Download - Part Handling 4-15-11
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Part Handling PlanPSQPTH100
March 2011
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Why a class on Part Handling Plans?
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• Analysis revealed that „Part Handling Plan‟ was cited as one of the top
5 root causes of critical WK e-CIMS.
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5. PFMEA
7. Control Plan
14. Layer Process Audit
17. Part Packing & Shipping Spec
15. SRE results & Evidence of Product Spec
2. Part Number, Description & Change Level
1. Advanced Quality Planning
16. Prod Demo Run8. Incoming & Outgoing Material Qual process
4. Test Samples & Freq
9. Part Handling - WIP
3. DFMEA
13. Error & Mistake Proofing
10. Operating Instructions
WK Critical e-CIMS - PSO Element Alignment
Broad
Categorizations.
Classes in place to
address
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Definition
• Part Handling Plan:
Procedure that detail all internal material handling
operations.
The plan shall include:
Identification of Containers
Methods to identify and differentiate rework/repair, scrap,
Work in Process (WIP), etc.
Procedures for in-process raw material re-stock (e.g. Kan-Ban)
First-In-First-Out (FIFO) material control
Procedure by which material is tracked and moved from one
process to another
Containment of nonconforming material and use of Chrysler
“Supplier Notification of Potential Nonconformance”
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SQEs role in Part Handling
• “Part Handling” is Element 9 in the Process Sign Off
7th Edition
• SQEs verify that Part Handling is robust and properly
executed by the supplier.
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• Procedures that detail all internal material handling
operations
• Describe the types of containers used in the internal
manufacturing process
Material dimensions
Quantity per container
Part number(s)
Stack height (mobile & static)
Weight
Ergonomic requirements
Maintenance requirements
Element 9- Parts Handling Plan
NOTE: Container information and maintenance may be included as a
part of the Packaging Instructions and/or Preventative Maintenance.
See elements 10 and 19.
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Element 9- Parts Handling Plan
• All parts shall be marked with the Supplier Code, Part
number and Manufacturing Dates based on Engineering
Standard PS-4480. PS-4480 defines the normal methods of applying part numbers,
supplier codes and date codes to individual parts. Specificidentification requirements are denoted by designations shown as
suffixes after the standard number in the Standards section of the
Part Information Page (PIP) or on the CATIA model.
• A cross reference sheet shall be used by the Supplierwhen the Chrysler part number is not used internally in the
Supplier‟s manufacturing plant to track the part.
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Lot Sampling Table
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Incoming/Outgoing Material Certification Plan How is it different from the Part Handling Plan?
• Outgoing Material Inspection Plan Procedures to qualify outgoing product prior to
shipment to the customer
Includes outgoing acceptance sampling plans for
both attribute and variable data
• Documented in the Control Plan
• Consider Severity, Occurrence, and Detection
values
• Inspected parts identified and traceable to the
process and auditor
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• Containers are clearly marked, e.g. scrap, Work in
Progress (WIP), etc.
• The Supplier shall have controls (Control Plan & Inspection
Procedures) in place to identify Work in Process (WIP) andnon-conforming material (e.g. scrap, rework/repair, sorted
and contained material)
WIP requires lot, part #, quantity, and stages
completed
• Chrysler returnable containers are not for WIP or sub-tier
Suppliers! This will result in the rejection of the PSO.
Element 9- Parts Handling Plan
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Misuseage of Storage Containers
Rack sitting on top of
Chrysler returnable
containers.
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• Procedures detailing in-process raw material re-stock and
FIFO (First In, First Out) inventory control
Material storage locations clearly identified, adequate
and well-maintained
Storage areas sufficiently sized and located well with
respect to process flow (easy access to product and
safe handling)
Effective method for FIFO stock rotation
Element 9- Parts Handling Plan
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• Procedure for tracking material from one process to another
(travelers, routing cards, etc.)
Lot number
Date
Pieces entering/exiting
Pieces repaired/reworked
Pieces scrapped
Operation number and shift
Element 9- Parts Handling Plan
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Additional traceability
• All parts require lot control and traceability within theSupplier‟s manufacturing facility.
• For parts required to meet the Chrysler Traceabilityspecification PS-10125, product identification and traceabilityshall be maintained and recorded through all stages ofproduction, delivery and installation.
A minimum, it is mandatory that record keeping track theusage of lots or batches back to the production date.
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Traceability
Good example of
stock with
traceability lot
control
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• Parts shall have traceability through all stages ofproduction, including sub-tier Suppliers
Lot size shall not exceed one shift or one production
run, whichever is less
Sorted, reworked or repaired material shall betraceable back to sort, rework or repair process
Traceability shall be independent of FIFO processes
• In other words, failure to follow FIFO will not result
in an inability to trace the part and its components
Element 9- Parts Handling Plan
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• Containment of Nonconforming Material Use of the “Supplier Notification of Potential
Nonconformance” process
Plan shall include:
• Handling and identification of nonconforming product
• Maximum time allowed for dispositiono Reviews of quarantined material daily (at a minimum)
• Coordination with Chrysler to purge and replace suspectmaterial
• Locked or controlled area for holding nonconforming,
quarantined, or non-production material (e.g. engineeringsamples)
o Clearly identified: Part number, number of pieces,date quarantined, reason for quarantine, anddisposition date.
Element 9- Parts Handling Plan
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Documentation required: The Parts Handling Plan shall include:Identification of Containers
Methods to identify and differentiate rework/repair, scrap, Work
in Process (WIP), etc.Procedures for in-process raw material re-stock (e.g. Kan-Ban)
First-In-First-Out (FIFO) material control
Procedure by which material is tracked and moved from one
process to another
Containment of nonconforming material and use of Chrysler
“Supplier Notification of Potential Nonconformance”
Electro-static Discharge (ESD) procedures
(if applicable)
Element 9- Parts Handling Plan
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Part Storage Area – Effective or Ineffective?
Clean floors and organized racks
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Part Storage Area – Effective or Ineffective?
At first glance, this looks
clean and organized
However, the question
should be asked as to the
correct quantity of stock
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Excessive
scrap or
regular stock?
Potential for
in system
damage
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Part Storage Area – Effective or Ineffective?
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Part Storage Area – Effective or Ineffective?
Excessive
scrap or
regular stock?
Potential for in
system
damage
Difficult to
maintain FIFO
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Are returnable
containers
being used for
their intended
purpose?
Appears that
Chrysler is
being used for
WIP.
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Part Storage Area – Effective or Ineffective?
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Excess stock
Packaging
garbage
everywhere.
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Part Storage Area – Effective or Ineffective?
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High value parts.
Current storage
allows for damage,thus impacting
quality
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Part Storage Area – Effective or Ineffective?
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At first glance, this area looks good.
However, the racks feeding each station are generously large.
Therefore, the presence of additional stock pallets only causes clutter
and forces employees to walk in the jitney aisle.29
Part Storage Area – Effective or Ineffective?
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Traceability
Operator to
working out of
dunnage bin due to
lack of room for
proper line side
display.
Quality risk –
contamination –
traceability?
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Traceability
Confirm that the material
is properly tagged.
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Wrap up – Did we answer the questions?
• Answer the question: “Part Handling – why do I needanother class on this?”
• Define “Part Handling Plan”.
• Define Supplier Quality Engineers role in Part Handling.
• How do Element 9, Part Handling Plan and Element 8,
Incoming & Outgoing Material Certification plan relate?
• Distinguish between effective and ineffective Part
Handling Plans.
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Wrap up