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ASM A utoliv S upplier M anual

ASM A utoliv S upplier M anual. Training Chapter Production Trial Runs (PTR): Process and Templates. Training Background. Production Trial Runs (PTR). Why does Autoliv require Production Trial Runs ? Verify & confirm information on actual part / process

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ASM A utoliv S upplier M anual

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  1. ASMAutoliv Supplier Manual Training Chapter Production Trial Runs (PTR): Process and Templates

  2. Training Background Production Trial Runs (PTR) Why does Autoliv require Production Trial Runs ? • Verify & confirm information on actual part / process • evaluate performance as early as possible by First Trial Runs • check against specifications (PPAP Trial Runs) • ensure PPAP samples are run under serial conditions (PPAP Trial Runs) • measure actual cycle times / capacities by Run@Rate What may happen if PTRs are not performed ? • late PPAP approval • endanger SOP • increase amount of waste / scrap

  3. Production Trial Run Participation & Documentation Production Trial Runs (PTR)

  4. Production Trial Runs (PTR) 1. Supplier First Production-Trial-Run Project Time Line Serial order and drawing „First-Off-Tool“ First- Production- Trial-Run Potential supplier internal Production-Trial-Runs to verify corrective actions. PPAP- Production- Trial-Run PPAP-Submission Run @ Rate SOP Corrective actions resulting from (First-) Production-Trials Production-Trial-Run- Requirement-Matrix: Forms / Templates First-Production- Trial-Run Trial-Run-Modules 1. Dimensional, Material, Test Result Report AIAG-Manual PPAP X X : Analysis and evaluation; “out of specification” results allowed 2. Capability Study - X Production-Trial-Run-Checklist 3. Process-Quality-Audit X 4. Capacity / Efficiency Audit Production-Trial-Capacity Report X Reviewing the PTR-modules and -templates through examples on the following pages !

  5. Example: Production Trial Runs (PTR) 1. Supplier First Production-Trial-Run • Specifications (e.g. Drawings, DRDs, Standards) • Tooling & Machine • Raw Material • Special Processes (e.g. Heat Treatment, Coating) • Inspection & Testing • Operators Cold Forming of Bolts

  6. Production Trial Runs (PTR) Module 1. Dimensional, Material, Test Result ReportExample: 1. Supplier First Production-Trial-Run Measure all dimensions and verify all drawing requirements !

  7. Production Trial Runs (PTR) Lower Spec Limit Upper Spec Limit Specified performance (voice of the customer) Actual performance (voice of the process) Lower Spec Limit Upper Spec Limit 1. Supplier First Production-Trial-Run Module 2. Capability Study- Example: The qualitycapability of a process is the comparison between the specified performance and the actual performance. Process capability is a powerful tool for predicting performance. For further explanations see AS 52 !

  8. Production Trial Runs (PTR) Module 3. Production Trial Run Checklist (1)Example: 1. Supplier First Production-Trial-Run Questionnaire

  9. Production Trial Runs (PTR) Module 3. Production Trial Run Checklist (2)Example: 1. Supplier First Production-Trial-Run Actions

  10. Production Trial Runs (PTR) Module 4. Production Trial Run Capacity ReportExample: 1. Supplier First Production-Trial-Run

  11. Production Trial Runs (PTR) 2. Supplier PPAP Production-Trial-Run Project Time Line Serial order and drawing „First-Off-Tool“ First- Production- Trial-Run Potential supplier internal Production-Trial-Runs to verify corrective actions. PPAP- Production- Trial-Run PPAP-Submission Run @ Rate SOP Corrective actions resulting from (First-) Production-Trials Production-Trial-Run- Requirement-Matrix: Forms / Templates First-Production- Trial-Run PPAP-Production- Trial-Run Trial-Run-Modules 1. Dimensional, Material, Test Result Report AIAG-Manual PPAP X X 2. Capability Study - X X 3. Process-Quality-Audit Production-Trial-Run-Checklist X 4. Capacity / Efficiency Audit Production-Trial-Capacity Report X X : Analysis and evaluation; “out of specification” results allowed : Final verification; “out of specification” results NOT allowed X

  12. Production Trial Runs (PTR) 3. Supplier Run@Rate Project Time Line Serial order and drawing „First-Off-Tool“ First- Production- Trial-Run Potential supplier internal Production-Trial-Runs to verify corrective actions. PPAP- Production- Trial-Run PPAP-Submission Run @ Rate SOP Corrective actions resulting from (First-) Production-Trials Production-Trial-Run- Requirement-Matrix: Forms / Templates First-Production- Trial-Run PPAP-Production- Trial-Run Trial-Run-Modules Run @ Rate 1. Dimensional, Material, Test Result Report AIAG-Manual PPAP X X 2. Capability Study - X X 3. Process-Quality-Audit Production-Trial-Run-Checklist X X 4. Capacity / Efficiency Audit Production-Trial-Capacity Report X X X : Analysis and evaluation; “out of specification” results allowed : Final verification; “out of specification” results NOT allowed X

  13. Production Trial Runs (PTR) Supplier Production-Trial-Run Conditions Project Time Line Serial order and drawing „First-Off-Tool“ First- Production- Trial-Run Potential supplier internal Production-Trial-Runs to verify corrective actions. PPAP- Production- Trial-Run PPAP-Submission Run @ Rate SOP Corrective actions resulting from (First-) Production-Trials First-Production- Trial-Run PPAP-Production- Trial-Run Run @ Rate Trial-Run-Conditions Full ProductionSpeed Demanded Trial-Run Condition Serial Production Equipment / Site Trial-Run Minimum Durance Not specified 1 hour 4 -8 ** Minimum Number of parts produced Not specified 300 Tbd ** All Shifts considered in Trial-Run(s) Change-Over Procedures considered Trained Operators PPAP-ed Sub-Components Control Plan Pre-Launch Serial Production *** Serial Production *** ** The trials durance and the number of parts produced must be representative of serial conditions. *** Serial Production Control Plan may be intensified (according to AS 412) upon Autoliv demand.

  14. ASM: Supplier Production-Trial-Run Standard Project Time Line Serial order and drawing „First-Off-Tool“ First- Production- Trial-Run Potential supplier internal Production-Trial-Runs to verify corrective actions. PPAP- Production- Trial-Run PPAP-Submission Run @ Rate SOP Production-Trial-Run- Requirement-Matrix: Corrective actions resulting from (First-) Production-Trials Forms / Templates First-Production- Trial-Run PPAP-Production- Trial-Run X : Analysis and evaluation; “out of specification” results allowed : Final verification; “out of specification” results NOT allowed Trial-Run-Modules Run @ Rate 1. Dimensional, Material, Test Result Report AIAG-Manual PPAP X X X 2. Capability Study - X X 3. Process-Quality-Audit* Production-Trial-Run-Checklist X X 4. Capacity / Efficiency Audit* Production-Trial-Capacity Report X X Full ProductionSpeed Serial Production Equipment / Site Demanded Trial-Run Condition; Trial-Run Minimum Durance Not specified 1 hour 4 -8 ** Trial-Run-Conditions Minimum No. of parts produced Not specified 300 Tbd ** All Shifts considered in Trial-Run(s) Change-Over Procedures considered Trained Operators PPAP-ed Sub-Components Control Plan Pre-Launch Serial Production *** Serial Production *** * : The whole, inhouse process chain must be considered for the audits. For capacity audit all potential bottle-neck processes must be investigated. ** : The trial‘s durance and the amount of parts produced must be representative of the process‘s serial conditions. ***: Serial Production Control Plan might be intensified (according to GP 12) upon Autoliv demand.

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