Run at Rate - Rev F

DATE: REVISION: DOC #: PAGE:
27-Aug -2008 G D_020_4_12_EN 1 of 6
Level 4 [Form]
Supplier Run at Rate
ALLOCATION WORKSHEET
Factor Shift Length (hrs) Short Breaks (hrs) Meal Break (hrs) Down Time per Shift (hrs) WORKING HOURS PER SHIFT 0.50 0.50 # of Occurrences Time (Enter as fraction of an hour) Total Working hours/shift (8 hrs max. is standard) Shifts/ day (Standard is 3) Days/ week (Standard is 5) Weeks/ year (Standard is 48) Number of Lines Available hours per year Available Hours per month
Formula
A A
B B
C C
D D
E 3600/D
F A/E + B*C
G F*12
H G/Total of G
I Total Part Number Reqmnts G/ Total TRW Reqmnts G
Part Number
Monthly Volume
Number of Setups per month
Setup time/run (hrs)
Adjusted Production Total monthly Total Allocation as Allocation as a % of Cycle Time Rate in pcs/hr working hrs Annual a % of TRW Total Hours (seconds) required working hrs Hours Available required
TRW Part Numbers
Date: 24 Jan 2008 Rev: E Doc No: D_020_4_12 Page 1 of 9
211180074.xls.ms_office; Allocation % Worksheet
Process Owner / Department: R. Spariosu / Supplier Development Approved by: R. Blanchette / Global Director, SDE
27-Aug -2008 G D_020_4_12_EN 1 of 6
Level 4 [Form]
Formula
A A
B B
C C
D D
E 3600/D
F A/E + B*C
G F*12
H G/Total of G
TRW Part Numbers
TRW Part Numbers
Part Number
Monthly Volume
TOTAL
0.00
0.00
0.00
0.00
0.00%
27-Aug -2008 G D_020_4_12_EN 1 of 6
Level 4 [Form]
Formula
A A
B B
C C
D D
E 3600/D
F A/E + B*C
G F*12
H G/Total of G
Part Number
Monthly Volume
Other Customers
TRW Total
Customer A Customer B
0.00
0.00
0.00
0.00
0.00%
TOTAL
TRW Part Numbers Overall Utilization Available Time (hours/yr)
0.00
0.00
0.00
0.00
0.00%
Run-at-Rate Verification
(1) Part Number (2) Part Description/Program TRW Annual Capacity Planning Volume (pcs/year)
4 5 6 7 8
Run@Rate Date Supplier Name Supplier Address City/State/Postal Code Supplier Country Supplier Vendor Code STEP 4 STEP 5 STEP 6
(3) TOTAL CPV (pcs/year)

10 11 48 49 12
0 STEP 1 STEP 2 STEP 3
13 14 15 16 17
Working hours/shift (8 hours is requirement) Shifts/ day (3 shifts is requirement) Days/ week (5 days is requirement) Weeks/ year (48 weeks is requirement) Number of lines, presses, etc. Total hours/year (12*13*14*15*16) % of line for TRW parts (Allocation %) Quoted Production Rate Quoted % scrap Quoted process efficiency Adjusted production rate (19*(1-20)*21) Available capacity ((19*21*(1-20)*17*18)) Utilization % (3/23) Quoted Status (28) Bottleneck operation Trial run duration (8hrs is default) Total parts produced Number of bad parts First time capability % ((28 - 29)/28) Number of good parts (28-29) Net output (31/27) Takt Time Rate (Target) (3/(17*18)) Downtime Reason Availability ((27-34)/27) Quality (31/28) Perfomance ((28/27)/19) Overall OEE (36*37*38) Run-Off utilization % Utilization as % of Allocation (40/18) Bottleneck operation Net Output-Weeks (32*12*13*14) Net Output-Months ((32*12*13*14*15)/12) Run at Rate Conducted by:
Process Step Process Description Number of Operators Equipment size Units hours shifts days weeks units hours % pcs/hour % % pcs/hour pcs/year % % X hours pcs pcs % pcs pcs/ hour pcs/ hour hours text % % % % % % X pcs/week pcs/month
I - Supplier Working Standards II - Supplier Quoted Capacity Data
18 19 20 21 22 23 24 25 26 27 28 29 30 31
Unacceptable
Unacceptable
Unacceptable
Unacceptable
Unacceptable
Unacceptable
III - RUN at RATE Results
32 33 34 35 36 37 38 39 40 50 41 42 43 44
0.00% 0.00% X #VALUE! #VALUE!
0.00% 0.00% X #VALUE! #VALUE!
0.00% 0.00% X #VALUE! #VALUE!

45
0.00% 0.00% X #VALUE! #VALUE!
0.00% 0.00% X #VALUE! #VALUE!

44
0.00% 0.00% X #VALUE! #VALUE!
SHADED CELLS ARE CALCULATED
Overall Process Utilization % 0.00%
Status Acceptable
TRW Reviewer Name: Product Line: Location:
Comments
46
47
Supplier representative name printed
Supplier representative signature 211180074.xls.ms_office; Run at Rate Form
Date
Process Owner / Department: R. Spariosu / Supplier Development Approved By: R. Blanchette / Global Director, SDE
Run at Rate Exception Form

DATE OF REQUEST: ORIGINATOR: SUPPLIER: SUPPLIER CODE: SDE: COMMODITY MANAGER: PART NUMBER: PROGRAM: PART NAME: RUN AT RATE CONDUCTED BY:
SDE REASON FOR THIS EXCEPTION:
RUN AT RATE DATE: NUMBER OF LINES: ANNUAL CPV: STANDARD CALCUATION: CALCULATION: UTILIZATION PERCENTAGE: SUPPLIER PLANNED SCHEDULE: CALCULATION: UTILIZATION PERCENTAGE: RED/YELLOW/GREEN STATUS: Shifts Hours Days
[3 Shifts; 8 hours; 5 Days (120 hour maximum rate)]
Shifts
Hours
Days
COMMODITY MANAGER EXPLAIN COST IMPLICATION:
APPROVED:
YES
NO
DATE:
PRODUCT LINE PROGRAM MANAGER SIGNATURE:
PRODUCT LINE PURCHASING SENIOR MANAGER SIGNATURE:
DATE:
PRODUCT LINE PURCHASING DIRECTOR APPROVAL SIGNATURE:
DATE:
APPROVAL COMMENTS:
211180074.xls.ms_office; Exception Form
Factor Shift Length (hrs) Short Breaks (hrs) Meal Break (hrs) Down Time per Shift (hrs) WORKING HOURS PER SHIFT 7.50 0.25 2 # of Occurrences Time (Enter as fraction of an hour) Total 8.00 0.50 0.00 Working hours/shift (8 hrs max. is standard) Shifts/ day (Standard is 3) Days/ week (Standard is 5) Weeks/ year (Standard is 48) Available hours per year Available Hours per month 7.50 3.00 5.00 48.00 5400.00 450.00
Formula
A A
B B
C C
D D
E 3600/D
F A/E + B*C
G F*12
H G/Total of G
I (Total Reqmnts H Total Reqmnts I)/ Total Reqmnts H Maximum Addition Allocation % available to TRW
Monthly Volume
Adjusted Production Total monthly Total Required Cycle Time Rate in pcs/hr working hrs Annual Allocation % (seconds) required working hrs required 7 7 514.29 514.29 50.61 50.61 607.33 607.33 27.30% 27.30%
TRW Part A TRW Part B
25,000 25,000
4 4
0.5 0.5
TRW Part Numbers
TOTAL
50,000
1.00
14
1028.57
101.22
1214.67
54.60%
81.30%
211180074.xls.ms_office; Allocation % Example
Factor Shift Length (hrs) Short Breaks (hrs) Meal Break (hrs) Down Time per Shift (hrs) WORKING HOURS PER SHIFT 7.50 0.25 2 # of Occurrences Time (Enter as fraction of an hour) Total 8.00 0.50 0.00 Working hours/shift (8 hrs max. is standard) Shifts/ day (Standard is 3) Days/ week (Standard is 5) Weeks/ year (Standard is 48) Available hours per year Available Hours per month 7.50 3.00 5.00 48.00 5400.00 450.00
Formula
A A
B B
C C
D D
E 3600/D
F A/E + B*C
G F*12
H G/Total of G
I (Total Reqmnts H Total Reqmnts I)/ Total Reqmnts H Maximum Addition Allocation % available to TRW
Monthly Volume
Adjusted Production Total monthly Total Required Cycle Time Rate in pcs/hr working hrs Annual Allocation % (seconds) required working hrs required
All Customers
TRW Total
Customer A Customer B
50,000 15,000 12,000
8 3 2 13
1.00 0.50 0.50 2.00
14 10 12 36
1028.57 360.00 300.00 1688.57
101.22 43.17 41.00 185.39
1214.67 518.00 492.00 2224.67
54.60% 23.28% 22.12% 100.00% 41.20% 3175.33
TRW Part Numbers
TOTAL
Overall Utilization Available Time (hours/yr)
77,000
211180074.xls.ms_office; Allocation % Example
Run-at-Rate Verification
(1) Part Number 31367943B Tube (2) Part Description/Program TRW Annual Capacity Planning Volume (pcs/year) 300000
4 5 6 7 8
Run@Rate Date Supplier Name Supplier Address City/State/Postal Code Supplier Country Supplier Vendor Code STEP 4 Flats 1 75 Ton Press 7.50 3.00 5.00 48.00 2.00 10800.00 50% 150.0 1.0% 90.00% 134 721,710 42% Acceptable
10-Jan-2008 Acme Stamping Company 12345 S. North Blvd. Wayout, ID 56565 USA 3478548 STEP 5 Bend 1 Franklin 240 7.50 3.00 5.00 48.00 1.00 5400.00 100% 120.0 1.0% 90.00% 107 577,368 52% Acceptable 10.00 1283 1 99.92% 1282 128 55.56 10.00 855 15 98.21% 840 84 55.56 Acceptable X 10.00 743 10 98.64% 733 73 55.56 STEP 6 Gage/Label/Pack 2 NA 7.50 3.00 5.00 48.00 1.00 5400.00 100% 100.0 1.0% 85.00% 84 454,410 66%
(3) TOTAL CPV (pcs/year)

10 11 48 49 12
300000 STEP 1 Weld Seam 2 Binford 3000 7.50 3.00 5.00 48.00 1.00 5400.00 50% 720.0 0.0% 85.00% 612 1,652,400 18% Acceptable 10.00 5790 0 100.00% 5790 579 111.11 Acceptable 2.00 1080 4 99.63% 1076 538 158.73 STEP 2 Endform 1 Former 7.50 3.00 5.00 48.00 1.00 5400.00 35% 500.0 1.0% 90.00% 446 841,995 36% Acceptable STEP 3 Holes 1 Drill Press
13 14 15 16 17
Working hours/shift (8 hours is requirement) Shifts/ day (3 shifts is requirement) Days/ week (5 days is requirement) Weeks/ year (48 weeks is requirement) Number of lines, presses, etc. Total hours/year (12*13*14*15*16) % of line for TRW parts (Allocation %) Quoted Production Rate Quoted % scrap Quoted process efficiency Adjusted production rate (19*(1-20)*21) Available capacity ((19*21*(1-20)*17*18)) Utilization % (3/23) Quoted Status (28) Bottleneck operation Trial run duration (8hrs is default) Total parts produced Number of bad parts First time capability % ((28 - 29)/28) Number of good parts (28-29) Net output (31/27) Takt Time Rate (Target) (3/(17*18)) Downtime Reason Availability ((27-34)/27) Quality (31/28) Perfomance ((28/27)/19) Overall OEE (36*37*38) Run-Off utilization % Utilization as % of Allocation (40/18) Bottleneck operation Net Output-Weeks (32*12*13*14) Net Output-Months ((32*12*13*14*15)/12) Run at Rate Conducted by:
Process Step Process Description Number of Operators Equipment size Units hours shifts days weeks units hours % pcs/hour % % pcs/hour pcs/year % % X hours pcs pcs % pcs pcs/ hour pcs/ hour hours text % % % % % % X pcs/week pcs/month
7.50 3.00 5.00 48.00 2.00 10800.00 50% 150.0 1.0% 90.00% 134 721,710 42%
I - Supplier Working Standards II - Supplier Quoted Capacity Data
18 19 20 21 22 23 24 25 26 27 28 29 30 31
III - RUN at RATE Results
32 33 34 35 36 37 38 39 40 50 41 42 43 44
10.00 1288 5 99.61% 1283 128 55.56
100.00% 100.00% 80.42% 80.42% 19.19% 38.38%
100.00% 99.63% 100.00% 99.63% 29.50% 84.30%
100.00% 99.61% 85.87% 85.53% 43.30% 86.60%
100.00% 99.92% 85.53% 85.47% 43.34% 86.67%
100.00% 98.25% 71.25% 70.00% 66.14% 66.14%
100.00% 98.65% 74.30% 73.30% 75.79% 75.79% X 8246 32985
SHADED CELLS ARE CALCULATED and protected
45
44
Roger Andover
Overall Process Utilization % 75.79%
Status Acceptable
TRW Reviewer Name: Roger Andover Product Line: Steering Location: Pamplona
Comments
46
47
Runyon Wraitt
Supplier representative name printed
Runyon Wraitt
Supplier representative Run signature 211180074.xls.ms_office; at Rate Form Example)
10-Jan-2008 Date Process Owner / Department: R. Spariosu / Supplier Development Approved By: R. Blanchette / Global Director, SDE
Run at Rate Exception Form

DATE OF REQUEST: ORIGINATOR: SUPPLIER: SUPPLIER CODE: SDE: COMMODITY MANAGER: PART NUMBER: PROGRAM: PART NAME: RUN AT RATE CONDUCTED BY:
SDE REASON FOR THIS EXCEPTION:
10-Jan-2007 R. U. Kedding S. Claus Manufacturing 57389 Runyon Wraitt Les Kost 42568799B Various Widget Runyon Wraitt
RUN AT RATE DATE: NUMBER OF LINES: ANNUAL CPV:
9-Nov-2006 1 Line 5.5 Million Annually
STANDARD CALCUATION:[3 Shifts; 8 hours; 5 Days (120 hour maximum rate)] CALCULATION: UTILIZATION PERCENTAGE: SUPPLIER PLANNED SCHEDULE: CALCULATION: UTILIZATION PERCENTAGE: RED/YELLOW/GREEN STATUS: 3 67.70% Yellow
Shifts
3 94.80%
Shifts
Hours
Days
Hours
Days
Original run at rate was calculated as yellow with 7 days (93.2% utilization) and red with 5 days (130.4% utilization). The supplier improved the process efficiency and has been able to provide utilization at 94.8% for 5 days. The volume utilized for the run at rate is 5.5 million pieces per year. A second supplier for this component provides TRW with approximately 1.2 million parts per year. TRW Commodity Management will secure a commitment from the second supplier to hold 600K capacity open for TRW to make the run at rate for S. Claus Manufacturing at 84.5% wich is acceptable (volume calculated would drop to 4.9 million).
COMMODITY MANAGER EXPLAIN COST IMPLICATION:
To add additional capacity at S. Claus Mfg. will cost $250,000 for dedicated capital equipment and tooling that this component requires.
APPROVED:
YES
NO
DATE:
PRODUCT LINE PROGRAM MANAGER SIGNATURE:
PRODUCT LINE PURCHASING SENIOR MANAGER SIGNATURE:
DATE:
PRODUCT LINE PURCHASING DIRECTOR APPROVAL SIGNATURE:
DATE:
APPROVAL COMMENTS:
211180074.xls.ms_office; Exception Form Example

Run at Rate - Rev F

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DATE: REVISION: DOC #: PAGE:

27-Aug -2008 G D_020_4_12_EN 1 of 6

Supplier Run at Rate

I Total Part Number Reqmnts G/ Total TRW Reqmnts G

Number of Setups per month

Setup time/run (hrs)

TRW Part Numbers

Date: 24 Jan 2008 Rev: E Doc No: D_020_4_12 Page 1 of 9

211180074.xls.ms_office; Allocation % Worksheet

DATE: REVISION: DOC #: PAGE:

27-Aug -2008 G D_020_4_12_EN 1 of 6

Supplier Run at Rate

I Total Part Number Reqmnts G/ Total TRW Reqmnts G

TRW Part Numbers

TRW Part Numbers

Number of Setups per month

Setup time/run (hrs)

Date: 24 Jan 2008 Rev: E Doc No: D_020_4_12 Page 2 of 9

211180074.xls.ms_office; Allocation % Worksheet

DATE: REVISION: DOC #: PAGE:

27-Aug -2008 G D_020_4_12_EN 1 of 6

Supplier Run at Rate

I Total Part Number Reqmnts G/ Total TRW Reqmnts G

Number of Setups per month

Setup time/run (hrs)

Date: 24 Jan 2008 Rev: E Doc No: D_020_4_12 Page 3 of 9

211180074.xls.ms_office; Allocation % Worksheet

(3) TOTAL CPV (pcs/year)

0 STEP 1 STEP 2 STEP 3

I - Supplier Working Standards II - Supplier Quoted Capacity Data

III - RUN at RATE Results

0.00% 0.00% X #VALUE! #VALUE!

0.00% 0.00% X #VALUE! #VALUE!

0.00% 0.00% X #VALUE! #VALUE!

0.00% 0.00% X #VALUE! #VALUE!

0.00% 0.00% X #VALUE! #VALUE!

0.00% 0.00% X #VALUE! #VALUE!

SHADED CELLS ARE CALCULATED

Overall Process Utilization % 0.00%

TRW Reviewer Name: Product Line: Location:

Date: 24 Jan 2008 Rev: E Doc No: D_020_4_12 Page 4 of 9

Supplier representative name printed

Supplier representative signature 211180074.xls.ms_office; Run at Rate Form

Run at Rate Exception Form

COMMODITY MANAGER EXPLAIN COST IMPLICATION:

PRODUCT LINE PROGRAM MANAGER SIGNATURE:

PRODUCT LINE PURCHASING SENIOR MANAGER SIGNATURE:

PRODUCT LINE PURCHASING DIRECTOR APPROVAL SIGNATURE:

Date: 24 Jan 2008 Rev: E Doc No: D_020_4_12 Page 5 of 9

211180074.xls.ms_office; Exception Form

Number of Setups per month

Setup time/run (hrs)

TRW Part A TRW Part B

TRW Part Numbers

Date: 24 Jan 2008 Rev: E Doc No: D_020_4_12 Page 6 of 9

211180074.xls.ms_office; Allocation % Example

Number of Setups per month

Setup time/run (hrs)

50,000 15,000 12,000

1.00 0.50 0.50 2.00

1028.57 360.00 300.00 1688.57

101.22 43.17 41.00 185.39

1214.67 518.00 492.00 2224.67