PDR Date:

Vehicle / MY:
Commodity:
Customer Plant Type:
Cust. Plant Country:
Customer Plant Name:
Plant Code:

Supplier:
Supplier Code:
Sup. Mfg. Location:

Square Color Key

(Where Data
Originates)

Supplier

Capacity Database (FCA US)

SQE

Contract (FCA Italy(

Contract

Calculated (Not Manual Input)

Part Information

PRE-PDR DATA

Part Number

Part Description

Contract Capacity (Daily

Tool Capacity)

Annual Capacity

Capacity Planning Volume

Annual Projected Volume

Contract Capacity (Daily Tool

Capacity) 1
1000

Vehicle / Model 2

Contract Capacity (Daily

Tool Capacity) 2

Are these parts included in a Common Process Group (CPG)?

If yes, input the CPG Daily Capacity here:
Is this a Shared Line?
Are these parts used on other vehicles?

Yes

Part Number

Part Description

0
0
0
0
0
0

0
0
0
0
0
0

Vehicle / Model 1
JC 2015

Vehicle / Model 3

Contract Capacity (Daily

Tool Capacity) 3

Total Additional
Capacity
1000
0
0
0
0
0

Include Total Additional Capacity in calculations?

PROCESS INFORMATION
PROCESS
Process #
1

Next Process(es)
Process Description
#
2
fundicion

OPERATING PATTERN
Shifts /
Day
3
2
2

Shifts / Week
15
10
10

Hours /
Shift
8
10
10

Working Days /
Week
5
5
5

DOWNTIME
Scheduled Breaks / Lunch
(min/shift)
50
50
50

Changeovers (min/shift)

Planned Maintenance (min/shift)

20
10
0

15
15
15

Est. Unplanned Downtime

(min/shift)
40
30
15

Time Scheduled for Other Parts /

Customers (min/shift)
120
0
0

Ideal Cycle Time

(seconds)
30
50
65

Fraction of Total Capacity

Required for this Process Step
1
1
1

Part Number

PDR RESULTS

PROCESS
Next Process(es)
Process #
Process Description
#
1
2
fundicion
2
0
3
0
4
0
5
0
6
0
7
0
8
0
9
0
10
0
11
0
12
0
13
0
14
0
15
0

Part Number

Actual Downtime (min)

0
0
0
0
0
0
0
0
0
0
0
0
0
0

PDR Start Time (24h

format)
9:00
9:30
10:30

PDR End Time (24h format)

Planned

Unplanned

Total Parts Attempted

12:43
15:12
17:29

40
40
40

0
11
0

376
369
352

PDR End Time (24h format)

Planned

Total Good Parts

Produced
369
352
350

40
51
40
0
0
0
0
0
0
0
0
0
0
0
0

0
PROCESS

Next Process(es)
Process #
Process Description
#
1
2
fundicion
2
0
3
0
4
0
5
0
6
0
7
0
8
0
9
0
10
0
11
0
12
0
13
0
14
0
15
0

Actual Downtime (min)

PDR Start Time (24h
format)
0
0
0
0
0
0
0
0
0
0
0
0
0
0

Unplanned

Total Parts Attempted

Total Good Parts

Produced
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

Part Number

PDR RESULTS

PROCESS
Next Process(es)
Process #
Process Description
#
1
2
fundicion
2
0
3
0
4
0
5
0
6
0
7
0
8
0
9
0
10
0
11
0
12
0
13
0
14
0
15
0

Part Number

Actual Downtime (min)

PDR Start Time (24h
format)

PDR End Time (24h format)

Planned

Unplanned

Total Parts Attempted

Total Good Parts

Produced
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0
0
0
0
0
0

0
PROCESS

Next Process(es)
Process #
Process Description
#
1
2
fundicion
2
0
3
0
4
0
5
0
6
0
7
0
8
0
9
0
10
0
11
0
12
0
13
0
14
0
15
0

Actual Downtime (min)

PDR Start Time (24h
format)
0
0
0
0
0
0
0
0
0
0
0
0
0
0

PDR End Time (24h format)

Planned

Unplanned

Total Parts Attempted

Total Good Parts

Produced
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

Part Number

0
PROCESS

PDR RESULTS

Process #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

Next Process(es)
Process Description
#
2
fundicion
0
0
0
0
0
0
0
0
0
0
0
0
0
0

Part Number

Actual Downtime (min)

PDR Start Time (24h
format)

PDR End Time (24h format)

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

Unplanned

Total Parts Attempted

Total Good Parts

Produced
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0
0
0
0
0
0

0
PROCESS

Process #

Planned

Next Process(es)
Process Description
#
2
fundicion
0
0
0
0
0
0
0
0
0
0
0
0
0
0

Actual Downtime (min)

PDR Start Time (24h
format)
0
0
0
0
0
0
0
0
0
0
0
0
0
0

PDR End Time (24h format)

Planned

Unplanned

Total Parts Attempted

Total Good Parts

Produced
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

PRODUCTION DEMONSTRATION RUN

NAFTA
Part Number(s):

PDR STAGE

Part Description(s):

Vehicle / MY:

Commodity:
Supplier
Code:

PA READINESS EVALUATION

Supplier Manufacturing Location:

PA PROCESS EVALUATION

Date

PDR STAGE 1

Date
BLOCK
DIAGRAM

OPEN ISSUES

Date

DATA SHEET

CAPACITY ANALYSIS

SCORING

CAPABILITY
SUMMARY

1 - PURCHASE ORDER

PA READINESS
EVALUATION SCORE*

CONSTRAINT
ANALYSIS

CAPABILITY DATA

3 - RESULTS

Tooling Status & Operating Conditions Capacity Verification

A
5

Spare / Service Parts

Operator Skill Level

Sub-tier Capacity

Required
Capacity
0

Process
fundicion
0
0
0
0
0
0
0
0
0
0
0
0
0
0

PPAP / FULL APPROVAL

PDR STAGE 2
Date

PDR SCORE

*The Readiness Evaluation should have a score of 3 or higher before running the PDR Stage 1
or Corrective Actions have been implemented to bring score to 3 or higher

2 - PROCESS

Contracted Capacity

R
E
L Date
E
A
S
E
T
O

5 - RESULTS

P
First Time Capability
Line Utilization
R
O
D
.
5
3
(
D
a
PProcess Performance and CapabilityConstraint Management
)

FINAL RESULTS
Actual Line
FTC %
Speed
#DIV/0!
98.1%

Required Line
Speed
0.0

4 - RESULTS

Line
Utilization %
0.0%

Avail. %

Perf. %*

OEE %

0%

#DIV/0!

#DIV/0!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!

Const.

Supplier:

DATE

ACC?
#DIV/0!

* Performance cannot exceed 100%. "Red" cells indicate an actual cycle time that is less than the "Ideal Cycle Time"; this should be modified on the Data Sheet
Sub-Component

Req'd
Capac.

Actual
Capac.

Acc

Sub-Component

Req'd
Capac.

Actual
Capac.

Acc

Sub-Component

Req'd
Capac.

Actual
Capac.

Acc

Sub-Component

Req'd
Capac.

Impact on Equipment / Tools / Human Resources if capacity increased:

10%:
25%:
50%:

SQE

SIGNATURE

DATE

SUPPLIER - QUALITY MGR.

SIGNATURE

DATE

ENGINEER

SIGNATURE

DATE

SUPPLIER - PLANT MGR.

SIGNATURE

DATE

Actual
Capac.

Acc

PDR Process Block Diagram

Part Number(s):

Part Description(s):

Vehicle / M.Y.:
Supplier:

Commodity:
Supplier Code:

Supplier Mfg.
Location:

Supplier Name
Part Number(s)
Part Description(s)
Contracted Capacity, Total

Annual:

Increased Contracted Capacity / Capacity

Planning Volume

Annual:

No. of process

Next process(es)

PRODUCTION SYSTEM

List each separate process

fundicion

OVERALL PROCESS

Shifts Per Week

Working Days Per

Week

15

15

No. of process

Next process(es)

List each separate process

fundicion

Total Downtime

Availability

40
51
40
0
0
0
0
0
0
0
0
0
0
0

0%
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!

#VALUE!

PDR
Start
Time

PDR
End
Time

9:00
9:30
10:30

12:43
15:12
17:29

Next process(es)

No. of process

Part #:

List each separate process

Next process(es)

No. of process

Part #:

List each separate process

PDR
Start
Time

PDR
End
Time

List each separate process

PDR
Start
Time

PDR
End
Time

Next process(es)

No. of process

Part #:

Next process(es)

No. of process

Part #:

List each separate process

PDR
Start
Time

PDR
End
Time

List each separate process

PDR
Start
Time

PDR
End
Time

Next process(es)

No. of process

Part #:

Next process(es)

No. of process

Part #:

List each separate process

PDR
Start
Time

PDR
End
Time

PDR SUMMARY FORM

Daily:

Daily:

NAFTA

SYSTEM AVAILABILITY (TIME)

Shifts Per Day

[=Shifts per Week /
Working Days]

Minutes Per Shift

Gross Min
Available Per Day

480

1440

Scheduled
Changeover / Tool
Break/Lunch
Changes [minutes
[minutes per day]
per day]

150

60

8
PDR STUDY RESULTS

Performance

#DIV/0!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!

Length
of
PDR
(minutes)

PDR
Total Parts
Attempted
[pcs.]

PDR
Good Parts
Produced
[pcs.]

Base Required
PDR Line Speed
(Parts/hour)

0.0

376

369

0.0

#VALUE!

PDR STUDY RESULTS

PDR Actual
Downtime [minutes]

Length
of
PDR
(minutes)

PDR
Total Parts
Attempted
[pcs.]

PDR
Good Parts
Produced
[pcs.]

40
51
40
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0
0

376
369
352
0
0
0
0
0
0
0

369
352
350
0
0
0
0
0
0
0

Base Required
PDR Line Speed
(Parts/hour)

0
0
0
0

0
0
0
0

0
0
0
0

0
0
0
0

PDR STUDY RESULTS

PDR Actual
Downtime [minutes]

Length
of
PDR
(minutes)

PDR
Total Parts
Attempted
[pcs.]

PDR
Good Parts
Produced
[pcs.]

0
0
0
0
0
0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0
0
0
0
0
0

Base Required
PDR Line Speed
(Parts/hour)

PDR STUDY RESULTS

PDR Actual
Downtime [minutes]

Length
of
PDR
(minutes)

PDR
Total Parts
Attempted
[pcs.]

PDR
Good Parts
Produced
[pcs.]

0
0
0
0
0

0
0
0
0
0

0
0
0
0
0

0
0
0
0
0

Base Required
PDR Line Speed
(Parts/hour)

0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0

PDR STUDY RESULTS

PDR Actual
Downtime [minutes]

Length
of
PDR
(minutes)

PDR
Total Parts
Attempted
[pcs.]

PDR
Good Parts
Produced
[pcs.]

0
0
0
0
0
0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0
0
0
0
0
0

Base Required
PDR Line Speed
(Parts/hour)

PDR STUDY RESULTS

PDR Actual
Downtime [minutes]

Length
of
PDR
(minutes)

PDR
Total Parts
Attempted
[pcs.]

PDR
Good Parts
Produced
[pcs.]

0
0

0
0

0
0

0
0

Base Required
PDR Line Speed
(Parts/hour)

0
0
0
0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0
0
0
0

PDR STUDY RESULTS

PDR Actual
Downtime [minutes]

Length
of
PDR
(minutes)

PDR
Total Parts
Attempted
[pcs.]

PDR
Good Parts
Produced
[pcs.]

0
0
0
0
0
0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0
0
0
0
0
0

Base Required
PDR Line Speed
(Parts/hour)

Planned
Maintenance
[minutes per day]

DY RESULTS

45

Unscheduled
Net Min Available
Downtime [minutes
Per Day
per day]

120

1065

Time Scheduled for

Other Parts /
Customers [minutes
per day]

Net minutes
available / day for
Study parts

360

705

Additional Parts/Hr
required (due to
true scrap)

Actual
PDR
Line Speed
[Parts/hour]

Actual PDR >= Required Line Speed +

Additional Req'd Parts?

PDR
FTC
(%)

0.0

#DIV/0!

#DIV/0!

98.1%

Actual
PDR
Line Speed
[Parts/hour]

Actual PDR >= Required Line Speed +

Additional Req'd Parts?

PDR
FTC
(%)

#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!

DY RESULTS

Additional Parts/Hr
required (due to
true scrap)

#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!

#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!

DY RESULTS

Additional Parts/Hr
required (due to
true scrap)

Actual
PDR
Line Speed
[Parts/hour]

Actual PDR >= Required Line Speed +

Additional Req'd Parts?

PDR
FTC
(%)

Actual
PDR
Line Speed
[Parts/hour]

Actual PDR >= Required Line Speed +

Additional Req'd Parts?

PDR
FTC
(%)

#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!

DY RESULTS
Additional Parts/Hr
required (due to
true scrap)
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!

#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!

DY RESULTS
Additional Parts/Hr
required (due to
true scrap)

Actual
PDR
Line Speed
[Parts/hour]

Actual PDR >= Required Line Speed +

Additional Req'd Parts?

PDR
FTC
(%)

Actual
PDR
Line Speed
[Parts/hour]

Actual PDR >= Required Line Speed +

Additional Req'd Parts?

PDR
FTC
(%)

#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!

DY RESULTS
Additional Parts/Hr
required (due to
true scrap)
#VALUE!
#VALUE!

#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!

DY RESULTS
Additional Parts/Hr
required (due to
true scrap)
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!

Actual
PDR
Line Speed
[Parts/hour]

Actual PDR >= Required Line Speed +

Additional Req'd Parts?

PDR
FTC
(%)

Completed by:

SYSTEM CAPACITY (UNITS)

Ideal Cycle Time

[seconds]

% Scrap

% True Scrap
(Total Loss)

Estimated
Throughput For
Study Parts Per
Day

30

1.86%

0.00%

1410

Required / Contracted
Parts Per Day

PDR Actual Scrap

[pcs.]

PDR Actual Scrap

[pcs.]

7
17
2
0
0
0
0
0
0
0

0
0
0
0
0

PDR Actual Scrap

[pcs.]

0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

PDR Actual Scrap

[pcs.]

0
0
0
0
0

0
0
0
0
0
0
0
0
0
0

PDR Actual Scrap

[pcs.]

0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

PDR Actual Scrap

[pcs.]

0
0

0
0
0
0
0
0
0
0
0
0
0
0
0

PDR Actual Scrap

[pcs.]

0
0
0
0
0
0
0
0
0
0
0
0
0
0
0

by:

Post Process Buffers

% Utilization

0.00%

RESULT: Possible
Constraint
Operation (>90%)
Are Marked [X]

Minimum

Maximum

Supplier Name
Part(s) Description
Part(s) Number

Increased Contracted Capacity / Capacity

Planning Volume

Annual:

Next operation(s)

Annual:

No. of operation

Contracted Capacity

0
0

Minutes Per Shift

List each separate SEQUENTIAL OPERATION
in the Constraint Line
Shift 1

Shift 2

Op1

600

600

Op2

600

600

Op3

600

600

Op4

600

600

Op5

600

600

No. of operation

Next operation(s)

OPERATIONS

0
0
0
0
0
0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0
0
0
0
0
0

List each separate SEQUENTIAL OPERATION

in the Constraint Line

Op1
Op2
Op3
Op4
Op5

Shifts Per Week

10
10
10
10
10

Gross Min
Available Per Day

0
0
0
0
0
0
0
0
0

1200
1200
1200
1200
1200
0
0
0
0
0
0
0
0
0

Next operation(s)

No. of operation

PRODUCTION SYSTEM

List each separate SEQUENTIAL OPERATION

in the Production Line

PDR
Start
Time

PDR
End
Time

Op1

10:30

17:29

Op2

10:30

17:29

Op3

10:30

17:29

0
0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0
0

Op4

10:30

17:29

Op5

10:30

17:29

0
0
0
0
0
0
0
0

This form to be used by the Supplier to identify a constraint operation when a process h

PDR SUMMARY FORM

Daily:
Daily:

CONSTRAINT PRODUCTION L

Minutes Per Shift

Scheduled Break/Lunch (minutes)

Shift 3

Per Day

Shift 1

Shift 2

Shift 3

1200

50

50

1200

50

50

1200

50

50

1200

50

50

1200

50

50

0
0
0
0
0
0
0

0
0
0

OPERATION AVAILABILITY (TIME)

Scheduled
Changeover / Tool
Break/Lunch
Changes [minutes
[minutes per day]
per day]

Planned
Unscheduled
Maintenance
Downtime [minutes
[minutes per day]
per day]

100
100
100
100
100
0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0
0
0
0
0
0

20
20
30
20
20
0
0
0
0
0
0
0
0
0

30
30
30
30
30
0
0
0
0
0
0
0
0
0

PDR Actual
Planned Downtime
[minutes]

PDR Actual
Unplanned
Downtime
[minutes]

Length
of
PDR
(minutes)

PDR
Total Parts
Attempted
[pcs.]

MCBF
[cycles]

PDR
Good Parts
Produced
[pcs.]

40

379.0

352

352

40

379.0

352

352

40

379.0

352

350

40

379.0

350

350

40

379.0

350

350

#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!

n when a process has been flagged as a potential constraint.

RAINT PRODUCTION LINE:

minutes)

Changeovers/Tool Changes (minutes)

Per Day

Shift 1

Shift 2

Shift 3

Per Day

100

100

100

100

100

MTTR [minutes]

Time allocated for

Net minutes
Net Min Available other PN's (FIAT,
available / day for
Per Day
Chrysler, or others)
Study parts
[minutes per day]

1050
1050
1040
1050
1050
0
0
0
0
0
0
0
0
0

1050
1050
1040
1050
1050
0
0
0
0
0
0
0
0
0

Cycle Time
[seconds]

55
55
65
50
55

PDR STUDY RESULTS

Base Required Additional Parts/Hr

PDR Line Speed
required (due to
(Parts/hour)
true scrap)

Actual
PDR
Line Speed
[Parts/hour]

Actual PDR >= Required Line Speed +

Additional Req'd Parts?

0.0

0.0

55.7

YES

0.0

0.0

55.7

YES

0.0

0.0

55.4

YES

0.0

0.0

55.4

YES

0.0

0.0

55.4

YES

#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!

Overall FTC

Date:
Completed by:

Planned Maintenance (minutes)

Unschedu

Shift 1

Shift 2

Shift 3

Per Day

Shift 1

10

10

20

15

10

10

20

15

15

15

30

15

10

10

20

15

10

10

20

15

0
0
0
0
0
0
0

0
0
0

OPERATION CAPACITY (UNITS)

Buffer Before
Operation

Buffer After
Operation

% True Scrap
(Total Loss)

Estimated
Throughput For
Study Parts Per
Day

#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!

0
0
0
0
0
0
0
0
0
0
0
0
0
0

1145
1145
960
1260
1145
0
0
0
0
0
0
0
0
0

#VALUE!

Availability

Performance

% Scrap

0.00%
0.00%
0.57%
0.00%
0.00%

PDR
FTC
(%)

PDR Actual Scrap

[pcs.]

Overall Equipment Effectiv

(OEE)

100.0%

100.0%

85.1%

100.0%

100.0%

85.1%

99.4%

100.0%

100.6%

100.0%

100.0%

77.0%

100.0%

100.0%

84.7%

85.1%
85.1%
100.0%
77.0%
84.7%

#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!

#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!

#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!

#VALUE!

#VALUE!

#VALUE!

#VALUE!

#VALUE!

#VALUE!

99.4%

Unscheduled Downtime (minutes)

Shift 2

Shift 3

Per Day

15

30

15

30

15

30

15

30

15

30
0
0
0
0
0
0
0

0
0
0

Contracted Parts Per

Day (Includes Spare
Parts), Daily Tooling
Capacity, or CPG

l Equipment Effectiveness
(OEE)

% Utilization

RESULT: Possible
Constraint
Operation (>90%)
Are Marked [X]

0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%

#NAME?

0.00%

#NAME?

True Scrap of Production

Lines DOWNSTREAM to
Constraint

#NAME?
#NAME?
#NAME?
#NAME?
#NAME?
#NAME?
#NAME?
#NAME?
#NAME?
#NAME?

85.1%
85.1%
100.0%
77.0%
84.7%
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!

Item

Guidelines

NAFTA

The contracted capacity (Daily Tooling Capacity) shall be enough to meet Customer requirements. If
the Increased Contract Capacity (FIAT) or Capacity Planning Volume (CPV) exceeds the contract
capacity, it shall be temporary and the Supplier shall be able to meet these requirements through
standard means (e.g., overtime, weekend runs, etc.). When running higher volumes, the Supplier
shall still be able to do all required maintenance activities, quality controls, etc.

1A

Contracted Capacity

1B

Spare / Service Parts

The Supplier's volumes of parts intended for Spare Parts (After Sales) shall be considered into the
evaluation of Supplier's production capacity. The Supplier shall meet the Required Line Speed with
the Spare Parts included.

2A

Tooling Status & Operating

Conditions

The PDR shall be run on production tooling; with production tooling, equipment, & gages; and in
production facilities. Operating conditions shall mimic those of regular production, with required
breaks, maintenance, etc. performed.

2B

Operator Skill Level

3A

Capacity Verification

3B

Sub-tier Capacity

The Supplier shall perform PDR (and other Process Audit) activities on their sub-tier suppliers and
components (see 2E on the Process Audit tool). Verify that all sub-tier suppliers are able to provide
the required number of parts per day.

Operators used in the PDR shall be fully trained on the process, and be intended production
operators.
The throughput of the Final process or operation (and also that of the Constraint process or
operation, if applicable) must meet or exceed the Required Line Speed.

4A

First Time Capability

The Supplier shall demonstrate a First Time Capability (FTC) of 90% or greater. For multiple
production lines, tools, and/or cavities, FTC shall each be calculated separately. Rework and repair
are NOT counted in the number of acceptable parts.

4B

Process Performance and

Capability

The parts shall meet all Performance and Capability requirements, as shown on the "Performance Capability Reqs." chart.

5A

Line Utilization

5B

Constraint Management

Minimal/minor Initial design Customer impac

Carryover
design

The Supplier's volumes of parts intended for Spare Parts (After Sales) shall be considered into the eval

Past
successful
launches

Supplier awareTooling Kick-ofKey program de

Supplier has aSupplier is "g Supplier meetin
Part or related Part or related part has low historical warranty (no field actions)
Complete
and
Supplier
acceptable
aware
of
list of special
requirements
characteristic
and can meet
s, good plan
them
for
management
Supplier

New
Past launch Some significDesign incomple
of Incomplete
Appearance paaware
Supplier awareTooling Kick-o One or more keSupplier has aSupplier is "y Supplier not me
Part or related Part or related part has some historical warranty (no field actions)
Chrysler
/ Capacity
commodity
issues
or
requirements list,
plan
FIAT design increase/new for
current limited
but
issues needs
responsible tooling
supplier
resources
exist
to improvement
location
(max. 3)
meeting them (max. 3)
(max. 3)
other
(see other
(see other
(see other
(see other
(see other
(see other
(see other
(see
other
(see other
(see other
(see other
(see other
(see other
(see other
(see other
(see
Comments) Comments) Comments) Comments) Comments) Comments) Comments) Comments)
Comments) Comments) Comments) Comments) Comments) Comments) Comments) Comments)

Review the * Minimum Review the * Minimum

Quality
Quality
Requireme
Requireme
nts (SQE)
nts (SQE)
*
*
Statement
Manufactu
of
ring
Requireme
Feasibility
nts (Sup.)
Assessmen
t (Sup.)

Line Utilization shall be 90% or less for all production lines. Otherwise, the Constraint Analysis shall
be performed with appropriate contingency (Risk Mitigation) plans in place.
If a constraint is identified, the Supplier shall demonstrate correct management techniques to
ensure the constraint is optimized. Part loading and unloading responsibility shall be assigned and
itemized in operator instructions, and buffer/WIP quantities before and after identified and
managed.

PDR SUMMARY FORM

PCPA - aprile 2011

Current
No
new
supplier
technology
location

Pagina 58 di 91

PDR SUMMARY FORM

AUDITOR REMARKS (SQE)

BOX

SCORE

Supplier _________________
(Name Signature)

OPEN ISSUE

CORRECTIVE ACTION

RESPONSIBLE

DEPARTMENT

SQE_____________________
(Name Signature)

AUDITOR REMARKS (SQE)

OPEN DATE

Supplier _________________
(Name Signature)

TARGET DATE

ACTUAL DATE

STATUS

SQE_____________________
(Name Signature)

PDR SUMMARY FORM

Score

Classification

Advance Quality D

JOB STOPPER

Very late to required milestone and will cause othe

required milestone/vehicle launch
Risk Mitigation Plan does not exist
Certain to cause delay in milestone/vehicle launch
Has resulted in critical build/launch issues and cer
production (yardholds, PRIs, field campaigns, etc.)
Total lack of quality system or systemic control

JOB STOPPER
RISK

Late to required milestone and may cause other d

milestone/vehicle launch
Risk Mitigation Plan exists but is not acceptable or
milestone
May cause delay in milestone/vehicle launch
Has resulted in moderate build/launch issues or m
production (yardholds, PRIs, field campaigns, etc.)
Chronic quality system or systemic control failures

MODERATE RISK

Potentially late to required milestone

Risk Mitigation Plan exists and is acceptable
Moderate Risk to milestone/vehicle launch
May result in moderate quality spills in production
characteristics
Non-chronic quality system or systemic control fai

LOW RISK

Progressing according to required milestone timin

Low Risk to milestone/vehicle launch
Isolated documentation issue

IMPLEMENTED
ACTIVITY

NA

NOT APPLICABLE

NV

NOT EVALUATED

Complete and approved

ance Quality Definition

ne and will cause other required deliverables to be late to their

nch
t exist
lestone/vehicle launch
launch issues and certain to cause critical quality spills in
eld campaigns, etc.)
or systemic control

nd may cause other deliverables to be late to their required

ut is not acceptable or requires unrealistic timing to meet

e/vehicle launch
ild/launch issues or may cause critical quality spills in
eld campaigns, etc.)
stemic control failures

milestone
nd is acceptable
vehicle launch
ity spills in production not impacting critical / safety

or systemic control failures

uired milestone timing

e launch
e

Item does not apply for this audit

Item was not evaluated at this audit; will be evaluated at a later date.

Current Production Definition

Has resulted in critical quality spills (yardholds, PRIs, field campaigns, etc.)
Corrective Action Plan does not exist.
Results in process producing defective material with no adequate controls in place
Total lack of quality system or systemic control

Has resulted in moderate quality spills (NCTs, Bills, etc.) or may result in critical quality
spills in the future
Corrective Action Plan exists but is not acceptable; needs containment action
Can result in process producing defective material with inadequate controls in place
Chronic quality system or systemic control failures

May result in moderate quality spills in the future not impacting critical / safety
characteristics
Corrective Action Plan exists and is acceptable
Can result in process becoming unstable (may need additional controls added)
Non-chronic quality system or systemic control failures

Low risk for quality spills

Corrective Action Plan / corrective actions initially implemented; verification on-going
Continuous improvement activities ongoing
Isolated documentation issue

Complete and approved

Best practice
not apply for this audit

his audit; will be evaluated at a later date.

Supplier Name
Part(s) Description
Part(s) Number
Quantity of Parts Measured

Char. #

Quantity of Parts Accepted

Class.

Characteristic Description

PDR SUMMARY FORM

Initial Process Study / Pro

Specification and Tolerance

Attribute / Variable

Process or
Machine Char?

PDR SUMMARY FORM

1.33

1.67

Initial Process Study / Process Performance and Capability

All parts OK? (Y/N)

Required PP / PPK

PP

PPK
#DIV/0!

Attribute

Variable

Process

Machine

Yes

No

Date:
Completed by:

bility
Required CP / CPK

CP

CPK
#DIV/0!

Required CM / CMK

CM

CMK

Gage R&R %

#DIV/0!

0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%

Acceptable? (Y/N)

0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%
0.00%

Char #

Classification

Characteristic Description

PDR SUMMARY FORM

REGULATORY - Safety <S> / Report

REGULATORY - Emissions <E>
REGULATORY - Homologation <H>
CRITICAL - Diamond <D> / 1D
CRITICAL - Stoplight
CAPABILITY - Qh
General / Non-critical

Specification

USL

LSL

Attribute/Variable

Attribute
Variable

Process or Machine?

Process
Machine

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

55

56

57

58

59

60

61

62

63

64

65

66

67

68

69

70

71

72

73

74

75

76

77

78

79

80

81

82

83

84

85

86

87

88

89

90

91

92

93

94

95

96

97

98

99

100

Gage R&R1

Gage R&R2

Gage R&R3

Gage R&R4

Mean

#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!

2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25

Range

#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!

1.128
1.693
2.059
2.326
2.534
2.704
2.847
2.97
3.078
3.173
3.258
3.336
3.407
3.472
3.532
3.588
3.64
3.689
3.735
3.778
3.819
3.858
3.895
3.931

Subgroup Size

Avg. Range

Std. Dev.

#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!

d2

#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A

Std. Dev. Est.

(Ravg/d2)

#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A

Dimensionally
Correct?

#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!

PP

PPK

#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!

CP

CPK

#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!

CM

CMK

#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!

Ppu / Cmu
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!

Ppl / Cml
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!

Cpu
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!

Cpl
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!

Date

Revision Number
21-Dec-12

2.0

12-Feb-13

2.1

19-Sep-13

2.2

14-Mar-14

2.3

14-Aug-14

2.4

05-Sep-14

2.5

05-Dec-14

2.6

27-Feb-15

2.7

Revision Description
Renamed tabs, added Data Sheet, new PDR Summary form, revised Capacity Analysis and Co
Analysis, added Capability Requirements, revised Open Issues (added Open Date and Actual D
columns), added Requirements tab
Fixed truescrap function for when scrap is zero

Added "Department" column and conditional formatting to Status column on Open Issues, add
to allow sector logo to switch when different sectors are chosen on the PDR Summary sheet; a
comments to cells on Data Sheet, fixed bug on Capacity Analysis when manually altering cell
of PDR Summary changed to match other tools
Fixed bug on PDR Summary, eliminated rounding errors on capacity analysis.

Revised FIAT Industrial logo to CNH Industrial, added logos to remaining sheets, added "Custo
Plant" and "Customer Plant Loc" to data sheet, keyed assumed working days to "Customer Pla

Removed assumed working days (made manual entry for annual volumes), removed CNH Ind
added Maserati
Added OEE calculations (Overall Equipment Effectiveness), along with Availability % and Perfo
%
Added Customer plant codes, names, and locations
Split Actual Downtime in the PDR Results section into Planned and Unplanned downtime
Revised method of determining additional parts required due to true scrap.
Unprotected Operating Pattern cells
Revised scoring (Moderate Issue to Moderate Risk; No Risk to Low Risk)
Plant name and code are manual entry
Revised logo to FCA logo
Added comments to Open Issues sheet
Revised "Planned Cycle Time" to "Ideal Cycle Time" and clarified comments.
Revised comments for downtime factors
Added note and conditional formatting for when Performance calculation exceeds 100%
Changed sector names to region names
Updated capability requirements to match global commonized standards
Fixed error on Capacity Analysis with Annual contracted capacities

Sheet
All
Capacity Analysis
Data Sheet, Open Issues, PDR Summary,
Capacity Analysis

All

PDR Summary, Capacity Analysis,

Constraint Analysis
Data Sheet
Data Sheet
Capacity Analysis
Data Sheet
Scoring
Data Sheet
All
Open Issues
Data Sheet, Capacity Analysis
Data Sheet
PDR Summary
PDR Summary
Performance - Capability Reqs.
Capacity Analysis