part handling 4-15-11

8/16/2019 Part Handling 4-15-11

1/34

Part Handling PlanPSQPTH100

March 2011

8/16/2019 Part Handling 4-15-11

2/34

8/16/2019 Part Handling 4-15-11

3/34

Why a class on Part Handling Plans?

3

• Analysis revealed that „Part Handling Plan‟ was cited as one of the top

5 root causes of critical WK e-CIMS.

24

17

6

1

1

1

2

23

4

5

5

6

6

0 5 10 15 20 25 30

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

8/16/2019 Part Handling 4-15-11

4/34

4

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”

8/16/2019 Part Handling 4-15-11

5/34

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.

5

8/16/2019 Part Handling 4-15-11

6/34

• 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.

6

8/16/2019 Part Handling 4-15-11

7/34


• 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.

7

8/16/2019 Part Handling 4-15-11

8/34

8/16/2019 Part Handling 4-15-11

9/349

Lot Sampling Table

8/16/2019 Part Handling 4-15-11

10/34

8/16/2019 Part Handling 4-15-11

11/3411

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

8/16/2019 Part Handling 4-15-11

12/34

• 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.


12

8/16/2019 Part Handling 4-15-11

13/34

Misuseage of Storage Containers

Rack sitting on top of

Chrysler returnable

containers.

13

8/16/2019 Part Handling 4-15-11

14/34

• 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


14

8/16/2019 Part Handling 4-15-11

15/34

8/16/2019 Part Handling 4-15-11

16/34

• 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


16

8/16/2019 Part Handling 4-15-11

17/34

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.

17

8/16/2019 Part Handling 4-15-11

18/34

Traceability

Good example of

stock with

traceability lot

control

18

8/16/2019 Part Handling 4-15-11

19/34

• 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


19

8/16/2019 Part Handling 4-15-11

20/34

• 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.


20

8/16/2019 Part Handling 4-15-11

21/34

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)


21

8/16/2019 Part Handling 4-15-11

22/34

Part Storage Area – Effective or Ineffective?

Clean floors and organized racks

22

8/16/2019 Part Handling 4-15-11

23/34

23


At first glance, this looks

clean and organized

However, the question

should be asked as to the

correct quantity of stock

8/16/2019 Part Handling 4-15-11

24/34

Excessive

scrap or

regular stock?

Potential for

in system

damage

24


8/16/2019 Part Handling 4-15-11

25/34

25


Excessive

scrap or

regular stock?

Potential for in

system

damage

Difficult to

maintain FIFO

8/16/2019 Part Handling 4-15-11

26/34

Are returnable

containers

being used for

their intended

purpose?

Appears that

Chrysler is

being used for

WIP.

26


8/16/2019 Part Handling 4-15-11

27/34

Excess stock

Packaging

garbage

everywhere.

27


8/16/2019 Part Handling 4-15-11

28/34

High value parts.

Current storage

allows for damage,thus impacting

quality

28


8/16/2019 Part Handling 4-15-11

29/34

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


8/16/2019 Part Handling 4-15-11

30/34

8/16/2019 Part Handling 4-15-11

31/34

Traceability

Operator to

working out of

dunnage bin due to

lack of room for

proper line side

display.

Quality risk –

contamination –

traceability?

31

8/16/2019 Part Handling 4-15-11

32/34

Traceability

Confirm that the material

is properly tagged.

32

8/16/2019 Part Handling 4-15-11

33/34

33

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.

8/16/2019 Part Handling 4-15-11

34/34

34

Wrap up

part handling 4-15-11

Documents