SECTION 2.13 - HIGH VOLUME PRODUCTION TRIAL
(HVPT)
***** PRODUCTION PREPARATION *****
PURPOSE: To explain the procedure for conducting a High Volume Production Trial.
EXPLANATION:
The goal of a High Volume Production Trial (HVPT) is to identify and countermeasure any quality or productivity problems prior to Start of Production in a Mass Production setting. The HVPT is a confirmation of supplier readiness for mass production. It must be conducted early enough to allow adequate time for improvement and countermeasure confirmation. Requirements and timing will be provided by Reyes Program Management Division.
Prior to the HVPT, it is the supplier’s responsibility to run production trials at the manufacturing location using Mass Production conditions (i.e. line-speed, tooling, cycle time, etc.) as closely as possible. The HVPT should be the culmination of these trials and all other elements of a successful part and process evaluation plan.
SUPPPLIER RESPONSIBILITY:
1. The HVPT shall be completed per the timing indicated on the REYES Master Schedule. The supplier must include the specific timing on the Quality Assurance Schedule. In some cases, REYES SPPT will coordinate specific dates with the supplier. The trial must be conducted early enough to allow adequate follow-up for problems discovered prior to SOP. REYES reserves the right to visit the supplier during any and all trials.
2. The supplier must include all required processes in the HVPT, with special attention paid to bottlenecks, final assembly and new processes, facilities or cells. All processes should be run in the correct sequence and notations made to indicate any processes which had to be run “off-line” due to new model/old model build out or change over requirements.
3. Trials must be representative of Mass Production.
A. Facilities, tooling, and equipment must be complete.
B. Operators must be trained and must be those who will be used for Mass Production. The trial should include operators on all shifts.
C. Trials shall be performed for each machine (e.g. die, mold cavity, etc.) or process (e.g. assembly line).
D. Production method must be the same as Mass Production and include:
1) Written Standardized work
2) Mass Production Quality Control system
3) Tool changes and set-ups
4) Mass Production line speed
E. Material must be the same as Mass Production materials, and should be produced at the required capacity set by REYES and/or a quantity equivalent to Mass Production scale.
Note: All Direct Run Good Parts can be used to support mass production shipments providing no late ECI changes or other tuning as required by REYES occur (any reworked parts must be approved by REYES Quality). These parts need to be identified as HVPT Parts or be traceable by date code (date code is the preferred method). REYES will not accept trial parts produced prior to supplier receipt of Provisional Approval.
4. Trial targets for quality and quantity must be clearly specified.
Definitions
Quality – Parts produced which satisfy the approved Part Inspection Standard, the Part Mass Production Drawing, and boundary sample (if applicable).
Quantity – Rate of Direct Run Good Parts (no re-worked parts) which satisfy REYES’s demand (Mass Production volume requirement).
Example 1
Supplier A – Dedicated REYES Facility
Operating Constraints*
Total daily operating time = 8.5 hours -20 minutes real allowance
-30 minutes meal break
-19 minutes for Quality checks
Net Operating Time = 7 hours 21 minutes
REYES daily requirement = 200 parts
200
Therefore, parts per hour to meet REYES demand = ------= 27.21 parts per hour
7.35hrs
Example 2
Supplier B – Shared Facility
Operating Constraints*
Total daily operating time = 8.5 hours -20 minutes rest allowance
-30 minutes meal break
-19 minutes for Quality Checks
-50 minutes for changeover
-151 minutes to produce another part
Net Operating Time = 4 hours
REYES daily requirement = 200 parts
200
Therefore, parts per hour to meet REYES demand = ------= 50 parts per hr
4 hrs
* NOTE: The supplier should incorporate their own unique operating constraints when calculating net operating time.
5. During each individual trial, production must be continuous at Mass Production speed with the output of the process constantly recorded, typically for a period of 1 hour. The process should then be stopped, reviewed, and countermeasured for improvement and then tried again. This cycle should be repeated until the target criteria for the process output is achieved. The supplier must record results on the High Volume Production Trial Status Sheet. The sheet is then evaluated and graded Pass/Fail by the REYES evaluation team.
6. The supplier should track problems found, countermeasures, and follow-up items, and document them on a Problem Follow-Up Sheet. The supplier should also consider workability, safety, and ergonomics issues, as well as problems related to parts and capacity.
7. When the trial is completed, the supplier must submit the High Volume Production Trial Status Sheet with results, and the Problem Follow-Up Sheet to both REYES Program Management and REYES Quality.
Note: The supplier must complete and submit any additional documentation (e.g. preparation checksheet), as requested by REYES to support this activity.
8. If the supplier is unable to achieve target levels after countermeasuring the process, they must notify REYES Program Management and REYES Quality immediately. This notification should include the supplier’s plan for achieving the target.
Revision 1 / Reyes Automotive GroupSan Antonio, TX / Section 2.13
March 2006 / Page 1 of 3