按預(yù)定能力生産
Run @ Rate GP-9 按預(yù)定能力生產(chǎn) I. PURPOSE 目的 The purpose of a Run @ Rate is to verify: Run @ Rate的目的是要核實： A. the supplier’s actual manufacturing process is capable of producing components that meet GM’s on-going quality requirements, as stated in the Production Part Approval Process (PPAP), at quoted tooling capacity for a specified period of time; and 供應(yīng)商的當(dāng)前制造過程是否有能力在指定的一段時間內(nèi)按聲稱的加工能力、生 產(chǎn)出符合通用汽車公司現(xiàn)行質(zhì)量要求的零部件。 如同在該零件“生產(chǎn)件批準(zhǔn)” (PPAP) 文件中所述一 致。 B. the supplier’s actual manufacturing process conforms to the manufacturing and quality plan documented by the supplier in PPAP, GP-12 and other required documentation 供應(yīng)商的當(dāng)前生產(chǎn)流程是否符合供應(yīng)商在PPAP，GP- 12或其它要求的文件中所記錄的 制 造 和 質(zhì) 量 計 劃 。 During a Run @ Rate, all production tooling is to be in place and running at full capacity, utilizing all regular production, direct and indirect, personnel and support systems. 在Run @ Rate過程中，所有的生產(chǎn)工具應(yīng)各就各位并且按最大能力運行，運用所有正 式 生產(chǎn)的 人 員 和支持系統(tǒng)，包括直接的和間接的。 SCOPE 適用范圍 All new parts require a Run @ Rate, unless exempted by the supplier quality engineer and approved by the Supplier Quality and Purchasing Directors of the procuring division. 所有新的零部件都要通過Run @ Rate，除非供應(yīng)商質(zhì)量工程師認為可以免除并且得到 采 購 部 供 應(yīng) 商質(zhì)量和采購負責(zé)人的認可。 SELECTION PROCESS 規(guī)程選擇 All new part numbers will be evaluated by GM, taking into consideration factors such as the following: history; new technology; irreversible tooling changes; and new supplier facilities. The need for the Run @ Rate will be confirmed by the Supplier Quality Engineer, and approved by the Supplier Quality and Purchasing Director(s) of the procuring division. The supplier will be notified of the need to perform a customer monitored or supplier monitored Run @ Rate as early in the Advanced Product Quality Planning Process as possible. Note: See Section VIII for Additional Requirements for Supplier monitored Run @ Rate. 所有新零件號中的零件都要經(jīng)過通用汽車公司的評審，將考慮到如下的一些因素： 生產(chǎn)歷史，新技術(shù)不能回復(fù)的模具更改，以及新的生產(chǎn)工廠等等。進行Run@Rate的 必要性由供應(yīng)商質(zhì)量工程師確認，并且得到采購部門的供應(yīng)商質(zhì)量及采購負責(zé)人的 認可。供應(yīng)商將在前期產(chǎn)品質(zhì)量計劃(APQP)規(guī)程中盡早被通知是否要作一次用戶監(jiān) 督或由供應(yīng)商自行監(jiān)督的Run @ Rate。 注：見第VIII節(jié)中有關(guān)于由供應(yīng)商自行監(jiān)督下的Run @ Rate R的附加要求。 GENERAL INFORMATION 概述 A. DURATION OF RUN@RATE Run @ Rate的周期 The number of components to be produced during the Run @ Rate should be sufficient to demonstrate manufacturing process capability and should be predetermined by the supplier and the procuring division’s Supplier Quality Engineer(s). Factors such as product complexity, shelf life, storage, cost and single shift vs. multiple shift operations are taken into consideration in determining the length of the Run @ Rate. The default length of the Run @ Rate is one day of the customer’s daily production requirement at full acceleration. 在Run@Rate過程中所生產(chǎn)的零部件的數(shù)量要足以表明其所具備的生產(chǎn)能力，并 且由供應(yīng)商和采購部門的質(zhì)量工程師們共同預(yù)先商定。諸如產(chǎn)品復(fù)雜程度，有 效期，貯存，費用，單班運作或多班輪 作等等，都是影響Run@Rate時間長短應(yīng)考慮的因素。Run@Rate的默認周期是用 戶滿負荷生產(chǎn)時一天的需求量。 TIMING OF RUN@RATE Run @ Rate的開始時間 The Run @ Rate should be performed after the supplier has attained an acceptable PPAP submission and prior to start of production acceleration. Although encouraged to be performed as early as possible, a key consideration in establishing the Run @ Rate date is the stability of the design. The exact date should be predetermined by the procuring division and the supplier. 供應(yīng)商必須在獲得PPAP生產(chǎn)件批準(zhǔn)后及在開始加速生產(chǎn)之前進行Run@Rate。盡 管越早進行越好但是進行Run@Rate的關(guān)鍵考慮因素是該零件設(shè)計的確定性。確 切的日期應(yīng)由采購部門和供應(yīng)商共同確定。 B. REQUIRED PARTICIPATION 要求參加的人員 1. Customer Monitored - 用戶監(jiān)督 Customer - A representative from the procuring division is to be present for the entire Run @ Rate. No portion of the Run @ Rate is to be performed without representation of the procuring division, without prior approval. The lead GM representative typically will be the Supplier Quality Engineer, with participation of the Buyer and/or Release Engineer upon request. Supplier - The lead supplier representative is to be the project manager or manager appointee. 用戶－－采購部門的一個代表到現(xiàn)場監(jiān)督整個生產(chǎn)過程。沒有預(yù)先的許可， 沒有代表到場，不得進行任何的操作，GM方面的首席代表是供應(yīng)商質(zhì)量工程 師。如有需要，采購員和產(chǎn)品放行工程師也可能被邀參加。 供應(yīng)商－－供應(yīng)方的首席代表應(yīng)是項目經(jīng)理或是該項目經(jīng)理指定的代表。 2. Supplier Monitored - 供應(yīng)商 監(jiān) 督 The lead supplier representative is to be the project manager or manager appointee. 供應(yīng)方的首席代表應(yīng)是項目經(jīng)理或其指定的代表 Note: Equipment and/or subcontractors may be asked to participate. 注：設(shè)備制造商和分包商也可能被要求參加。 C. SUPPLIER PREPARTATION FOR RUN@RATE 供應(yīng)商為Run @ Rate所作的準(zhǔn)備 To make effective use of time, the supplier should conduct a practice Run @ Rate and/or production simulations, as well as complete as much of the Run @ Rate Worksheet (Attachment B), before the official Run @ Rate is conducted. 為了能有效地利用時間，在正式的Run@Rate進行之前，供應(yīng)商應(yīng)作一次演習(xí)或 相應(yīng)的模擬生產(chǎn)，并完成工作表 (附錄B) 上所規(guī)定的盡可能多的項目和所有問答。 D. INVENTORYE. 存貨 If parts are produced ahead of production schedules, the supplier will hold all parts produced until authorized to ship. The supplier will ensure that sufficient production containers and packaging are available to prevent part damage. 如果零件的制造發(fā)生在總裝廠需要之前，供應(yīng)商應(yīng)保存全部的零件直到允許裝 運。供應(yīng)商應(yīng)保證有足夠的生產(chǎn)用裝運箱和合適的成品包裝以防止零部件的損 壞。 IV. RUN@RATE REVIEW CONTENT Run @ Rate檢查內(nèi)容 The Run @ Rate will verify that the results of the supplier’s actual manufacturing process meet customer requirements for on-going quality, as stated in PPAP, and quoted tooling capacity. Also, it will verify that the supplier’s actual process is to plan, as documented in PPAP, GP-12 and the other documentation listed below. Run@Rate的目的是要核實供應(yīng)商的實際制造過程是否符合現(xiàn)行質(zhì)量要求(如在PPAP 文件中所說的)以及報價所稱的工裝能力，并且供應(yīng)商實際生產(chǎn)過程是否按照已訂 的計劃，正如在PPAP、GP12及下列其它文件中所述的。 During the Run @ Rate, the following will be reviewed: documentation; the manufacturing process and results; part quality requirements and results; sub-supplier requirements and Run @ Rate results; and packaging. 在Run@Rate過程中，檢查以下一些項目：文件，制造工藝和其結(jié)果，零件質(zhì)量要求 和其結(jié)果，對分供方的要求及其Run @ Rate 的 結(jié) 果，還有包裝和搬運。 A. DOCUMENTATION : At the time of the Run@Rate , the following support documentation should be available for review: 文件 : 在作 Run @ Rate審核時，應(yīng)出具下列證明性文件以備查閱。 1. PPAP package including : PPAP 文件包括: a) Process flow diagram 過程流程 b) Process control plan, with reaction plan 具有反應(yīng)計劃的過程控制計劃 c) DFMEA / PFMEA 設(shè)計/過程失效模式及后果分析 d) Master part(s) 標(biāo)樣 2. GP-12( Pre-launch ) control plan GP-12初期生產(chǎn)次品遏制的控制計劃 3. Tool capacity information 工 裝 能 力 情況 4. Operator/inspection instruction 操作 /檢驗指導(dǎo)書 5. Prototype / pilot concerns (PR/R’s) 樣件/試生產(chǎn)時發(fā)生的問題(如PR/R) 6. Sub- contractor control / capacity data 分供方控制/能力數(shù)據(jù) 7. Sub-contractor material schedules and transportation 分供應(yīng)商材料（含零件）生產(chǎn)計劃及運輸 8. Packaging / labeling plan 包裝/ 標(biāo)記計劃 9. Acceleration plan 生產(chǎn)加速計劃 Note : All documentation must be complete and correct 注: 所有文件都應(yīng)完備及正確。 B. MANUFACTURING PROCESS – ACTUAL TO PLAN 制造過程– 實際相對于計劃 1. The product is being manufactured at the production site using the production tooling, gaging, process, materials, operators, environment, and process settings. 產(chǎn)品應(yīng)在生產(chǎn)現(xiàn)場用正式生產(chǎn)的工裝、測量系統(tǒng)、工藝、材料、操作人員、 環(huán)境和過程設(shè)定來進行生產(chǎn)。 2. The actual process flow agrees with the process flow diagram, as documented in PPAP. 實際生產(chǎn)流程應(yīng)與PPAP 文件中的流程圖相同。 3. Operator instructions/visual aids are available and adhered to at each work station. 應(yīng)將操作指導(dǎo)書/目視參考圖表置于相應(yīng)的每個工作崗位。 4. All in-process documents, such as process control charts, are in place at the time of the Run @ Rate. The documentation is utilized to drive a defined reaction plan and corrective action process. 在進行Run@Rate時，所有過程文件都應(yīng)在工位上，如過程控制計劃。這些文 件應(yīng)用于實施規(guī)定的反應(yīng)計劃和糾正措施。 5. Production boundary samples, when required, are available at required work stations. 當(dāng)需要時，在需要的工位上應(yīng)擁有邊際樣品。 6. Maintenance plans are in place; repair and maintenance parts are available; and there is planned downtime for preventative maintenance. 應(yīng)具備保養(yǎng)計劃和用于維修和保養(yǎng)的備件以及進行預(yù)防性維修保養(yǎng)的停機計 劃。 Note: All of the preceding requirements must be met to pass the Run @ Rate. 注：上述所有要求都須合格才能通過 Run @ Rate。 C. MANUFACTURING CAPACITY RESULTS 制造能力結(jié)果 The following will be verified while the process is running. 在進 行 生產(chǎn)時, 要核實以下內(nèi)容： 1. Net output from each operation can support quoted capacity. 每 道 工 序的凈產(chǎn)量與報價生產(chǎn) 能 力相符。 2. During the Run @ Rate, the tooling must meet the quoted up time requirements (net vs. gross quoted output). Any unexpected downtime must be documented and corrective action taken. 在按預(yù)定能 力生產(chǎn)時 ,工 裝 應(yīng)滿 足報 價所 要求 的開機 時間要求(報 價凈產(chǎn)量和標(biāo)稱毛產(chǎn)量)。 記下任何意外的停工時間和要求的改進措施計劃。 3. All line changeovers, if any, can be performed within the quoted tooling capacity requirements. 所有在線工裝的更換應(yīng)在報價工裝能力要求范圍內(nèi)進行。 4. The net through-put of good p...
按預(yù)定能力生産