| INFORMATION
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| Cells marked in white shall be filled in |
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| Cells marked in grey are either calculated or linked between the sheets |
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| Worksheets marked in red are mandatory to use. |
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| Worksheets marked in green are optional to use. The organization may use its own template to show the values. |
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| Workflow: |
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Step 1-3 are made before the trial |
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1, Fill in the "Basic data" in the "Summary" sheet |
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2, Fill in the "Process information" in the "Summary" sheet |
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3, Fill in required data in the "Allocation" sheet |
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4, Fill in "Run@Rate data" from the trial in the "Summary" sheet |
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| See calculation example below. |
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| CALCULATION EXAMPLE |
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| Basic data |
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1 |
The Scania part number as shown on the Scania drawing.
Scania part number: |
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1377179 |
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6 |
The date when the trial was run.
Run@Rate Date: |
12/31/2010 |
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2 |
The Scania part name as shown on the Scania drawing.
Scania part name: |
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D12-crankshaft |
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7 |
The name of the supplier
Supplier Name: |
Turn & Mill GmBh |
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3 |
ECO (Engineering Change Order) number.
It corresponds to the latest drawing date and is given on the purchase order.
The PPAP is made against this number.
ECO number: |
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48569 |
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8 |
Either the four of the seven digit number
Supplier Number: |
2338-01 |
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4 |
PPAP approval date is the date when the SQA signed the PSW.
PPAP approval date |
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12/24/2010 |
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9 |
The location (adress) for the manufacturing plant.
Supplier location: |
Reykavik |
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5 |
This is the estimated annual volume.
If it is not shown in the delivery plans, the data can be obtained from the Sourcing Manager at Scania.
VERY IMPORTANT: THIS VOLUME IS NOT BINDING
Estimated Scania Annual Volume: |
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14,000 |
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| Process information |
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Process step: |
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Process 1 |
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10 |
The name of the process.
(example: drilling, punching, rolling, assembly)
Process description |
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Soft machining |
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11 |
If the process/line has an individual number or name it is given here.
Examples: "32666", "Tapering2" or "Heat treat line 1"
Line denomination |
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Milling 2 |
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12 |
State the total number of working hours per week, summarizing all shifts.
Example:
1-shift 40 hours
2-shift 80 hours
3 shift 120 hours
5-shift 164 hours
Working hours per week |
hr/week |
40 |
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13 |
Estimate the number of working days days per year.
Example:
- working only weekdays, having 25 days of vacation gives about 225 working days.
- working 24 hours/day, all days per week, closing five weeks for vacation, Christmas etc, gives 330 working days.
Working days per year |
days |
220 |
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14 |
Fill in the annual working hours for the process.
As an example, in the Scania production the following hours are used:
5-shift= 7600 hours
3-shift= 5100 hours
2-shift= 3400 hours
1 shift= 1800 hours
Total hours/year |
hr/year |
5400 |
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| Supplier Planned Capacity Data |
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16 |
The annual volume of subparts that is needed for the part number given in item [5].
One Scania part number can need several sub parts.
For example: a tube can have one ball joints assembled on each side, or a gear selector component can have four push buttons.
If the line is used for other Scania part numbers, other than the one given in [1], they are not included in this figure.
Estimated Scania total volume |
pcs/year |
14,000 |
Taken from the allocation sheet |
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144000 |
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17 |
The number of setups for the part number per year.
Number of setups |
event/year |
132 |
Taken from the allocation sheet |
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108000 |
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18 |
The average time for setting up the machine for the investigated part.
Setup time/run |
min/setup |
15.0 |
Taken from the allocation sheet |
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19 |
The cycle time for the investigated part, according to the supplier.
Shall be measured with a clock at the process.
True Cycle Time |
sec/pc |
51 |
Taken from the allocation sheet |
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3600 |
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20 |
If the machine is not dedicated for one part number, other customers have also allocated hours.
If 0, the process is dedicated for Scania
Working hours needed for other customers |
hr/year |
441 |
Taken from the allocation sheet |
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80 |
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21 |
Stop hours each year for maintenance, employee brakes (education, lunch, shift overlap, etc).
Planned stops |
hr/year |
0.0 |
Taken from the allocation sheet |
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22 |
The number of hours required to produced the Scania total volume, including setup time.
The hours are calculated with 100% OCE, which is not possible to achieve.
Please note: other Scania part numbers is not included in this figure. Only the one given by the basic data.
Annual working hrs required for Scania |
hr |
231 |
Taken from the allocation sheet |
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23 |
The number of hours not allocated for other customers or for scheduled stops.
Unplanned/free hours (14-20-21-22) |
hr |
4,959 |
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24 |
This value is showing the allocation of the line that is needed for Scania with 100% OEE (which is not possible to obtain).
When calculating this value, the scheduled stops shall be extracted from the total hours/year.
Allocation for Scania 22/(14-21) |
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4% |
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| RUN@RATE Data |
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26 |
The length of the trial.
Filled in as accurate as possible.
Trial run duration |
hr |
8.3 |
The total length of the trial, including stops, as accurate as possible. |
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27 |
Total stop time during the trial.
All short stops shall be included.
Stop time |
hr |
0.40 |
The total stop time during the trial. |
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28 |
Only approved parts, without rework, shall be counted.
Number of approved parts |
pcs |
450 |
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29 |
The number of scrapped or re-worked parts.
Also include parts that are being blocked for further investigating in this number.
Number of scrapped/reworked parts |
pcs |
23 |
The total number of scrapped or re-worked parts during the trial. |
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30 |
Net output (28/26) |
pcs/hr |
54 |
During the trial, the produced quantity per hour |
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31 |
Maximum possible output (30x14) |
pcs/year |
292,771 |
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32 |
Overall Equipment Efficiency
Calculated as:
(true cycle time x number of approved parts) / trial run duration
OEE during the trial (19x28/26) |
% |
77% |
Calculated as: (true cycle time x number of approved parts)/trial run duration |
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33 |
Possible production for Scania if using all free hours.
Maximum capacity for Scania (30x(22+23)) |
pcs/year |
281,425 |
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| Process 1 |
Soft machining |
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A |
B |
C |
D |
E |
F |
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SCHEDULED STOPS |
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3600/D |
A/E+(B*C/60) |
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Hours/day |
Yearly effect (hours/year) |
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Estimated Annual Volume |
Number of Setups per year |
Duration of the time the equipment is not producing parts.
The setup end when the first approved part comes out of the process.
Single setup time (min) |
True cycle time:
Period required to complete one cycle of an operation.
It starts when a good part comes out until another good part comes out. The process shall run without stops or interruptions when measuring this time.
Only approved parts are considered.
Time measured by the clock by the supplier.
True Cycle Time (sec) |
Planned Production Rate (pcs/hour) |
Total Annual working hrs planned |
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Maintenance |
0.85 |
0.00 |
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Estimated Scania annual volume |
14,000 |
132 |
15 |
51 |
70.59 |
231 |
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Employee breaks |
0.50 |
0.00 |
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Other customers |
28,000 |
255 |
14 |
49 |
73.47 |
441 |
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Other stops |
0.35 |
0.00 |
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Produced annual volume |
42,000 |
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672 |
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TOTAL |
1.70 |
0.00 |
| RUN AT RATE REPORT
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| Basic data |
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1 |
The Scania part number as shown on the Scania drawing.
Scania part number: |
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6 |
The date when the R@R will be made.
Run@Rate Date |
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2 |
The Scania part name as shown on the Scania drawing.
Scania part name |
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7 |
Supplier Name |
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3 |
ECO (Engineering Change Order) number.
It corresponds to the latest drawing date and is given on the purchase order.
The PPAP is made against this number.
ECO number |
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8 |
State either the four or seven digit supplier number
Supplier Number |
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4 |
PPAP approval date is the date when the SQA signed the PSW.
PPAP approval date |
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9 |
The manufacturing site of the supplier
Supplier location |
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5 |
This is the estimated annual volume.
If it is not shown in the delivery plans, the data can be obtained from the Sourcing Manager at Scania.
VERY IMPORTANT: THIS VOLUME IS NOT BINDING
Estimated Scania annual volume |
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| Process information |
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Process step: |
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Process 1 |
Process 2 |
Process 3 |
Process 4 |
Process 5 |
Process 6 |
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10 |
The name of the process.
(example: drilling, punching, rolling, assembly)
Process description |
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11 |
If the process/line has an individual number or name it is given here.
Examples: "32666", "Tapering2" or "Heat treat line 1"
Line denomination |
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12 |
State the total number of working hours per week, summarizing all shifts.
Example:
1-shift 40 hours
2-shift 80 hours
3 shift 120 hours
5-shift 164 hours
Working hours per week |
hours |
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13 |
Estimate the number of working days days per year.
Example:
- working only weekdays, having 25 days of vacation gives about 225 working days.
- working 24 hours/day, all days per week, closing five weeks for vacation, Christmas etc, gives 330 working days.
Working days per year |
days |
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14 |
Fill in the annual working hours for the process.
As an example, in the Scania production the following hours are used:
5-shift= 7600 hours
3-shift= 5100 hours
2-shift= 3400 hours
1 shift= 1800 hours
Total hours/year |
hr/year |
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| Supplier Planned Capacity Data |
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16 |
The annual volume of subparts that is needed for the part number given in item [5].
One Scania part number can need several sub parts.
For example: a tube can have one ball joints assembled on each side, or a gear selector component can have four push buttons.
If the line is used for other Scania part numbers, other than the one given in [1], they are not included in this figure.
Estimated Scania annual volume |
pcs/year |
0 |
0 |
0 |
0 |
0 |
0 |
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17 |
The number of setups for the part number per year.
Number of setups |
event/year |
0 |
0 |
0 |
0 |
0 |
0 |
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18 |
The average time for setting up the machine for the investigated part.
Setup time/run |
min/setup |
0.0 |
0.0 |
0.0 |
0.0 |
0.0 |
0.0 |
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19 |
The cycle time for the investigated part, according to the supplier.
Shall be measured with a clock at the process.
True Cycle Time |
sec |
0 |
0 |
0 |
0 |
0 |
0 |
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20 |
If the machine is not dedicated for one part number, other customers have also allocated hours.
If 0, the process is dedicated for Scania
Working hours needed for other customers |
hr |
0 |
0 |
0 |
0 |
0 |
0 |
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21 |
Stop hours each year for maintenance, employee brakes (education, lunch, shift overlap, etc).
Planned stops |
hr/year |
0 |
0 |
0 |
0 |
0 |
0 |
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22 |
The number of hours required to produced the Scania total volume, including setup time.
The hours are calculated with 100% OCE, which is not possible to achieve.
Please note: other Scania part numbers is not included in this figure.
Annual working hrs planned for Scania |
hr |
0 |
0 |
0 |
0 |
0 |
0 |
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23 |
The number of hours not allocated for other customers or for scheduled stops.
Unplanned/free hours (14-20-21-22) |
hr |
0 |
0 |
0 |
0 |
0 |
0 |
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24 |
This value is showing the allocation of the line that is needed for Scania with 100% OEE (which is not possible to obtain).
When calculating this value, the scheduled stops shall be extracted from the total hours/year.
Allocation for Scania 22/(14-21) |
% |
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| RUN@RATE Data |
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26 |
The length of the trial.
Filled in as accurate as possible.
Trial run duration |
hr |
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27 |
Total stop time during the trial.
All short stops shall be included.
Stop time |
hr |
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28 |
Only approved parts, without rework, shall be counted.
Number of approved parts |
pcs |
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29 |
The number of scrapped or re-worked parts.
Also include parts that are being blocked for further investigatin in this number.
Number of scrapped/reworked parts |
pcs |
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30 |
Net output (28/26) |
pcs/hr |
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31 |
Technical capacity (14/19) |
pcs/year |
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32 |
Overall Equipment Efficiency
Calculated as:
(true cycle time x number of approved parts) /trial run duration
OEE during the trial (19x28/26) |
% |
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33 |
Scania volume with current allocation (22x30) |
pcs/year |
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34 |
Possible production for Scania if using all free hours.
Scania volume, including free hours (30x(22+23)) |
pcs/year |
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| ALLOCATION SHEET
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| Process 1 |
0 |
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B |
C |
D |
E |
F |
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SCHEDULED STOPS |
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3600/D |
A/E+(B*C/60) |
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Hours/day |
Yearly effect (hours/year) |
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Annual Volume |
Number of Setups per year |
Single setup time (min) |
True Cycle Time (sec) |
Planned Production Rate (pcs/hour) |
Total Annual working hrs planned |
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Maintenance |
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0.00 |
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Estimated Scania annual volume |
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0.00 |
0 |
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Employee breaks |
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0.00 |
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Other customers |
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0.00 |
0 |
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Other stops |
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0.00 |
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Produced annual volume |
0 |
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0 |
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TOTAL |
0.00 |
0.00 |
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| Process 2 |
0 |
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A |
B |
C |
D |
E |
F |
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SCHEDULED STOPS |
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3600/D |
A/E+(B*C/60) |
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Hours/day |
Yearly effect (hours/year) |
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Annual Volume |
Number of Setups per year |
Setup time each time (min) |
True Cycle Time (sec) |
Planned Production Rate [pcs/hour] |
Total Annual working hrs required |
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Maintenance |
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0.00 |
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Estimated Scania annual volume |
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0.00 |
0 |
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Employee breaks |
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0.00 |
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Other customers |
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0.00 |
0 |
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Other stops |
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0.00 |
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Produced annual volume |
0 |
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0 |
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TOTAL |
0.00 |
0.00 |
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| Process 3 |
0 |
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A |
B |
C |
D |
E |
F |
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SCHEDULED STOPS |
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3600/D |
A/E+(B*C/60) |
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Hours/day |
Yearly effect (hours/year) |
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Annual Volume |
Number of Setups per year |
Setup time each time (min) |
True Cycle Time (sec) |
Planned Production Rate [pcs/hour] |
Total Annual working hrs required |
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Maintenance |
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0.00 |
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Estimated Scania annual volume |
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0.00 |
0 |
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Employee breaks |
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0.00 |
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Other customers |
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0.00 |
0 |
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Other stops |
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0.00 |
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Produced annual volume |
0 |
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0 |
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TOTAL |
0.00 |
0.00 |
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| Process 4 |
0 |
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A |
B |
C |
D |
E |
F |
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SCHEDULED STOPS |
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3600/D |
A/E+(B*C/60) |
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Hours/day |
Yearly effect (hours/year) |
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Annual Volume |
Number of Setups per year |
Setup time each time (min) |
True Cycle Time (sec) |
Planned Production Rate [pcs/hour] |
Total Annual working hrs required |
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Maintenance |
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0.00 |
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Estimated Scania annual volume |
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0.00 |
0 |
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Employee breaks |
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0.00 |
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Other customers |
|
|
|
|
0.00 |
0 |
|
Other stops |
|
0.00 |
|
|
Produced annual volume |
0 |
|
|
|
|
0 |
|
TOTAL |
0.00 |
0.00 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
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|
|
|
|
|
| Process 5 |
0 |
|
|
A |
B |
C |
D |
E |
F |
|
SCHEDULED STOPS |
|
|
|
|
|
|
|
3600/D |
A/E+(B*C/60) |
|
|
Hours/day |
Yearly effect (hours/year) |
|
|
|
Annual Volume |
Number of Setups per year |
Setup time each time (min) |
True Cycle Time (sec) |
Planned Production Rate [pcs/hour] |
Total Annual working hrs required |
|
Maintenance |
|
0.00 |
|
|
Estimated Scania annual volume |
|
|
|
|
0.00 |
0 |
|
Employee breaks |
|
0.00 |
|
|
Other customers |
|
|
|
|
0.00 |
0 |
|
Other stops |
|
0.00 |
|
|
Produced annual volume |
0 |
|
|
|
|
0 |
|
TOTAL |
0.00 |
0.00 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
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|
|
|
|
|
|
| Process 6 |
0 |
|
|
A |
B |
C |
D |
E |
F |
|
SCHEDULED STOPS |
|
|
|
|
|
|
|
3600/D |
A/E+(B*C/60) |
|
|
Hours/day |
Yearly effect (hours/year) |
|
|
|
Annual Volume |
Number of Setups per year |
Setup time each time (min) |
True Cycle Time (sec) |
Planned Production Rate [pcs/hour] |
Total Annual working hrs required |
|
Maintenance |
|
0.00 |
|
|
Estimated Scania annual volume |
|
|
|
|
0.00 |
0 |
|
Employee breaks |
|
0.00 |
|
|
Other customers |
|
|
|
|
0.00 |
0 |
|
Other stops |
|
0.00 |
|
|
Produced annual volume |
0 |
|
|
|
|
0 |
|
TOTAL |
0.00 |
0.00 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
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|
Filetype Excel XLSX | Posted on 18 Aug 2022 | 3 years ago
