Capacity Planning

A. New Model Required OEE -

A1) Supplier & Part Information A2) Capacity Requirements APW MPW A3) Key Contacts
Supplier Name Program Code <PA> Requirements Name Phone # Email
Location/Site Code Model Year STA Site Engineer
Part Name Source of Capacity Requirements Supplier Lead
Part Number Date of Study Ford Buyer
Capacity Requirements Supplier to demonstrate APW of parts per week operating no more than 5 days per week
Supplier to demonstrate MPW of parts per week operating no more than 6 days per week
A4) Planned Departmental Operating Process 1 Process 2 Process 3 Process 4 Process 5 Process 6 Process 7 Process 8
Pattern & Net Available Time 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
A Process description (in value stream order)
B Days / Week
C Shifts / Day
D Total Hours / Shift
E Contractual Planned Downtime - lunch, breaks, etc.
(minutes/shift)
F Allocation Percent (enter 100 for dedicated)
G Net Available Time (hours / week) [B*C*(D-(E/60))*F] - - - - - - - - - - - - - - - -
G1 Planned Minutes per Changeover (into this part #)
G2 Planned Changeover Frequency / Week (into this part #)

A5) Required Good Parts / Week 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
H Percent of parts scrapped
J Req'd Good Parts / Week to Support Next Process
[Process 1 Req'd Parts = Process 2 Req'd Parts /
- - - - - - - - - - - - - - - -
(100% - Process 2 Scrap%)] Avg. Weekly Max Weekly
Required Incoming Parts for - -

A6) Required OEE 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
K Ideal Cycle Time per Tool or Machine (sec/cycle)
L # of Tools or Machines in parallel
M # of identical parts produced per Tool or Machine Cycle
N Net Ideal Cycle Time (sec/part) [K / (L*M)] - - - - - - - - - - - - - - - -
P Theoretical Parts per week at 100% OEE [G x 3600 / N] - - - - - - - - - - - - - - - -

Q Required OEE [J / P] - - - - - - - - - - - - - - - -
R Percent of parts reworked (re-run through process)
S 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

Enter any other assumptions for clarification

A7) Shared Process - Total Allocation Plan - - - - - - - -

U 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 Supplier Name
W Supplier Location
X Site Code for Surrogate Process
Y Surrogate Customer & Program Reference (~Ford P221)
List reference Surrogate Process (~Stamping Press #12)
Z Average Surrogate OEE - - - - - - - -
Enter any other assumptions for clarification
(Part Number, Annual Volume, Operating Pattern, etc.)

B2) Process Specific Weekly Part Estimate [P * Z] - - - - - - - - - - - - - - - -

C. Gap Analysis - Required OEE vs. Demonstrated OEE; Predicted Good Parts / Week
Process Description
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 APW Result MPW Result

Demonstrated OEE > Required OEE? (Is Z > Q?)

Predicted Good Parts / Week Req'd OEE at APW Req'd OEE at MPW Surrogate Demonstrated OEE

APW MPW
1200.0%

1000.0%
OEE %

NOTES 800.0%

600.0%

400.0%

200.0%

0.0%

SUPPLIER OPERATION MANAGEMENT APPROVAL FOR STA USE

Insert Version 4.3

Authorized Representative Name / Title Signat

Email Site Engineer STA LL6 Supervisor
Approved

Rejected
ure
© 2010 Ford Motor Company
Signature Date Image Phone Number Signature/Date Signature/Date

from
file

Capacity Analysis Report version 4.3 Page 1 Date Revised: 8-Oct-10

Date Printed:11/04/2019
 Phase 0 PPAP (Run @ Rate)
A. New Model Required OEE - 1 1
Select for
A1) Supplier & Part Information A2) Capacity Requirements APW MPW Analysis A3) Key Contacts
Supplier Name Program Code <PA> Requirements ● Name Phone # Email
Location/Site Code Model Year Revised Requirements STA Site Engineer
Part Name Source of Capacity Requirements Supplier Lead
Part Number Date of Study GCP/MCPV Ford Buyer
Capacity Requirements Supplier to demonstrate APW of parts per week operating no more than 5 days per week
Supplier to demonstrate MPW of parts per week operating no more than 6 days per week
A4) Planned Departmental Operating Process 1 Process 2 Process 3 Process 4 Process 5 Process 6 Process 7 Process 8
Pattern & Net Available Time 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
A Process description (in value stream order)
B Days / Week
C Shifts / Day
D Total Hours / Shift
E Contractual Planned Downtime - lunch, breaks, etc.
(minutes/shift)
F Allocation Percent (enter 100 for dedicated)
G Net Available Time (hours / week) [B*C*(D-(E/60))*F] - - - - - - - - - - - - - - - -
G1 Planned Minutes per Changeover (into this part #)
G2 Planned Changeover Frequency / Week (into this part #)

A5) Required Good Parts / Week 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
H Percent of parts scrapped
J Req'd Good Parts / Week to Support Next Process
- - - - - - - - - - - - - - - -
[Process 1 Req'd Parts = Process 2 Req'd Parts /
(100% - Process 2 Scrap%)] Avg. Weekly Max Weekly
Required Incoming Parts for - -

A6) Required OEE 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
K Ideal Cycle Time per Tool or Machine (sec/cycle)
L # of Tools or Machines in parallel
M # of identical parts produced per Tool or Machine Cycle
N Net Ideal Cycle Time (sec/part) [K / (L*M)] - - - - - - - - - - - - - - - -
P Theoretical Parts per week at 100% OEE [G x 3600 / N] - - - - - - - - - - - - - - - -
Q Required OEE [J / P] - - - - - - - - - - - - - - - -
R Percent of parts reworked (re-run through process)
S 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

Enter any other assumptions for clarification

A7) Shared Process - Total Allocation Plan - - - - - - - -

U Enter Total % Allocation from "Shared - Loading Plan" Tab

B. Supplier Demonstrated OEE - Phase 0 PPAP (Run @ Rate)

B1) Equipment Availability - - - - - - - -

V Total Available Time (ACTUAL changeover NOT included for

Shared) (minutes)
W Planned Downtime - lunches/breaks/mtgs. (minutes)
X Net Available Time (minutes) [V - W] - - - - - - - -
Y Shared Equip Changeover Time ACTUAL (minutes) NOT REQUIRED NOT REQUIRED NOT REQUIRED NOT REQUIRED NOT REQUIRED NOT REQUIRED NOT REQUIRED NOT REQUIRED
Z Shared Equip Changeover Time Weekly Scaled (minutes)
- - - - - - - -
[(G1 * G2 * X) / (60*G - (G1 * G2))]
AB Observed Unplanned Downtime (minutes)
AC Operating Time (minutes) [X - AB] - - - - - - - -
AD Equipment Availability [(X - AB) / (X + Z) * 100] - - - - - - - -
B2) Performance Efficiency
AE Total Parts Run (Good, Scrapped, & Reworked)
AF Planned Net Ideal Cycle Time (seconds/part) [N or Other] - - - - - - - -
AG Performance Efficiency (AE * AF / AC) - - - - - - - -
AH "Availability" and/or "Performance Efficiency" Losses Not
- - - - - - - -
Captured (minutes) [AC - (AE * AF)]

B3) Quality Rate # % # % # % # % # % # % # % # %

AJ # Parts Scrapped - - - - - - - -
AK # Parts Reworked - - - - - - - -
AL Quality Rate [(AE - AJ - AK) / AE] - - - - - - - -
B4) Overall Equipment Effectiveness (OEE)
AM Phase 0 OEE [AD * AG * AL] - - - - - - - -
B5) Process Specific Weekly Part Estimate [P * AM] - - - - - - - - - - - - - - - -
B6) Observed Average Cycle Time (sec/cycle)
C. Gap Analysis - Required OEE vs. Demonstrated OEE; Predicted Good Parts / Week
Process Description
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 APW Result MPW Result

Demonstrated OEE > Required OEE? (Is AM > Q?)

Predicted Good Parts / Week Req'd OEE at APW Req'd OEE at MPW Demonstrated OEE

APW MPW 1200.0%

1000.0%
OEE %

800.0%

NOTES
600.0%

400.0%

200.0%

0.0%

SUPPLIER OPERATION MANAGEMENT APPROVAL FOR STA USE

Insert Version 4.3

Approved
Authorized Representative Name / Title Signat
Email Site Engineer STA LL6 Supervisor

ure © 2010 Ford Motor Company

Rejected

Signature Date Image Phone Number Signature/Date Signature/Date

Capacity Analysis Report version 4.3

from Page 1 Date Revised: 8-Oct-10

file Date Printed:11/04/2019

 Phase 3 PPAP (Capacity Verification)
A. New Model Required OEE - 1 1
Select for
A1) Supplier & Part Information A2) Capacity Requirements APW MPW Analysis A3) Key Contacts
Supplier Name Program Code <PA> Requirements Name Phone # Email
Location/Site Code Model Year Revised Requirements STA Site Engineer
Part Name Source of Capacity Requirements Supplier Lead
Part Number Date of Study GCP/MCPV Ford Buyer
Capacity Requirements Supplier to demonstrate APW of parts per week operating no more than 5 days per week
Supplier to demonstrate MPW of parts per week operating no more than 6 days per week
A4) Planned Departmental Operating Process 1 Process 2 Process 3 Process 4 Process 5 Process 6 Process 7 Process 8
Pattern & Net Available Time 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
A Process description (in value stream order)
B Days / Week
C Shifts / Day
D Total Hours / Shift
E Contractual Planned Downtime - lunch, breaks, etc.
(minutes/shift)
F Allocation Percent (enter 100 for dedicated)
G Net Available Time (hours / week) [B*C*(D-(E/60))*F] - - - - - - - - - - - - - - - -
G1 Planned Minutes per Changeover (into this part #)
G2 Planned Changeover Frequency / Week (into this part #)

A5) Required Good Parts / Week 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
H Percent of parts scrapped
J Req'd Good Parts / Week to Support Next Process
- - - - - - - - - - - - - - - -
[Process 1 Req'd Parts = Process 2 Req'd Parts /
(100% - Process 2 Scrap%)] Avg. Weekly Max Weekly
Required Incoming Parts for - -

A6) Required OEE 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
K Ideal Cycle Time per Tool or Machine (sec/cycle)
L # of Tools or Machines in parallel
M # of identical parts produced per Tool or Machine Cycle
N Net Ideal Cycle Time (sec/part) [K / (L*M)] - - - - - - - - - - - - - - - -
P Theoretical Parts per week at 100% OEE [G x 3600 / N] - - - - - - - - - - - - - - - -
Q Required OEE [J / P] - - - - - - - - - - - - - - - -
R Percent of parts reworked (re-run through process)
S 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

Enter any other assumptions for clarification

A7) Shared Process - Total Allocation Plan - - - - - - - -

U Enter Total % Allocation from "Shared - Loading Plan" Tab

B. Supplier Demonstrated OEE - Phase 3 PPAP (Capacity Verification)

B1) Equipment Availability - - - - - - - -

V Total Available Time (Include ACTUAL changeover time for

Shared) (minutes)
W Planned Downtime - lunches/breaks/mtgs. (minutes)
X Net Available Time (minutes) [V - W] - - - - - - - -
Y Shared Equip Changeover Time ACTUAL (minutes)
Z Shared Equip Changeover Time Weekly Scaled (minutes)
- - - - - - - -
[Y * (X / 60) / (G / G2)]
AB Observed Unplanned Downtime (minutes)
AC Operating Time (minutes) [X - Y - AB] - - - - - - - -
AD Equipment Availability [(X - Z - AB) / X * 100] - - - - - - - -
B2) Performance Efficiency
AE Total Parts Run (Good, Scrapped, & Reworked)
AF Net Ideal Cycle Time (seconds/part) [N] - - - - - - - -
AG Performance Efficiency (AE * AF / AC) - - - - - - - -
AH "Availability" and/or "Performance Efficiency" Losses Not
- - - - - - - -
Captured (minutes) [AC - (AE * AF)]
B3) Quality Rate # % # % # % # % # % # % # % # %

AJ # Parts Scrapped - - - - - - - -
AK # Parts Reworked - - - - - - - -
AL Quality Rate [(AE - AJ - AK) / AE] - - - - - - - -
B4) Overall Equipment Effectiveness (OEE)
AM Phase 3 OEE [AD * AG * AL] - - - - - - - -
B5) Process Specific Weekly Part Estimate [P * AM] - - - - - - - - - - - - - - - -
B6) Observed Average Cycle Time (sec/cycle)
C. Gap Analysis - Required OEE vs. Demonstrated OEE; Predicted Good Parts / Week
Process Description
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 APW Result MPW Result

Demonstrated OEE > Required OEE? (Is AM > Q?)

Predicted Good Parts / Week Req'd OEE at APW Req'd OEE at MPW Demonstrated OEE

APW MPW 1200.0%

1000.0%
OEE %

800.0%
NOTES
600.0%

400.0%

200.0%

0.0%
Rejected
SUPPLIER OPERATION MANAGEMENT APPROVAL FOR STA USE
Insert Version 4.3
Approved
Authorized Representative Name / Title Signat
Email Site Engineer STA LL6 Supervisor

ure Rejected
© 2010 Ford Motor Company
Signature Date Image Phone Number Signature/Date Signature/Date

from
Date Revised: 8-Oct-10
file
Capacity Analysis Report version 4.3 Page 1
Date Printed:11/04/2019
 Surrogate OEE Summary

Demonstrated GPP = Good Parts Produced NICT = Net Ideal Cycle Time (sec/part) NAT = Net Available Time (hrs/wk) OEE = Overall Equipment Effectiveness [GPP/(NAT/NPICT)]
(Surrogate) Performance
History
WK# Date (mm/dd/yyyy) GPP NICT NAT OEE GPP NICT NAT OEE GPP NICT NAT OEE GPP NICT NAT OEE GPP NICT NAT OEE GPP NICT NAT OEE GPP NICT NAT OEE GPP NICT NAT OEE
WK1 - - - - - - - -
WK2 - - - - - - - -
WK3 - - - - - - - -
WK4 - - - - - - - -
WK5 - - - - - - - -
WK6 - - - - - - - -
WK7 - - - - - - - -
WK8 - - - - - - - -
WK9 - - - - - - - -
WK10 - - - - - - - -
WK11 - - - - - - - -
WK12 - - - - - - - -
WK13 - - - - - - - -
WK14 - - - - - - - -
WK15 - - - - - - - -
WK16 - - - - - - - -
WK17 - - - - - - - -
WK18 - - - - - - - -
WK19 - - - - - - - -
WK20 - - - - - - - -
WK21 - - - - - - - -
WK22 - - - - - - - -
WK23 - - - - - - - -
WK24 - - - - - - - -
WK25 - - - - - - - -
AVERAGE SURROGATE OEE - - - - - - - -

OEE OEE OEE OEE

OE
OE E
E OE OE
100.0% E E

100.0% 100.0%
Surrogate OEE

90.0% 100.0%

Surrogate OEE
Surrogate OEE

Surrogate OEE
90.0% 90.0%
80.0% 90.0%
80.0% 80.0%
70.0% 80.0%
70.0% 70.0%
70.0%
60.0%
60.0% 60.0%
60.0%
50.0%
50.0% 50.0% 50.0%
40.0%
40.0% 40.0% 40.0%
30.0%
30.0% 30.0% 30.0%

20.0% 20.0% 20.0% 20.0%

10.0% 10.0% 10.0% 10.0%

0.0% 0.0% 0.0% 0.0%

OEE OEE OEE OEE

OE OE OE OE
E E E E
100.0% 100.0% 100.0% 100.0%
Surrogate OEE

Surrogate OEE

Surrogate OEE

90.0%

Surrogate OEE
90.0% 90.0% 90.0%

80.0% 80.0% 80.0% 80.0%

70.0% 70.0% 70.0% 70.0%

60.0% 60.0% 60.0% 60.0%

50.0% 50.0% 50.0% 50.0%

40.0% 40.0% 40.0% 40.0%
30.0% 30.0% 30.0% 30.0%
20.0% 20.0% 20.0% 20.0%
10.0% 10.0% 10.0% 10.0%
0.0% 0.0% 0.0% 0.0%

Date Revised: 8-Oct-10

Capacity Analysis Report version 4.3 Page 1
Date Printed:11/04/2019
 Shared - Loading Plan

Shared Process Loading Plan NICT = Net Ideal Cycle Time (sec/part) Date of Study

Study Phase PROCESS

Departmental Operating Pattern for Average Weekly Departmental Operating Pattern for Max Weekly
Days / Week
Shifts / Day
Total Hours / Shift
Contractual Planned Downtime - lunch,
breaks, etc. (minutes/shift)
Net Available Time (NAT) (hrs/week)
Demonstrated OEE:
Enter average OEE from most recent
production performance data; Surrogate OEE
tab may be used for this calculation

Loading Plan to meet Average Weekly Loading Plan to meet Max Weekly
Req'd Req'd
Time Req'd @ Time Req'd @
Good % Allocation Good % Allocation
Part Ford Part # or "Non-Ford" NICT Demonstrated NICT Demonstrated
Parts / Minimum Required Parts / Minimum Required
OEE (hrs/week) OEE (hrs/week)
Week Week
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21 Other % Allocation - Description
22 Other % Allocation - Description
Percentage of Net Available Time not utilized for production (%) {PM, etc.}
Total % Allocation
If Total % Allocation > 100%, loading plan exceeds capacity

Date Revised: 8-Oct-10

Capacity Analysis Report version 4.3 Page 1
Date Printed:11/04/2019