Tech Review Guideline Please arrive at your Tech Review ready to present and discuss all of the following information.
Agenda Company Overview (Limited to 20 mins) Quality Manufacturing Product design Questions/Clarifications Packaging and logistics Commercial
Company Overview (Limited to 20 mins) Commercial Overview of Company Resource Plan Total corporate organization chart clearly identifying the resources allocated for each particular program quoted. Staffing ramp up chart, engineering plan. Program Timing Plan (ref. last slide) Average seniority of the management with your company at the proposed manufacturing site Employee turn over rate at the proposed manufacturing site Unigraphics Compliance and data communication process between Allison, your company and Tier II suppliers. Program management and change management system. Summarize the key technology, concept, or strategy on which your business is based. Show similar products currently producing.
Company Overview (Continued) Summarize the key technology, concept, or strategy on which your business is based. Show similar products currently producing. Safety Major OSHA/safety violations last 5 years Work related accidents within last 5 years. Continuous Improvements Investment in production technology and equipment as a % of sales last year. Change in man hours per ton by year for the last 5 years. Organizational charts and ownership structure Free trade zone location
Quality Quality metrics Internal PPM (Parts per million), External PPM, Scrap %, PPM reduction internal & external per year for the last 5 years Delivery performance Certifications (ie. TS, QS, ISO ) APQP (Advance Product Quality Planning) Warranty Warranty data for Allison and other customers. Provide quality control process and tools through development and production. Preliminary PFMEA / Control Plan Process Flow (must identify all operations and type of machine model)
Manufacturing Follow the following outline for casting if applicable, if not follow a similar format for the commodity being quoted. List the critical tolerances for the components being quoted & what is the proposed inspection method. Provide examples of similar parts and tolerances your facility currently produces with the historical CpK values for those dimensions. If any operations will be outsourced provide the company names that will conduct the outsourced operation.
Manufacturing-Casting Process Flow Including: Manufacturing location, plant w/duns code, capacity, plant layout, manufacturing process validation plan Furnace- equipment brand, model, year, size Core Process - equipment brand, model, year, size, est. cycle time Molding Process - equipment brand, model, year, size, est. cycle time Flow modeling / simulation Special Tooling material, size, patterns per mold, gating & riser locations Special Gauging Special Testing Error Proofing/Detection Tier II Suppliers Any process/operations that is completed outside of manufacturing location.
Manufacturing-Value Added (Machining, Heat Treat, Testing/ Assembly) Process Flow Including: Manufacturing location, plant w/duns code, capacity, plant layout, manufacturing process validation plan Proposed machine brand, model, year, number of machines, Estimated cycle time (AT-1960-C) Clamp & Fixturing locations ( ie. pictures) Dimensions Machined Understanding of critical features. (ie KPC (Key Product Characteristics), PQC (Product Quality Characteristics), SCCPC s (Standard Care Control Plan Characteristics) Leak Tests, Porosity Specs., Deburring, Hardness, TES, TIS, TMS specs. Special Tooling Listed Special Gaging Complete Gage list needs to be reflected on control plan Error Proofing/Detection Listed for each operation including packaging (preventing mixed parts) & labeling Explain how the parts will be cleaned & deburred Tier II Suppliers Any process/operations that is completed outside of manufacturing location.
Product Design/ Manufacturability Product description Bill of Materials Illustrations, Exploded Views, etc.(new connectors, routing channels, etc.) Technologies used Itemize quote assumptions and exceptions to prints and Component Technical Specs. Review acceptance of SOR (Standard of Requirements) by paragraph number (yes / no / exceptions) Review print dimensions & special specifications that are called out. Review details of material specification.
Product Design/ Manufacturability Design & Process Validation Plan Analysis, design and validation plan. Testing/validation facilities and capabilities Leak test Functional test Math Data capability- Unigraphics Compliance Supplier Proposals to Improve Cost, Weight and Quality not constrained by Allison Mandatory Requirements.
Packing and Logistics Anticipated packaging design (AT1703) Provide detail costs for returnable and expendable packaging designs Quoted Inco Term International Suppliers provide the warehouse name and address Ship from address Review AT-1700 & AT-1724 and provide a list of any questions or exceptions Specify the Tariff classification List minimum purchase quantities if any
Commercial Review and feedback: Commercial Data Provide and review: Completed Cost Breakdown sheets (1804, 1810 documents) all operations must be broken down on 1804. Costed BOM detail Tooling cost, capacity & line-ups Provide a list of your potential sub tier 2-3 Suppliers and the selection criteria used.
Closing Questions and clarifications Recap action items, assign owners & dates
Required Forms AT-1804 - Every operation must be listed AT-1810 All tooling must be detailed out AT-1927-02 Program Timing Chart AT-1960-C Run @ Rate Summary (Estimated) AT-1927-03 SQ SOR AT-1927-04 Required Quality Info AT-1927-05 APQP Open Issues AT-1927-17 APQP Contact List AT-1927-19 Supplier Mfg Assmt Ltr AT-1703-Packaging *All forms are to be filled out completely and submitted before tech. review. All forms can be located on http://www.allisontransmission.com/suppliers/supplier-forms