run at rate (r@r)

Run at Rate (R@R)

Polaris Supply Chain – Supplier Training

Revised: June 6, 2016

Revision Number: 1Polaris CONFIDENTIAL

2

Welcome

Add the slide take-away here!Polaris CONFIDENTIAL

Welcome to the Run@Rate Training Module

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Agenda

Name of Training Topic: Run@Rate Training Module

Learning Objectives

Why the Training Topic is Important? When?

Define Training Topic – What is It?

Training Content

Tools and References

Demo / Example

Learning Objectives Recap

Thank you!

Polaris CONFIDENTIAL

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Learning Objectives

Effective R@R Audit

At the end of this training, participants will be able to:

• Understand importance of the R@R

• Know when to schedule a R@R

• Know how to perform a R@R


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Why is a R@R Important?

R@R Audits Determine State Of Production ReadinessPolaris CONFIDENTIAL

A R@R audit is used to:

Validate the readiness of your manufacturing process.Comprehensive process review: receipt to shipment.

Demonstrates capability over multiple shifts and production set ups.

Evaluate the process controls with regards to production readiness.

Evaluate capability.True capacity.

Equipment effectiveness.

Quality systems management.

Expose process variation prior to SOP.Drive production like requirements

Evaluate sub-tier supplier management.Review formal selection process.

Review PPAP completion of sub-tier suppliers.

Uncover and address quality risks before SOP.

The Quality Lifecycle Management process is a

process to ensure product quality assurance.

Process Usage: Run@Rate

Supplier selected for

R@R

R@R schedule

R@R requirements

Pre-R@R meeting(s)

held

Perform on site R@R

Close our action

register items

Follow up R@R if needed

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Process Overview

R@R Audits Are Key Part Of PDP And APQPPolaris CONFIDENTIAL

P

P

A

P

Supplier

QualificationPDP

EOL

Safe Launch

Supplier Performance

Product

Assurance

ControlMonitoring Improvement

APQPQuality Event

Resolution

Supplier On-

Boarding

………….Serial

Production…….………MaturityVolume Ramp….SOP PPAP…..APQP……

SupplierSelection

All suppliers selected for APQP will require R@R audit.

Detail of APQP selection process can be found in this link.

SQE can conduct R@R audit as risk mitigation on any supplier.

Examples:

Validation of process change: sub-tier change, new equipment, etc.

In response to a design change.

Verify process due to seasonal manufacturing schedule.

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R@R Selection

Suppliers Selected From APQP Process or as Risk MitigationPolaris CONFIDENTIAL


R@R

R@R schedule

R@R requirements

Pre-R@R meeting(s)

held

Perform on site R@R

Close out action

register items


http://internal.polarisind.com/operations/supplychain/suppliermanagement/supplierdevelopment/suppliermanagementprocesses/Shared Documents/APQP/Training/APQP Process Training_Supplier_PDPDEV1002.pptx

The R@R should be scheduled with PV parts production.

Higher risk parts/suppliers should have pre-audit visits.

Recommended at PI so that suggestions can be given before tooling has been completed.

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R@R Timing

Schedule R@R Based on Project TimelinePolaris CONFIDENTIAL


R@R

R@R schedule

R@R requirements

Pre-R@R meeting(s)

held

Perform on site R@R

Close our action

register items


Use PV or Pulse to Drive Requirements9

Audit to be performed at production of PV parts.Timing driven by PV timing.

High risk parts/suppliers will require earlier audit.

Quantities driven by PV volume.

If PV volume too low then use pulse process.

Significant production run(s) should be performed before R@R as well.

Production should be off tool, off process.Any changes to process after R@R will require PCR.

Should be at planned production volume.

Frozen design must be achieved.

R@R Requirements


R@R

R@R schedule

R@R requirements

Pre-R@R meeting(s)

held

Perform on site R@R

Close ouaction

register items


Preparation is Key to Successful R@R10

Your preparedness is critical for success.

Steps to ensure you are prepared:Participate in the pre-audit meetings to set expectations.

• Go through the audit form with the SQE.• Perform the self assessment and send results back to SQE prior to formal audit.• Complete capacity tab and send back to SQE before the audit.

Audit is from receipt – shipment. Prepare all processes!

Conduct a significant production run before audit.

Review the agenda before audit.

Off tool, off process.Also means operators run the process not engineers.

Make sure the right representatives are present!• Senior Management (kickoff and wrap up).• Quality.• Engineering.• Manufacturing.

If your schedule changes let SQE know before arriving at audit.

This is meant to help your process be successful.

R@R Preparation


R@R

R@R schedule

R@R requirements

R@R preparation

Perform on site R@R

Close out action

register items


Poor planning will result in a poor

audit!

It’s time for the R@R! How are we successful?

Review the agenda.

Have copies of print, control plan, and process flow available.

Make sure production operators are running the processes.

The SQE will Review the entire process

• Receiving – Shipment

• Poke yokes

• Labeling/barcoding

• Doc control

• Rework procedure

Review multiple shifts.

If not enough time to see entire process make sure critical processes are running for audit.

Stage any other processes for general review.

Have a closing meeting.

Work with SQE to complete action register.

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Performing the R@R

Production Readiness & Risk Should be Fully UnderstoodPolaris CONFIDENTIAL


R@R

R@R schedule

R@R requirement

Pre-R@R meeting(s)

held

Perform on site R@R

Close out action

register items


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Action Register

Action Register Drives Required ImprovementPolaris CONFIDENTIAL

Use the action register tab to:

List any non-conformance items.

Assign responsible person for each item.

Assign due date for each item.

Drive process improvements for production.

Be prepared for all follow up meetings with updates.

As with the audit itself make sure the correct people participate in each meeting.

Complete all tasks on the action register!


R@R

R@R schedule

R@R requirement

Pre-R@R meeting(s)

held

Perform on site R@R

Close out action

register items


Preparation Prevents Repeat Audits & Follow-up13

A follow up R@R will be required if:

The process was not ready when the SQE was present for the first R@R.

• Fixtures

• Machines

Late design change requires process changes.

The process was not able to complete enough parts for a full production run.

• Not enough raw material

• Equipment failure

High risk suppliers/parts as part of safe launch.

Validate any PCRs after R@R.

Follow Up


R@R

R@R schedule

R@R requirement

Pre-R@R meeting(s)

held

Perform on site R@R

Close out action

register items


Standard Work; Use of Form is Required 14

R@R form can be accessed via the SQAM.

Tools / Other References


Snap Shot Of Blank To Completed Audit Tab15

Example – Audit Tab

Complete All Fields16


First fill out the top section of the audit tab. Supplier

fills out top portion, SQE fills out bottom portion. All

orange sections must be completed.

Use Criteria as the Guideline to Score Audit17


Now it is time to work through the audit process.

Each item is graded on a 0-3 scale. If the item is not

applicable then it can be marked “NA.” The grading

criteria is provided as a guideline for each line. Take

all time required to review each line.

Utilize Objective Evidence to Justify18


The objective evidence is the section to insert the

detail justifying the rating given for each item. The

criteria gives the guideline for rating but the SQE is

still responsible for giving further detail when

necessary.

Tip: While objective evidence is important for all line items it is especially

important when the supplier and Polaris ratings are different and when giving a 0

or 3.

Use The AR Tab To Capture Improvement Plan19

Example – Action RegisterThere will be some improvement

items with each audit. The AR tab

is the place to capture the CA plan.

Quick Assessment to Prioritize Improvement Area(s)20

Example – Scoring SummaryOnce the scoring has been completed

on the audit tab use this summary to

show where most improvement is

needed.

Ensure Your Supplier Is Prepared!21

Example – Pre-Run@Rate AR

Prior to each audit the pre-run@rate AR must be completed. This is your checklist

to ensure the supplier is prepared for the audit.

Important to Verify Actual Capacity22

Example – Capacity

Line capacity is also a crucial part of the success for a supplier’s process. Before

arriving for the run@rate the supplier should have the capacity tab filled out. Make

sure to pay attention to the bottle neck(s) in the process. These should be attacked

for future improvements.

Complete Summary for Concise Reporting23

Example – Summary

The summary page is important for giving quick feedback in meetings where the full

detail is not needed. This should give a snapshot of the audit results.

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You should understand:

Understand importance of the R@R

Know when to schedule a R@R

Know how to perform a R@R

Learning Objectives Recap

What you learned from this trainingPolaris CONFIDENTIAL

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Thank you!

Thank you for attending!Polaris CONFIDENTIAL

Thank you for taking the time to complete the Polaris R@R Training Module.

• Please make sure to take the Quiz and provide training feedback.

• Taking the Quiz gives visibility to us that you have read and understand this

training!

Questions? Please contact your Supplier Quality Engineer or Buyer.