Assessment & Process. Plan

Transcription

1 Manufacturability Assessment & Process Plan Supplier MAPP Overview Training

2 Training Goals Communicate Nexteer s new approach to launch Understand what Nexteer is doing differently to improve launch performance Understand Nexteer s new Manufacturability Assessment & Process Plan (MAPP) process 2

3 GSM Launch Objectives Proactive Risk Assessment throughout Launch Process Cross Functional BOM Risk Assessment (Nexteer) Internal Print Reviews (Nexteer) Internal Key Stakeholder Meeting (Nexteer) Manufacturability Assessment & Process Plan (Nexteer-Supplier) PFD, PFMEA & Control Plan Submission prior to PPAP (Supplier) Identify Target Supplier prior to Design Validation Supplier input for Design Validation Production intent process for Design Validation to mitigate risk Production intent supplier for High Priority Parts to mitigate risk Emphasis on Collaborative relationships Buyer-AQE-PE-Supplier are responsible for flawless launch of product Nexteer-Supplier teamwork approach to achieve quality & cost targets 3

4 Nexteer GSM Launch Goals Foster a Nexteer-Supplier Collaborative Culture Goal: Name a Target Supplier 6 weeks after issuing RFQ Engage the supplier earlier to allow for supplier input into the design Improve Launch Performance PPAP On-time Run at Rate On-time Delivery On-time Zero problem cases during launch Achieve cost targets 4

5 What is Nexteer Doing Differently? Question: What is Nexteer Going to do Differently? Answer: Collaborative Sourcing & Concurrent Engineering Traditionally, Nexteer Product Engineering worked independently to develop the product design APQP Review Develop Business Case Engineering Development Source Supplier Implement Mfg System Validate Mfg System Final Negotiations Sourcing Approval PPAP Approval Run at Rate Approval Supplier Quotes Team Feasibility Technical Reviews 5

6 What is Nexteer Doing Differently? The Collaborative Sourcing Process & Concurrent Engineering Philosophy brings the Target Supplier into the development phase to obtain supplier input into the design Supplier MCA Pre-Bid Approval PE&AQE Bid List Approval Internal Tech Review Category Strategies Risk Assessment Develop Business Case Develop Sourcing Strategy Initial Gaging Plan Initial PFMEA FMEA Reviews Agreed Upon Design/Process Technical Reviews Indentify Target Supplier Collaborate Pre-PPAP Process Flow Pre-PPAP Control Plan Pre-PPAP PFMEA Source Supplier APQP Review Implement Mfg System Validate Mfg System Strategic Partnerships Supplier Quotes Team Feasibility Characteristic Summary Process Flow Diagram Technical Review PE-AQE Target Supplier Input Final Negotiations Sourcing Approval PPAP Approval Run at Rate Approval Line Side Reviews 6

7 What We are Doing Differently? Question: What is Nexteer Going to do Differently? Answer: Identify & Mitigate Risk Rigorous Internal Risk Reviews Identify Target Supplier Early Implement the Manufacturability Assessment & Process Plan (MAPP) 7

8 What is the MAPP? MAPP = Manufacturability Assessment & Process Plan Global Supply Management s MAPP to a Flawless Launch Based on the Compliance Matrix that is required by our customers to be submitted with our new business pursuit quotes The MAPP template is located in the Nexteer Supplier Portal: Home > Frequently Used Documents > Supplier Standards > Direct Material Sourcing Requirements or copy & paste the link: Click on excel icon for an example MAPP Template 461b-47e2-9fb e2a67f8&groupId= Microsoft Excel Worksheet 8

9 Why do we need the MAPP? Take Action for Quality: It s everyone s job We must eliminate any Customer perception that Nexteer is a risky supplier during the Launch Phase. If we don t win new business, our suppliers won t win new business Encourages a collaborative relationship between the supplier and the Nexteer Buyer, Supplier Quality and PE Collaborationis the act of working with others on a joint project 9

10 How is the MAPP Used? MAPP: Risk Identification & Mitigation Tool Communicate expectations to the supplier Guides the Supplier, AQE, PE & Buyer to identify risk as early as possible Allows the team to assess risk to use their experience & judgment whether a supplier is capable to make the part Documents risk mitigation plans The MAPP requires the supplier to consider each dimension, feature or requirement on the drawing, or in the product spec, and document how the it will be manufactured, measured and controlled in production. 10

11 MAPP & Supplier Selection Mechanism to Identify the Target Supplier MAPP Template is sent out with RFQ Supplier is encouraged to use the MAPP as a tool to generate their Quote Supplier MAPP must be provided to Nexteer prior to the Supplier Capability & Selection Review (first tech review) Open issues should be expected and welcomed Goal is to identify a Target Supplier 6 weeks from RFQ issue date; in some cases, multiple suppliers may be selected. Identifies issues so that Nexteer can select a Target Supplier to allow collaboration to begin earlier in the process 11

12 Initial PFMEA & MAPP Review Supplier Kickoff MAPP Process Timeline 1. Supplier esigns MAPP with MAPP Submission 2. PC&L, PE & AQE/SQE Sign MAPP after Capability & Selection Review(s) 3. Buyer identifies a Target Supplier Issue RFQ Receive Supplier Quote Capability & Selection Review(s) Name Target Supplier Design & Supplier Process Collaboration Activity 4. Supplier signs MAPP. PC&L, PE and/or SQE/AQE sign if there are exceptions. Required for Final Sourcing Approval & Supplier Kickoff. Nexteer Sourcing Activity 1 Receive Supplier MAPP 4 Final Sourcing Approval

13 MAPP Contents 1. Team Feasibility ** 2. Supplier Assessment ** 3. Manufacturability Assessment 4. Process Flow Diagram ** 5. APQP Contact List ** 6. Supplier Kickoff Information ** 7. Approval Sheet ** 8. APQP Open Issues List (at AQE discretion) 9. Supplemental Technical Review Questions (at AQE discretion) ** Required for Supplier Capability & Selection Review Pilot Only: Required for Supplier Capability & Selection Review ** Completed by Nexteer 13

14 MAPP Process Timeline 14 Initial PFMEA & MAPP Review Final Sourcing Approval Supplier Kickoff Supplier submits Sections 1, 2, 4 & 5 of the MAPP Issue RFQ Receive Supplier Quote Receive Supplier MAPP Capability & Selection Review(s) Name Target Supplier Design & Supplier Process Collaboration Activity NOTE: Section 3 will be required on pilot programs as directed by the Nexteer Buyer/AQE Supplier esigns the MAPP and s Excel file to the Buyer prior to the Supplier Capability & Selection Review (1 st Tech Review) Nexteer Sourcing Activity

15 MAPP Instructions Instructions with document links are included in the MAPP Template 15

16 MAPP Directions & Information Detailed comments are included in the MAPP Template for additional information and support for the supplier 16

17 1. Team Feasibility Requirements SUPPLIER: Answer each Team Feasibility question in Section 1. Add comments are as required. NEXTEER: The Buyer assigns a status for each item. Each item should be marked Closed & Approved before kicking off supplier tooling. Open items must have a mitigation plan completed before closing out the item. 17

18 2. Supplier Assessment SUPPLIER: Answer 44 questions pertaining to your Manufacturing Site, Outside Processing, Quality, Program Management, Timing, etc. NEXTEER: The Buyer/AQE assigns a status for each item. Each item should be marked Closed & Approved before kicking off supplier tooling. Open items must have a mitigation plan completed before closing out the item. 18

19 4. Supplier Process Flow SUPPLIER: Attach a high level process flow diagram in the SECTION 4 - SUPPLIER PFD workbook tab. The Process Flow Diagram should be a sketch that adequately defines the process quoted. This may be a handwritten PDF file pasted into the workbook tab. 19

20 5. APQP Contact List SUPPLIER: Complete the highlighted fields in the APQP Project Contact List in the SECTION 5- CONTACT LIST worksheet tab. 20

21 3. Manufacturability Assessment SUPPLIER: Fill out the Process Operation Number & Process Concept/Method SUPPLIER: Road Map the print and enter the Road Map #, the Requirement, Dimension, Note or Spec and the Class & Characteristic Number of each SUPPLIER: Complete a Manufacturing Process Feasibility Assessment for each dimension/process step. 21

22 3. Manufacturability Assessment SUPPLIER: Select whether the process will be completed In-House or at a Sub-Supplier SUPPLIER: The required Process Indices automatically populates based on the class of the dimension. Select whether or not there is a commitment to meet the required indices. SUPPLIER: Enter the control method for each item and the verification method See comments in the column headers for further instruction 22

23 Example Example provided for the supplier within the MAPP Template 23

24 Supplier MAPP esign Supplier esigns the MAPP by entering the date and Name of their team responsible to address open issues and strive to achieve Nexteer business (cost and quality) targets Excel file ed to the Buyer prior to the Supplier Capability & Selection Review 24

25 MAPP Process Timeline 25 Initial PFMEA & MAPP Review Final Sourcing Approval Supplier Kickoff Internal Nexteer Signoff & Approval Nexteer Buyer names Target Supplier Nexteer AQE, PE & Supplier begin the Design & Supplier Process Collaboration Activity Issue RFQ Receive Supplier Quote Receive Supplier MAPP Capability & Selection Review(s) Name Target Supplier Design & Supplier Process Collaboration Activity Buyer completes the Supplier Kickoff and APQP Contact List; Supplier completes the APQP Contact List Nexteer Sourcing Activity

26 5. APQP Contact List NEXTEER: Buyer completes the APQP Project Contact List during the Design and Supplier Process Collaboration Activity 26

27 5. APQP Contact List SUPPLIER: Complete the APQP Project Contact List during the Design and Supplier Process Collaboration Activity. 27

28 6. Supplier Kickoff Information NEXTEER: Buyer, with PLPL support, fills out the QTC and Timing information during the Design & Supplier Process Collaboration Activity 28

29 8. APQP Open Issues The AQE will document APQP Open issues within the MAPP Document 29

30 9. Supplemental Questions Commodity Technical Supplement questions are included in the MAPP and used at the AQE/SQE s discretion 30

31 MAPP Process Timeline 31 Initial PFMEA & MAPP Review Final Sourcing Approval Supplier Kickoff Initial PFMEA & MAPP Review in preparation for Supplier Kickoff of production tooling Issue RFQ Receive Supplier Quote Receive Supplier MAPP Capability & Selection Review(s) Name Target Supplier Design & Supplier Process Collaboration Activity Upon completion of the MAPP review, the Supplier prints the Sections 1, 2, 3, 6 & 7 MAPP excel tab and the Supplier s Key Stakeholders date & sign the MAPP. PDF scan of signed document is ed to the Nexteer Buyer & AQE. Nexteer Sourcing Activity

32 Supplier MAPP Signoff for Kickoff SUPPLIER: Prior to Supplier Kickoff, the Supplier prints the Sections 1, 2, 3, 6 & 7 MAPP excel tab and the Supplier s Key Stakeholders date & sign the MAPP. SUPPLIER: A signed PDF copy is ed to the Buyer and AQE. 32

33 MAPP Process Timeline 33 Initial PFMEA & MAPP Review Final Sourcing Approval Supplier Kickoff The Nexteer Buyer obtains Final Sourcing Approval and issues POs to kickoff the supplier to tool for production Issue RFQ Receive Supplier Quote Receive Supplier MAPP Capability & Selection Review(s) Name Target Supplier Design & Supplier Process Collaboration Activity Nexteer Sourcing Activity

34 Supplier Frequently Asked Questions 34

35 Supplier FAQs Question: Why is Nexteer burdening my company with this additional work? Answer: This may appear to be a burden but this is all work that is completed during the launch process. This appears to be a burden because we are shifting from a reactive organization to a proactive organization. This also prepares the supplier for their PFD & Control Plan. 35

36 Supplier FAQs Question: What if my company refuses to fill out the MAPP? Answer: If your company wants our business, then you will need to comply with our request and use the MAPP. Keep in mind the intent of this document will help both of our organizations to flawlessly execute the program and minimize launch costs. 36

37 Supplier FAQs Question: What if my company won t provide this information without a PO? Answer: Our policy is that we do not issue suppliers with a Purchase Order until our Design Validation is complete. Nexteer will communicate the planned Supplier Kickoff Date to the supplier. 37

38 Supplier FAQs Question: What if I am being pressured to provide a quote? Won t this delay my RFQ response? Answer: No. You can provide a quote without completing the MAPP. The MAPP and SPI must be submitted to Nexteer prior to any tech reviews. 38

39 Supplier FAQs Question: What if I am asked to support a Tech Review as soon as possible? Answer: Nexteer should give you adequate time to prepare the MAPP for the Supplier Capability and Selection Review (1 st Tech Review). However, there may be special circumstances. If you have concerns, please contact your Buyer or AQE/SQE. 39

40 Supplier FAQs Question: What about a print with hundreds of dimensions? Answer: In cases where there are many dimensions, you may group a large quantity into one line item. Example: If there are 50 non-critical cast dimensions, give them all the same road map number and document control method. Please contact your AQE if you have any questions regarding the MAPP. 40

41 Supplier FAQs Question: Does my company have to have Covisint access to obtain a copy of the MAPP? Answer: No. The MAPP is stored on the Supplier Portal and anyone can access this via the web. The link to Supplier Portal is included in the RFQ template. Please remember that Covisint Registration is required for all Nexteer Suppliers. 41