按预定能力生产

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1、Run Rate GP-9按预定能力生产I. PURPOSE目的The purpose of a Run Rate is to verify:Run Rate的目的是要核实：A. the suppliers actual manufacturing process is capable of producing components that meet GMs on-going quality requirements, as stated in the Production Part Approval Process (PPAP), at quoted tooling capacity fo

2、r a specified period of time; and供应商的当前制造过程是否有能力在指定的一段时间内按声称的加工能力、生 产出符合通用汽车公司现行质量要求的零部件。如同在该零件“生产件批准” (PPAP)文件中所述一致。B. the suppliers actual manufacturing process conforms to the manufacturing and quality plan documented by the supplier in PPAP, GP-12 and other required documentation供应商的当前生产流程是否符合供应

3、商在PPAP，GP-12或其它要求的文件中所 记录的制造和质量计划。During a Run Rate, all production tooling is to be in place and running at full capacity, utilizing all regular production, direct and indirect, personnel and support systems.在Run Rate过程中，所有的生产工具应各就各位并且按最大能力运行，运用所有 正式生产的人员和支持系统，包括直接的和间接的。II. SCOPE适用范围 All new parts

4、require a Run Rate, unless exempted by the supplier quality engineer and approved by the Supplier Quality and Purchasing Directors of the procuring division.所有新的零部件都要通过Run Rate，除非供应商质量工程师认为可以免除并且得 到采购部供应商质量和采购负责人的认可。III. SELECTION PROCESS规程选择All new part numbers will be evaluated by GM, taking into

5、consideration factors such as the following: history; new technology; irreversible tooling changes; and new supplier facilities. The need for the Run Rate will be confirmed by the Supplier Quality Engineer, and approved by the Supplier Quality and Purchasing Director(s) of the procuring division. Th

6、e supplier will be notified of the need to perform a customer monitored or supplier monitored Run Rate as early in the Advanced Product Quality Planning Process as possible.Note: See Section VIII for Additional Requirements for Supplier monitored Run Rate.所有新零件号中的零件都要经过通用汽车公司的评审，将考虑到如下的一些因 素：生产历史，新技

7、术不能回复的模具更改，以及新的生产工厂等等。进行 RunRate的必要性由供应商质量工程师确认，并且得到采购部门的供应商质量 及采购负责人的认可。供应商将在前期产品质量计划(APQP)规程中尽早被通知 是否要作一次用户监督或由供应商自行监督的Run Rate。注：见第VIII节中有关于由供应商自行监督下的Run Rate R的附加要求。IV. GENERAL INFORMATION概述A. DURATION OF RUNRATERun Rate的周期The number of components to be produced during the Run Rate should be suf

8、ficient to demonstrate manufacturing process capability and should be predetermined by the supplier and the procuring divisions Supplier Quality Engineer(s). Factors such as product complexity, shelf life, storage, cost and single shift vs. multiple shift operations are taken into consideration in d

9、etermining the length of the Run Rate. The default length of the Run Rate is one day of the customers daily production requirement at full acceleration.部门的质量工程师们共同预先商定。诸如产品复杂程度，有效期，贮存，费用， 单班运作或多班轮 作等等，都是影响RunRate时间长短应考虑的因素。 RunRate的默认周期是用户满负荷生产时一天的需求量。B. TIMING OFRun Rate的开始时间The Run Rate should be

10、performed after the supplier has attained an acceptable PPAP submission and prior to start of production acceleration. Although encouraged to be performed as early as possible, a key consideration in establishing the Run Rate date is the stability of the design. The exact date should be predetermine

11、d by the procuring division and the supplier. 越好但是进行RunRate的关键考虑因素是该零件设计的确定性。确切的日期应 由采购部门和供应商共同确定。C. REQUIRED PARTICIPATION要求参加的人员1. Customer Monitored -用户监督Customer - A representative from the procuring division is to be present for the entire Run Rate. No portion of the Run Rate is to be performed

12、 without representation of the procuring division, without prior approval. The lead GM representative typically will be the Supplier Quality Engineer, with participation of the Buyer and/or Release Engineer upon request.Supplier - The lead supplier representative is to be the project manager or mana

13、ger appointee.用户一一采购部门的一个代表到现场监督整个生产过程。没有预先的许 可，没有代表到场，不得进行任何的操作，GM方面的首席代表是供应商 质量工程师。如有需要，采购员和产品放行工程师也可能被邀参加。供应商一一供应方的首席代表应是项目经理或是该项目经理指定的代表。2. Supplier Monitored -供应商监督The lead supplier representative is to be the project manager or manager appointee.供应方的首席代表应是项目经理或其指定的代表Note: Equipment and/or subc

14、ontractors may be asked to participate. 注：设备制造商和分包商也可能被要求参加。D. SUPPLIER PREPARTATION FOR RUNRATE供应商为Run Rate所作的准备To make effective use of time, the supplier should conduct a practice Run Rate and/or production simulations, as well as complete as much of the Run Rate Worksheet (Attachment B), before

15、the official Run Rate is conducted.为了能有效地利用时间，在正式的RunRate进行之前，供应商应作一次演习或 相应的模拟生产，并完成工作表(附录B)上所规定的尽可能多的项目和所有问答。E. INVENTORYE.存货If parts are produced ahead of production schedules, the supplier will hold all parts produced until authorized to ship. The supplier will ensure that sufficient production c

16、ontainers and packaging are available to prevent part damage.如果零件的制造发生在总装厂需要之前，供应商应保存全部的零件直到允许装 运。供应商应保证有足够的生产用装运箱和合适的成品包装以防止零部件的损 坏。V. REVIEW CONTENTRun Rate检杳内容The Run Rate will verify that the results of the suppliers actual manufacturing process meet customer requirements for on-going quality, a

17、s stated in PPAP, and quoted tooling capacity. Also, it will verify that the suppliers actual process is to plan, as documented in PPAP, GP-12 and the other documentation listed below.During the Run Rate, the following will be reviewed: documentation; the manufacturing process and results; part qual

18、ity requirements and results; sub-supplier requirements and Run Rate results; and packaging.在RunRate过程中，检查以下一些项目：文件，制造工艺和其结果，零件质量要求 和其结果，对分供方的要求及其Run Rate的结果，还有包装和搬运。A. DOCUMENTATION : At the time of the RunRate , the following support documentation should be available for review:文件：在作Run Rate审核时，应出

19、具下列证明性文件以备查阅。1. PPAP package including :PPAP文件包括：a) Process flow diagram 过程流程b) Process control plan, with reaction plan 具有反应计划的过程控 制计划c) DFMEA / PFMEA设计/过程失效模式及后果分析d) Master part(s)标样2. GP-12( Pre-launch ) control planGP-12初期生产次品遏制的控制计划3. Tool capacity information工装能力情况4. Operator/inspection instru

20、ction操作/检验指导书5. Prototype / pilot concerns (PR/Rs)样件/试生产时发生的问题(如PR/R)6. Sub- contractor control / capacity data分供方控制/能力数据7. Sub-contractor material schedules and transportation分供应商材料(含零件)生产计划及运输8. Packaging / labeling plan包装/标记计划9. Acceleration plan生产加速计划Note : All documentation must be complete and

21、 correct注：所有文件都应完备及正确。B. MANUFACTURING PROCESS - ACTUAL TO PLAN制造过程-实际相对于计划1. The product is being manufactured at the production site using the production tooling, gaging, process, materials, operators, environment, and process settings.产品应在生产现场用正式生产的工装、测量系统、工艺、材料、操作人员、 环境和过程设定来进行生产。2. The actual p

22、rocess flow agrees with the process flow diagram, as documented in PPAP.实际生产流程应与PPAP文件中的流程图相同。3. Operator instructions/visual aids are available and adhered to at each work station.应将操作指导书/目视参考图表置于相应的每个工作岗位。4. All in-process documents, such as process control charts, are in place at the time of the

23、Run Rate. The documentation is utilized to drive a defined reaction plan and corrective action process.在进行RunRate时，所有过程文件都应在工位上，如过程控制计划。这些 文件应用于实施规定的反应计划和纠正措施。5. Production boundary samples, when required, are available at required work stations.当需要时，在需要的工位上应拥有边际样品。6. Maintenance plans are in place;

24、 repair and maintenance parts are available; and there is planned downtime for preventative maintenance.应具备保养计划和用于维修和保养的备件以及进行预防性维修保养的停机计划。Note: All of the preceding requirements must be met to pass the Run Rate. 注：上述所有要求都须合格才能通过Run Rate.C. MANUFACTURING CAPACITY RESULTS制造能力结果The following will be v

25、erified while the process is running.在进行生产时，要核实以下内容：1. Net output from each operation can support quoted capacity. 每道工序的净产量与报价生产能力相符。2. During the Run Rate, the tooling must meet the quoted up time requirements (net vs. gross quoted output). Any unexpected downtime must be documented and corrective

26、action taken.在按预定能力生产时，工装应满足报价所要求的开机时间要求(报 价净产量和标称毛产量)。记下任何意外的停工时间和要求的改进措施计划。3. All line changeovers, if any, can be performed within the quoted tooling capacity requirements.所有在线工装的更换应在报价工装能力要求范围内进行。4. The net through-put of good pieces (scrap taken out, any allowable rework) meet daily quoted capa

27、city.合格零件的净产量(剔除废品，保留返工合格零件)应与报价日生产能力相 符。5. The acceleration plan is sufficient to meet requirements. 加速生产计划足以满足客户要求。Note: All of the preceding five requirements must be met to pass the Run Rate. 注：上述所有五项要求都须合格才能通过un Rate。D. PART QUALITY PLAN TO ACTUAL零件质量计划同实际相对比1. All production checking fixtures

28、must be complete, with acceptable measurement system studies ., gage R and R） performed, and operator instructions/visual aids available.所有生产检验设备应完备并且作了可接受的测量系统分析工作（即量具的重 复性和再现性）。应具备操作指导书/目视参考图表。2. All in process gaging and controls must be complete, functional and in place.所有生产过程中的测量和控制设备应完备，功能齐全并且

29、到位。3. The process control plan （normal and GP-12） must agree with the actual process. Production part checks and statistical monitoring must take place as outlined on the process control plan过程控制计划（一般的和GP12）应与现行过程相符，应按过程控制计划作零 件检验和统计监测。4. Potential failure modes, as identified in the PFMEA, are addr

30、essed through error-proofing or the control plan.在PFMEA中所确定的潜在失效模式应有防错措施或控制计划来处置5. The process control plan reaction plan as well as the supplier,s corrective action process to ensure containment and correction should be available for review.过程控制计划的反应计划与供应商的改正措施一确保在检查时有遏制措施及施改正措施。Note: All of the pr

31、eceding five requirements must be met to pass the Run Rate.注：上述所有要求都须合格才能通速un Rate。E. PART QUALITY RESULTS零件质量结果1. All parts produced off production tooling during the Run Rhte meet GM,s requirements for ongoing quality, as stated in PPAP.量要求。2. The manufacturing process is in control.制造过程必须受控。3. Th

32、e manufacturing process demonstrates the required capability. 制造过程应证明所要求的生产能力。4. The process control plan is sufficient to effectively meet the design record requirements ., control points, frequency of checks, etc.). 过程控制计划应能有效地满足设计要求，(即控制点，检验频率等)。5. Nonconformance不符合性Note: The total number of part

33、s produced, the pieces rejected and the pieces reworked need to be documented on the summary sheet.注：生产出来的零件总数，不合格零件数，返工合格零件数都应底9总结表 上纪录a) The non-conformances yielded by the process were identified by thenormal PPAP control plan. If identified by the GP-12 Process Control Plan or an activity outsid

34、e documented plans, corrective action is required.生产过程中的不符合项可由一般的PPAP控制计划识别出来。如果是由 GP12过程控制计划或是由其他措施认别出来，则要求修改PPAP控制计 划。b) The PFMEA identified the potential failure modes. If not, the PFMEAneeds to be updated and corrective action put in place.生产过 程中的不符合项在PFMEA中应有预见，若未能做到，则PFMEA需要更新 并且要采取改进措施。c) Al

35、l rework and repairs effectively correct the nonconformance(s).返工及修复措施能有效地纠正不合格项。d) All prototype and pilot concerns, if any, have been corrected andvalidated.所有在工装样件及试生产件制造时发生的问题应已修正和验证。Note: All of the preceding five requirements must be met to pass the Run Rate. 注：上述所有要求都须合格才能通过Run Rate。F. SUBCON

36、TRACTOR REQUIREMENTS分供方要求1. Subcontractor(s), abilities to meet the customers quality and capacity requirements must be confirmed by the supplier prior to the Run Rate being conducted at the suppliers facility. Verification of the subcontractor(s) manufacturing processes should be accomplished throu

37、gh a Run Rate or similar process conducted by the supplier.在进行RunRate以前，供应商应该对分供方是否能满足用户的质量和数量 要求进行确认。上述核实应由供应商采用Run Rate规程或相似的过程加以实施。2. Controls must be in place to isolate incoming material until it has been approved.应采取措施来隔离外来材料流入生产线，直到它被认可。Note: The preceding requirements must be met to pass the

38、 Run Rate. 注：上述要求都须合格才能通过Run Rate,G. PACKAGING AND HANDLING包装及装卸1. In process and final shipment packaging will be reviewed for preservation of part quality and ease of use by suppliers operators loading and unloading parts. (Refer to GM 1738 for requirements.) 将检查在生产过程中和最终运输的包装情况以保证零件的质量并且便于供 应商的操作

39、人员装卸零件。(参见GM1738中的要求)。2. The suppliers method for in process and final shipping packaging and handling must effectively eliminate the potential for process errors or mixed stock.在生产过程中及最终运输时所采用的包装及装卸方式应能有效地杜绝可能 的程序差错及混装。VI. CORRECTIVE ACTIONS REQUIRED需要做的纠正措旅A. Actual to Requirements. If the results

40、 of the actual manufacturingprocess do not meet customer requirements for on-going quality and quoted tool capacity, corrective action must be taken to correct any non-conformances.实际产量与用户要求：如果实际生产过程的结果达不到用户当前质量和声称的工装能力要求，应采取 纠正措施消除这些不一致的地方。B. Actual to Plan. If the manufacturing and quality plan do

41、 not agree with the actual process, changes must be made to bring them into agreement. 实际制造与质量计划：如果实际过程达不到制造和质量计划要求，则应作相应的变动使两者达成一致。C. Nonconformances. If nonconformances occurred during the Run Rate which were not identified previously by the normal PPAP control plan, a corrective action plan needs

42、 to be put in place ., error proofing or a change in the control plan） and documented in the PFMEA and/or process flow diagram.不一致性：如果在进行RunRate中,发生的不合格未能被一般的PPAP控制计划识别，必须 采取纠正措施（即防错措施或修改控制计划），并在PFMEA或工艺流程图中记录。VII. APPROVAL审定Upon completion of the Run Rate, the worksheets must be reviewed for comple

43、teness and a decision made whether or not to approve the review. The Run Rate can have one of three results: pass; open or fail.Run Rate 一结束，应审查工作记录表以确保完整性，同时应作 出决定：审查是否通过。可以有下述三种结果之一：通过， 待定，失败。A. Pass通过1. Definition 定.义Pass indicates that all Run Rate requirements were met. The supplier demonstrate

44、d the capability to produce parts that meet GM,s on-going quality requirements at quoted capacity (net output). All key product characteristics were monitored and meet Cpk/Ppk requirements. GP-12 requirements were met. The suppliers actual manufacturing process agreed with the manufacturing and qual

45、ity plan, as documented by the supplier in PPAP, GP-12 and other required documentation. Quality systems were documented and practiced.通过意味着满足全部的RunRate的要求。表明供应商具备 生产出符合GM现行质量要求的产品及具备所要求的生产能力。所有关键 的产品性能是在监督测定并且满足CPK/PPK的要求。满足GP12的要求。 供应商的实际制造过程符合制造和质量计划，这些规划由供应商记录在 PPAP，GP-12和其它要求的文件中。质量体系有成文记录并切实执行

46、。B. Open彳寺定1. Definition Open indicates that some minor non-conformances to the requirements were found that need to be corrected. Examples of this are net output meets volume requirements but not quoted capacity;quality systems have minor deficiencies ., preventative maintenance system lacking, lac

47、k of error proofing, incomplete or inadequate operator instructions/visual aids, operator training not complete, minor deficiencies in meeting customers ongoing quality requirements).定义：待定意味着产品的有些方面与所要求的稍有不一致，需要作改进。 比如，产量符合客户数量要求但达不到报价声称的生产能力；质量系统 有小缺陷(例：缺少预防性保养计划，缺少防错措施，操作规则等不完备 或不合适，操作人员培训不充分，有些地方

48、不符合用户现行质量要 求)。2. Corrective Action Required A documented Action Plan to correct the non-conformances is required. At a minimum, it must include the name of the individual at the Supplier who is responsible for implementing the Corrective Action and the timing and validation of the Corrective Action

49、Plan. This plan is due to the GM Run Rate Supplier Quality Engineer for approval, within two (2) business days of the completion of the Run Rate.需做的改进措施：要求一个成文的纠正这些偏差的措施。并且，它应包括供 应方负责执行整改措施、控制进度及考核成效的人员名单。该计划需由GM 负责RunRate评审的供应商质量工程师来审核，并在RunRate结束后两天 之内完成。3. Verification of Corrective Action GM ver

50、ification of successful completion of the corrective action plan can be accomplished in several different ways, for example, through correspondence, a part review or a plant visit. Generally an additional Run Rate is not required. Once the Corrective Action plan is successfully completed,the Supplie

51、r Quality Engineer will change the Run Rateresult from open to pass.改进措施的验证:验证改进措施是否顺利完成有几种不同的方法。例如，通 过联系，对一批零件的检查或是参观生产现场。通常不需要再作RunRate。 一旦改进措施顺利地完成，供应商质量工程师将把RunRate的结果由待定 改为通过。C. Fail失败1. Definition Fail indicates a serious non-conformance exists that requires significant action by the supplier

52、to correct, such as quality systems are not in place and serious non-onformances exist; Ppk values (Cpk values) do not meet requirements for KPCs; or supplier fails to meet Volume Requirements. An additional Run Rate will be required.定义：“失败”意味着存在着严重的不一致的地方，要求供应商采取一些重 大的措施来加以改进。这些不一致有：质量系统不存在并有严重不一致质

53、量 问题存在，关键产品特性的Ppk值(Cpk值)达不到KPC的要求，或者供应商 达不到产量要求，因此要求重新作Run Rate。2. Corrective Action Required A documented Action Plan to correct the non-conformances is required. At a minimum, it must include the name of the individual at the Supplier who is responsible for implementing the Corrective Action and t

54、he timing and validation of the Corrective Action Plan. This plan is due to the GM Run Rate Supplier Quality Engineer for approval, within two (2) business days of the completion of the Run Rate.需做的改进措施：要求有一个成文的改正这些偏差的措施。并且，它应包括 供应方负责执行整改措施、控制进度及考核成效的人员名单，该计划的要由GM负责RunRate评审的供应商质量工 程师来审核，并在Run Rate结

55、束 后两天内完成。3. Verification of Corrective Action. Once the Corrective Action plan is completed, the Supplier Quality Engineer will schedule the new Run Rate to verify the successful implementation of the corrective action plan.改进措施的验证:改进措施计划完成以后，供应商质量工程师将按排进行新 的RunRate，以验证改进措施是否有执行成效。VIII. Supplier Mon

56、itored Run Rate Additional Requirements供应商监督下的Run Rate的附加要求A. All Run Rate requirements identified in Sections IV. V, VI and VII of this procedure apply to both supplier monitored and customer monitored Run Rates.所有在本程序第IV、V、VI、VII节中对RunRate的要求不论是供应商监督或 是由用户监督下的Run Rate均适用。Note: The scheduled date f

57、or the Run Rate must be approve by The Supplier Quality Engineer.注：由供应商监督的5n Rate的日期安排应得到供应商质量工程师的认可。B. Since a customer representative will not be present during the Run Rate, the following must be completed.由于用户代表将不参加Run Rate，因此供应商应该完成以下工作。1. Within twenty-four hours of completing the scheduled Ru

58、n Rate, thesupplier must complete the Run Rate Summary and Worksheets (Attachments A and B) and provide them to the responsible customer Supplier Quality Engineer, with a recommendation for the result of the Run Rate.在完成RunRate以后24小时内，供应商应写出RunRate总结及工作表(附 录A和B)并将其交给用户方负责人供应商质量工程师，并对Run Rate的 结果提出某些

59、建议。2. In addition, if any non-conformances were identified, the supplier will develop and implement a corrective action plan, using Sections VI and VII as reference. Within two days of completing thecheduled Run Rate, the supplier will provide this information to the responsible customer Supplier Qu

60、ality Engineer.另外，如果发现有不一致的地方，供应商应参照第VI、VII节的要求，制定 并实施改进计划，并在完成Run Rate两天内，将该信息通知用户方负责 人供应商质量工程师。3. Based on the information provided by the supplier, the customer Supplier Quality Engineer will:根据供应商提供的信息，客户方供应商质量工程师要做如下几项工作：a) Determine whether the Run Rate results in a pass, open or fail.确定运行结果是通

61、晕，待定还是不通过。b) Review and approve the corrective action plan. 审批改进措施计划c) Determine the need for an additional Run Rate.确定是否需要再作Run Rated) Communicate the results of the above review to the supplier. 将上述审查结果驼知供应商4. If the result of the Run Rate is open or fail, the process describedin Section VII appli

62、es. 如果Run Rate的结果是待定或失败，则第VII节的内 容将适用。Note: If the supplier monitoredRun Rate results in a fail, another Run Rate must be scheduled with a customer representative present注：如果由供应监督的Run Rate结果失败，则下一次的Run Rate 须有用户方代表参加。Part Name零件名称Part #零件号 Drawing #图号Change Level更改级别GP-9 RUN RATE SUMMARYGP9“按预定能力生产”

63、总结Supplier供应商 Mfg. Location制造地址 DUNsSupplier Quoted production rate供应商报价生产能力/ Hr 小时/Day 天CustomerBuyerPhone用户采购员电话Planned usage:DailyweeklySQEPhone计划要货率：每天每周质量工程师电话Planned Run Date计划运行日期Planned Hours To Run计划运行小时数Planned ShiftsPlanned Downtime计划班次计划停工时间Reason for Planned Downtime计划停工的原因RESULTS 结果Actual HoursFromTo实际小时数欧至Actual shiftsdate实际班数F期Actual Downtime Hours(planned & unplanned)实际停工时间(计划和非计划)一Goal （net good parts）目标（合格零件净数）ur小时/shift 班/day天Actual (net good parts)实际（合格零件净数）小时/shift 班/ hour/dayExplain :解释：Total