(539) 08336(694) 08337(695) 05320(687),05321(688) 08141(526) 05405(690),05437(691) 08114(641) 05284(696) 05283(697) 71719(704) 71844(705) 07340,07341,07351,07352 04536,04537,04474 08331(699),08332(700)
18
00449,00443,00439,00447,00441,03249
19
08281,08282,08286,08287,08289,08290
20
08455(773) Other % Allocation - Description Other % Allocation - Description
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
21 22
Req'd Good Parts / Week
NICT
Time Req'd @ Demonstrated OEE (hrs/week)
% Allocation Minimum Required
Req'd Good Parts / Week
NICT
Time Req'd @ Demonstrated OEE (hrs/week)
% Allocation Minimum Required
4700 2350 2350 2350 2650 785 2740 2740 3920 785 3920 590 2740 2740 6280 590 3725 980 2350 2350
4.86 5.40 4.86 4.86 4.62 5.85 4.86 4.86 4.03 5.85 4.86 3.31 4.68 3.60 4.68 4.68 4.86 3.47 4.41 6.68
6.7 3.7 3.3 3.3 3.6 1.3 3.9 3.9 4.6 1.3 5.6 0.6 3.7 2.9 8.6 0.8 5.3 1.0 3.0 4.6
7.6% 4.2% 3.8% 3.8% 4.1% 1.5% 4.4% 4.4% 5.2% 1.5% 6.3% 0.6% 4.3% 3.3% 9.7% 0.9% 6.0% 1.1% 3.4% 5.2%
6000 3000 3000 3000 3370 1000 3488 3488 4990 1000 4990 750 3488 3488 7992 750 4740 1247 3000 3000
4.86 5.40 4.86 4.86 4.62 5.85 4.86 4.86 4.03 5.85 4.86 3.31 4.68 3.60 4.68 4.68 4.86 3.47 4.41 6.68
8.5 4.7 4.3 4.3 4.5 1.7 4.9 4.9 5.9 1.7 7.1 0.7 4.8 3.7 10.9 1.0 6.7 1.3 3.9 5.8
7.6% 4.2% 3.8% 3.8% 4.1% 1.5% 4.4% 4.4% 5.2% 1.5% 6.3% 0.6% 4.3% 3.3% 9.7% 0.9% 6.0% 1.1% 3.4% 5.2%
81.4%
65781
91.3
81.5%
Percentage of Net Available Time not utilized for production (%) {PM, etc.}
Total % Allocation 51635
71.7
If Total % Allocation > 100%, loading plan exceeds capacity
Capacity Analysis Report version 4.3
Page 1
Date Revised: 8-Oct-10 Date Printed:09/26/2013
A. New Model Required OEE - DİNAMİK YAY 2014 B460 08455-100 (773) A1) Supplier & Part Information
A2) Capacity Requirements Supplier Name Location/Site Code Part Name Part Number
DİNAMİK YAY DEMİRKAPI/EYÜP/İSTANBUL B460 08455-100 (773)
Source of Capacity Requirements
Supplier to demonstrate APW of Supplier to demonstrate MPW of
A4) Planned Departmental Operating Pattern & Net Available Time
Process 1 APW Plan
Process description (in value stream order) Days / Week Shifts / Day Total Hours / Shift Contractual Planned Downtime - lunch, breaks, etc. (minutes/shift) Allocation Percent (enter 100 for dedicated) Net Available Time (hours / week) [B*C*(D-(E/60))*F] Planned Minutes per Changeover (into this part #) Planned Changeover Frequency / Week (into this part #)
F G G1 G2
A5) Required Good Parts / Week H J
forming & heat treatment
2352
APW
MPW
2350
3000
A3) Key s Name STA Site Engineer Supplier Lead TAYFUN TURGAÇ Ford Buyer
Other (specify in Notes at bottom left)
2350 3000
Process 2
MPW Plan
Phone #
212 4933374
[email protected]
parts per week operating no more than 5 days per week parts per week operating no more than 6 days per week
Process 3
Process 4
Process 5
Process 6
Process 7
Process 8
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
forming & heat treatment
5.5 2 8
7 2 8
0
0
6.2% 5.46
6.2% 6.94
-
-
-
-
-
-
-
-
-
-
-
-
-
-
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
90 0.13 APW Plan
Percent of parts scrapped Req'd Good Parts / Week to Next Process [Process 1 Req'd Parts = Process 2 Req'd Parts / Avg. Weekly Max Weekly (100% - Process 2 Scrap%)] Required Incoming Parts for
Date of Study
11-Sep-13
Capacity Requirements
A B C D E
Program Code Model Year
B460 2014
0.1%
2350
3000
-
-
-
-
-
-
-
-
-
-
-
-
-
-
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
6.68 1 1 6.68
6.68 1 1 6.68
-
-
-
-
-
-
-
-
-
-
-
-
-
-
2940
3742
-
-
-
-
-
-
-
-
-
-
-
-
-
-
79.9%
80.2%
-
-
-
-
-
-
-
-
-
-
-
-
-
-
3002
A6) Required OEE K L M N P
Ideal Cycle Time per Tool or Machine (sec/cycle) # of Tools or Machines in parallel # of identical parts produced per Tool or Machine Cycle Net Ideal Cycle Time (sec/part) [K / (L*M)] Theoretical Parts per week at 100% OEE [G x 3600 / N]
Q
Required OEE
R S
Percent of parts reworked (re-run through process) Can process contain its changeover, scrap & rework assumptions? [Is J/(100%-H) + (JxR) + (G1x60xG2/N) <= P]
T
% Remaining for Availability & Performance Efficiency losses {P - [(J/(100%-H)) + (JxR) + (G1x60xG2/N)]} / P
[J / P]
0.0% YES
YES
-
-
-
-
-
-
-
-
-
-
-
-
-
-
16.6%
17.1%
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Enter any other assumptions for clarification
A7) Shared Process - Total Allocation Plan U
forming & heat treatment
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Enter Total % Allocation from "Shared - Loading Plan" Tab
B. Supplier Demonstrated OEE - Surrogate Historical Performance B1) Surrogate Performance (from Surrogate OEE Summary) Process Description V W X Y
forming & heat treatment
Supplier Name Supplier Location Site Code for Surrogate Process Surrogate Customer & Program Reference (~Ford P221) List reference Surrogate Process (~Stamping Press #12) Average Surrogate OEE Enter any other assumptions for clarification (Part Number, Annual Volume, Operating Pattern, etc.)
Z
B2) Process Specific Weekly Part Estimate [P * Z]
Dinamik Yay İstanbul
95.2%
2798
3562
-
-
-
-
-
-
-
-
-
-
-
-
-
-
C. Gap Analysis - Required OEE vs. Demonstrated OEE; Predicted Good Parts / Week Process Description
forming & heat treatment
APW Result
MPW Result
OK
OK
Demonstrated OEE > Required OEE? (Is Z > Q?)
APW Result
MPW Result
Predicted Good Parts / Week
APW Result MPW Result APW Result MPW Result APW Result MPW Result APW Result MPW Result APW Result MPW Result APW Result MPW Result
Req'd OEE at APW
APW
MPW
2976
3790
100% 90%
Req'd OEE at MPW
Surrogate Demonstrated OEE
95%
80% 70%
NOTES OEE %
60% 50% 40% 30% 20% 10% 0%
79.9%
80%
forming & heat treatment
SUPPLIER OPERATION MANAGEMENT APPROVAL
Authorized Representative Name / Title
Signature
Capacity Analysis Report version 4.3
Date
Insert Signatu Email re Image from file
FOR STA USE Version 4.3 Approved Site Engineer
STA LL6 Supervisor
Signature/Date
Signature/Date
Rejected
© 2010 Ford Motor Company Phone Number
Page 1
Date Revised: 8-Oct-10 Date Printed:09/26/2013
Phase 0 PPAP (Run @ Rate)
A. New Model Required OEE - DİNAMİK YAY 2014 B460 08455-100 (773) A1) Supplier & Part Information Supplier Name Location/Site Code Part Name Part Number
DİNAMİK YAY DEMİRKAPI/EYÜP/İSTANBUL B460 08455-100 (773)
Required Incoming Parts for
Date of Study
11-Sep-13
Process 1
forming & heat treatment
2352
MPW
2350
3000
1 Select for Analysis
A3) Key s Name STA Site Engineer Supplier Lead TAYFUN TURGAÇ Ford Buyer
G/MV
2350 3000
Process 2
MPW Plan
Phone #
212 4933374
[email protected]
parts per week operating no more than 5 days per week parts per week operating no more than 6 days per week
Process 3
Process 4
Process 5
Process 6
Process 7
Process 8
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
forming & heat treatment
5.5 2 8
7 2 8
0
0
6.2% 5.46
6.2% 6.94
-
-
-
-
-
-
-
-
-
-
-
-
-
-
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
90 0.13 APW Plan
Percent of parts scrapped Req'd Good Parts / Week to Next Process [Process 1 Req'd Parts = Process 2 Req'd Parts / Avg. Weekly Max Weekly (100% - Process 2 Scrap%)]
3000
APW
Revised Requirements Source of Capacity Requirements
APW Plan
Process description (in value stream order) Days / Week Shifts / Day Total Hours / Shift Contractual Planned Downtime - lunch, breaks, etc. (minutes/shift) Allocation Percent (enter 100 for dedicated) Net Available Time (hours / week) [B*C*(D-(E/60))*F] Planned Minutes per Changeover (into this part #) Planned Changeover Frequency / Week (into this part #)
A5) Required Good Parts / Week H J
2350
Supplier to demonstrate APW of Supplier to demonstrate MPW of
A4) Planned Departmental Operating Pattern & Net Available Time
F G G1 G2
Program Code Model Year
B460 2014
Capacity Requirements
A B C D E
1
A2) Capacity Requirements
0.1%
2350
3000
-
-
-
-
-
-
-
-
-
-
-
-
-
-
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
6.68 1 1 6.68
6.68 1 1 6.68
-
-
-
-
-
-
-
-
-
-
-
-
-
-
2940
3742
-
-
-
-
-
-
-
-
-
-
-
-
-
-
79.9%
80.2%
-
-
-
-
-
-
-
-
-
-
-
-
-
-
3002
A6) Required OEE K L M N P
Ideal Cycle Time per Tool or Machine (sec/cycle) # of Tools or Machines in parallel # of identical parts produced per Tool or Machine Cycle Net Ideal Cycle Time (sec/part) [K / (L*M)] Theoretical Parts per week at 100% OEE [G x 3600 / N]
Q
Required OEE
R S
Percent of parts reworked (re-run through process) Can process contain its changeover, scrap & rework assumptions? [Is J/(100%-H) + (JxR) + (G1x60xG2/N) <= P]
T
% Remaining for Availability & Performance Efficiency losses {P - [(J/(100%-H)) + (JxR) + (G1x60xG2/N)]} / P
[J / P]
0.0% YES
YES
-
-
-
-
-
-
-
-
-
-
-
-
-
-
16.6%
17.1%
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Enter any other assumptions for clarification
A7) Shared Process - Total Allocation Plan U
forming & heat treatment
-
-
-
-
-
-
-
-
-
-
-
-
-
-
0 390 NOT REQUIRED
NOT REQUIRED
NOT REQUIRED
NOT REQUIRED
NOT REQUIRED
NOT REQUIRED
NOT REQUIRED
NOT REQUIRED
14
-
-
-
-
-
-
-
Enter Total % Allocation from "Shared - Loading Plan" Tab
B. Supplier Demonstrated OEE - Phase 0 PPAP (Run @ Rate) B1) Equipment Availability V W X Y Z AB AC AD
forming & heat treatment
Total Available Time (ACTUAL changeover NOT included for Shared) (minutes) Planned Downtime - lunches/breaks/mtgs. (minutes) Net Available Time (minutes) [V - W] Shared Equip Changeover Time ACTUAL (minutes) Shared Equip Changeover Time Weekly Scaled (minutes) [(G1 * G2 * X) / (60*G - (G1 * G2))] Observed Unplanned Downtime (minutes) Operating Time (minutes) [X - AB]
390
Equipment Availability [(X - AB) / (X + Z) * 100]
0 390
-
-
-
-
-
-
-
96.6%
-
-
-
-
-
-
-
B2) Performance Efficiency AE AF AG AH
Total Parts Run (Good, Scrapped, & Reworked) Planned Net Ideal Cycle Time (seconds/part) [N or Other]
Performance Efficiency (AE * AF / AC)
3500 6.7
-
-
-
-
-
-
-
99.9%
-
-
-
-
-
-
-
"Availability" and/or "Performance Efficiency" Losses Not Captured (minutes) [AC - (AE * AF)]
0
-
B3) Quality Rate
#
%
AJ AK AL
0 0
-
# Parts Scrapped # Parts Reworked
Quality Rate [(AE - AJ - AK) / AE]
#
%
#
-
100.0%
%
#
-
-
%
#
-
-
%
#
-
-
%
#
-
-
%
#
%
-
-
-
-
-
B4) Overall Equipment Effectiveness (OEE) AM
Phase 0 OEE [AD * AG * AL]
96.5%
B5) Process Specific Weekly Part Estimate [P * AM] B6) Observed Average Cycle Time (sec/cycle)
2837
3611
-
-
-
-
-
-
-
-
-
-
-
-
-
-
C. Gap Analysis - Required OEE vs. Demonstrated OEE; Predicted Good Parts / Week Process Description
forming & heat treatment
APW Result
Demonstrated OEE > Required OEE? (Is AM > Q?)
OK
MPW Result APW Result MPW Result
APW Result MPW Result APW Result MPW Result APW Result MPW Result APW Result MPW Result APW Result MPW Result APW Result MPW Result
OK
Predicted Good Parts / Week
Req'd OEE at APW
APW
MPW
120%
2896
3686
100%
Req'd OEE at MPW
Demonstrated OEE
97%
80% OEE %
NOTES
60% 40% 20% 0%
79.9%
80%
forming & heat treatment
SUPPLIER OPERATION MANAGEMENT APPROVAL
FOR STA USE
Insert Email Signat ure Image from file
Version 4.3 Approved
[email protected]
Authorized Representative Name / Title
A. Tayfun Turgaç
Signature
Capacity Analysis Report version 4.3
6/13/2013
Date
Site Engineer
STA LL6 Supervisor Rejected
0212 493 33 74
© 2010 Ford Motor Company
Phone Number
Signature/Date
Page 1
Signature/Date Date Revised: 8-Oct-10 Date Printed:09/26/2013
Phase 3 PPAP (Capacity Verification)
A. New Model Required OEE - DİNAMİK YAY 2014 B460 08455-100 (773) A1) Supplier & Part Information Supplier Name Location/Site Code Part Name Part Number
DİNAMİK YAY DEMİRKAPI/EYÜP/İSTANBUL B460 08455-100 (773)
Program Code Model Year
B460 2014
Process 1
Process description (in value stream order) Days / Week Shifts / Day Total Hours / Shift Contractual Planned Downtime - lunch, breaks, etc. (minutes/shift) Allocation Percent (enter 100 for dedicated) Net Available Time (hours / week) [B*C*(D-(E/60))*F] Planned Minutes per Changeover (into this part #) Planned Changeover Frequency / Week (into this part #)
2352
3000
MPW
2350
3000
1 Select for Analysis
A3) Key s Name
●
STA Site Engineer Supplier Lead TAYFUN TURGAÇ Ford Buyer
G/MV
2350 3000
Process 2
MPW Plan
Phone #
212 4933374
[email protected]
parts per week operating no more than 5 days per week parts per week operating no more than 6 days per week
Process 3
Process 4
Process 5
Process 6
Process 7
Process 8
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
forming & heat treatment
5.5 2 8
7 2 8
0
0
6.2% 5.46
6.2% 6.94
-
-
-
-
-
-
-
-
-
-
-
-
-
-
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
90 0.13 APW Plan
Percent of parts scrapped Req'd Good Parts / Week to Next Process [Process 1 Req'd Parts = Process 2 Req'd Parts / Avg. Weekly Max Weekly (100% - Process 2 Scrap%)] forming & heat Required Incoming Parts for treatment
0.1%
2350
3000
-
-
-
-
-
-
-
-
-
-
-
-
-
-
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
APW Plan
MPW Plan
6.68 1 1 6.68
6.68 1 1 6.68
-
-
-
-
-
-
-
-
-
-
-
-
-
-
2940
3742
-
-
-
-
-
-
-
-
-
-
-
-
-
-
79.9%
80.2%
-
-
-
-
-
-
-
-
-
-
-
-
-
-
3002
A6) Required OEE K L M N P
Ideal Cycle Time per Tool or Machine (sec/cycle) # of Tools or Machines in parallel # of identical parts produced per Tool or Machine Cycle Net Ideal Cycle Time (sec/part) [K / (L*M)] Theoretical Parts per week at 100% OEE [G x 3600 / N]
Q
Required OEE
R S
Percent of parts reworked (re-run through process) Can process contain its changeover, scrap & rework assumptions? [Is J/(100%-H) + (JxR) + (G1x60xG2/N) <= P] % Remaining for Availability & Performance Efficiency losses {P - [(J/(100%-H)) + (JxR) + (G1x60xG2/N)]} / P
T
Date of Study
11-Sep-13
APW Plan
A5) Required Good Parts / Week H J
Supplier to demonstrate APW of Supplier to demonstrate MPW of
A4) Planned Departmental Operating Pattern & Net Available Time
F G G1 G2
2350
APW
Revised Requirements Source of Capacity Requirements
Capacity Requirements
A B C D E
1
A2) Capacity Requirements
[J / P]
0.0% YES
YES
-
-
-
-
-
-
-
-
-
-
-
-
-
-
16.6%
17.1%
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Enter any other assumptions for clarification
A7) Shared Process - Total Allocation Plan U
forming & heat treatment
-
-
-
-
-
-
-
-
-
-
-
-
-
-
0 405
-
-
-
-
-
-
-
0
-
-
-
-
-
-
-
Enter Total % Allocation from "Shared - Loading Plan" Tab
B. Supplier Demonstrated OEE - Phase 3 PPAP (Capacity Verification) B1) Equipment Availability V W X Y Z AB AC AD
forming & heat treatment
Total Available Time (Include ACTUAL changeover time for Shared) (minutes) Planned Downtime - lunches/breaks/mtgs. (minutes) Net Available Time (minutes) [V - W] Shared Equip Changeover Time ACTUAL (minutes) Shared Equip Changeover Time Weekly Scaled (minutes) [Y * (X / 60) / (G / G2)] Observed Unplanned Downtime (minutes) Operating Time (minutes) [X - Y - AB]
405
Equipment Availability [(X - Z - AB) / X * 100]
0 405
-
-
-
-
-
-
-
100.0%
-
-
-
-
-
-
-
B2) Performance Efficiency AE AF AG AH
Total Parts Run (Good, Scrapped, & Reworked) Net Ideal Cycle Time (seconds/part) [N]
Performance Efficiency (AE * AF / AC)
3500 6.7
-
-
-
-
-
-
-
96.2%
-
-
-
-
-
-
-
"Availability" and/or "Performance Efficiency" Losses Not Captured (minutes) [AC - (AE * AF)]
15
-
B3) Quality Rate
#
%
AJ AK AL
0 0
-
# Parts Scrapped # Parts Reworked
Quality Rate [(AE - AJ - AK) / AE]
-
#
%
-
#
%
-
100.0%
-
#
%
-
-
#
-
-
%
#
-
-
%
#
-
-
%
#
%
-
-
-
-
-
B4) Overall Equipment Effectiveness (OEE) AM
Phase 3 OEE [AD * AG * AL]
96.2%
B5) Process Specific Weekly Part Estimate [P * AM]
2828
3599
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
B6) Observed Average Cycle Time (sec/cycle)
C. Gap Analysis - Required OEE vs. Demonstrated OEE; Predicted Good Parts / Week Process Description
forming & heat treatment
APW Result
MPW Result
OK
OK
Demonstrated OEE > Required OEE? (Is AM > Q?)
APW Result
MPW Result
Predicted Good Parts / Week
APW Result MPW Result APW Result MPW Result APW Result MPW Result APW Result MPW Result APW Result MPW Result APW Result MPW Result
Req'd OEE at APW
APW
MPW
120%
3128
3982
100%
Req'd OEE at MPW
Demonstrated OEE
96%
80% OEE %
NOTES
60% 40% 20% 0%
79.9%
80%
forming & heat treatment
SUPPLIER OPERATION MANAGEMENT APPROVAL
Authorized Representative Name / Title
Signature
Capacity Analysis Report version 4.3
Date
Insert Signat Email ure Image from file
Rejected
FOR STA USE Version 4.3
Approved Site Engineer
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© 2010 Ford Motor Company Phone Number
Signature/Date
Page 1
Signature/Date
Date Revised: 8-Oct-10 Date Printed:09/26/2013
Surrogate OEE Summary Demonstrated (Surrogate) Performance History
GPP = Good Parts Produced
NICT = Net Ideal Cycle Time (sec/part)
NAT = Net Available Time (hrs/wk)
OEE = Overall Equipment Effectiveness [GPP/(NAT/NPICT)]
forming & heat treatment
WK#
Date (mm/dd/yyyy)
GPP
NICT
NAT
OEE
WK1
6/6/2013 6/7/2013 6/8/2013 6/10/2013 6/11/2013 6/12/2013 6/13/2013
10000 10000 10000 10000 10000 10000 10000
4.9 4.9 4.9 4.0 4.0 4.0 4.0
14.8 14.8 13.5 12.2 11.2 12.2 11.2
91.5%
-
-
-
-
-
-
-
91.5% 100.0% 91.8% 100.0% 91.8% 100.0% 95.2%
-
-
-
-
-
-
-
WK19 WK20 WK21 WK22 WK23 WK24 WK25 AVERAGE SURROGATE OEE
OEE
forming & heat treatment OE E
80%
Surrogate OEE
60% 50% 40% 30%
GPP
NICT
100%
80%
90%
90%
70%
80%
80%
60%
70%
70%
60%
60%
50% 40% 30%
50% 40% 30% 20%
6/6/2013
6/13/ 2013
6/12/2013
6/11/2013
6/10/2013
6/9/2013
6/8/2013
6/7/2013
OEE
OEE OE E
OEE OE E
OE E
100%
90%
90%
90%
90%
80%
80%
80%
80%
70%
70%
70%
70%
60%
60%
60%
60%
30%
Surrogate OEE
100%
Surrogate OEE
100%
Surrogate OEE
100%
40%
50% 40% 30%
50% 40% 30%
Page 1
6/13/2013
6/12/2013
6/11/2013
6/10/2013
6/9/2013
6/8/2013
6/7/2013
6/6/2013
6/13/2013
6/12/2013
6/11/2013
6/10/2013
6/9/2013
6/8/2013
6/ 7/2013
6/6/2013
6/13/2013
0%
6/12/2013
0%
6/11/2013
10%
0%
6/10/2013
10%
6/ 9/ 2013
20%
10%
0% 6/ 8/2013
20%
6/7/2013
20%
10% 6/6/2013
20%
Capacity Analysis Report version 4.3
OEE
20%
6/6/2013
6/13/2013
6/12/2013
6/11/2013
6/10/2013
6/9/2013
6/8/2013
6/ 7/ 2013
6/6/2013
6/13/2013
6/12/2013
6/11/2013
0%
6/10/2013
0%
6/9/2013
0% 6/8/2013
10%
0% 6/7/2013
10%
30%
NAT
30%
10%
50%
NICT
40%
10%
40%
GPP
50%
20%
50%
OEE
OE E
100%
OE E
NAT
OEE
90%
OEE
Surrogate OEE
OEE
20%
6/6/2013
Surrogate OEE
70%
NAT
OE E
Surrogate OEE
90%
NICT
OEE
OE E
100%
100%
GPP
6/13/2013
WK18
OEE
6/ 13/ 2013
WK17
NAT
6/12/2013
WK16
NICT
6/12/2013
WK15
GPP
6/11/2013
WK14
OEE
6/11/2013
WK13
NAT
6/10/2013
WK12
NICT
6/10/2013
WK11
GPP
6/ 9/ 2013
WK9 WK10
OEE
6/9/2013
WK8
NAT
6/8/2013
WK7
NICT
6/8/2013
WK6
GPP
6/7/2013
WK5
OEE
6/7/2013
WK4
NAT
6/6/2013
WK3
NICT
Surrogate OEE
WK2
GPP
Date Revised: 8-Oct-10 Date Printed:09/26/2013
Shared - Loading Plan Shared Process Loading Plan
NICT = Net Ideal Cycle Time (sec/part)
11-Sep-2013
Date of Study
Study Phase Phase 0 PPAP (Run @ Rate)
PROCESS
FORMING AND HEAT TREATMENT
Departmental Operating Pattern for Average Weekly
Departmental Operating Pattern for Max Weekly
5.5 2 8
7 2 8
0
0
Net Available Time (NAT) (hrs/week)
88.00
112.00
Demonstrated OEE: Enter average OEE from most recent production performance data; Surrogate OEE tab may be used for this calculation
95.2%
95.2%
Loading Plan to meet Average Weekly
Loading Plan to meet Max Weekly
Days / Week Shifts / Day Total Hours / Shift Contractual Planned Downtime - lunch, breaks, etc. (minutes/shift)
Part
Ford Part # or "Non-Ford"
17
07772(765) 07773(766) 07791(768) 07972(772) 00352(512),00368(513) 08171(667).08170(668) 08241(538) 08242(539) 08336(694) 08337(695) 05320(687),05321(688) 08141(526) 05405(690),05437(691) 08114(641) 05284(696) 05283(697) 71719(704) 71844(705) 07340,07341,07351,07352 04536,04537,04474 08331(699),08332(700)
18
00449,00443,00439,00447,00441,03249
19
08281,08282,08286,08287,08289,08290
20
08455(773) Other % Allocation - Description Other % Allocation - Description
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
21 22
Req'd Good Parts / Week
NICT
Time Req'd @ Demonstrated OEE (hrs/week)
% Allocation Minimum Required
Req'd Good Parts / Week
NICT
Time Req'd @ Demonstrated OEE (hrs/week)
% Allocation Minimum Required
4700 2350 2350 2350 2650 785 2740 2740 3920 785 3920 590 2740 2740 6280 590 3725 980 2350 2350
4.86 5.40 4.86 4.86 4.62 5.85 4.86 4.86 4.03 5.85 4.86 3.31 4.68 3.60 4.68 4.68 4.86 3.47 4.41 6.68
6.7 3.7 3.3 3.3 3.6 1.3 3.9 3.9 4.6 1.3 5.6 0.6 3.7 2.9 8.6 0.8 5.3 1.0 3.0 4.6
7.6% 4.2% 3.8% 3.8% 4.1% 1.5% 4.4% 4.4% 5.2% 1.5% 6.3% 0.6% 4.3% 3.3% 9.7% 0.9% 6.0% 1.1% 3.4% 5.2%
6000 3000 3000 3000 3370 1000 3488 3488 4990 1000 4990 750 3488 3488 7992 750 4740 1247 3000 3000
4.86 5.40 4.86 4.86 4.62 5.85 4.86 4.86 4.03 5.85 4.86 3.31 4.68 3.60 4.68 4.68 4.86 3.47 4.41 6.68
8.5 4.7 4.3 4.3 4.5 1.7 4.9 4.9 5.9 1.7 7.1 0.7 4.8 3.7 10.9 1.0 6.7 1.3 3.9 5.8
7.6% 4.2% 3.8% 3.8% 4.1% 1.5% 4.4% 4.4% 5.2% 1.5% 6.3% 0.6% 4.3% 3.3% 9.7% 0.9% 6.0% 1.1% 3.4% 5.2%
81.4%
65781
91.3
81.5%
Percentage of Net Available Time not utilized for production (%) {PM, etc.}
Total % Allocation 51635
71.7
If Total % Allocation > 100%, loading plan exceeds capacity
Capacity Analysis Report version 4.3
Page 1
Date Revised: 8-Oct-10 Date Printed:09/26/2013
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