3 Run at Rate Procedure

KSS Global Standard
Supplier Run at Rate Procedure
KSS GLOBAL STANDARD
KSS 702
Document No: 1005108

Author:
Frank Lin
Approved by:
Brian Schantz
Hubert Ross
Dieter Hahn
Mike Rawson
Alexandru Iedu
Jim Scarpa
Rodolfo Ventresca
Christa Kerlin
Document History
Revision:
Release Date
ECP No.
03
07 June 2013
54513
02
Revise Responsible Depar
Procurement
23 June 2009
36121
Revise document to refle
Doc. No: 1005108 Rev. 3 Page 1 pyof printed:11 07Unc-J
(KSS template no. 10338

KSS Global Standard
Rate Forms
Run at Rate to be conduc Run at Rate Documentatio SQA with PPAP
Documentat Revise wording for clari Release as North America
01 13 January 2005 83889A
Corporate 82000913)
Doc. No: 1005108 Rev. 3 Page 2 pyof printed:11 07Unc-J

KSS Global Standard
Table of Contents
INTRODUCTION ..................................................................................................................................................
1
PURPOSE ...................................................................................................................................................
2
SCOPE ........................................................................................................................................................
RESPONSIBILITY.......................................................................................................................................
DEFINITIONS / ABBREVIATIONS .............................................................................................................
5
PROCESS MAP ..........................................................................................................................................
5
6
PROCEDURE ..............................................................................................................................................
6.1 PREPARATION FOR RUN AT RATE ............................................................................................
6.1.1 TRIALS MUST BE REPRESENTATIVE .................................. OFMASS PR

7
6.1.2
MATERIALS ........................................................................................................................
6.1.3
SUPPLIER ..........................................................................................................................
6.1.4
QUALITY AND QUANTITY .............................................................................. TARGETS

8
6.1.5
DOCUMENTATION ............................................................................................................
6.1.6
PARTICIPATION ................................................................................................................
8
6.2 PERFORMING THE ............................................................................................... RUNATRATE
9
6.2.1
PRODUCTION ................................................................................................ TRIALRUN

9
RUN AT RATE REVIEW CONTENT........................................ANDDOCUMENTA9
6.2.3
PACKAGING AND..........................................................................................HANDLING
6.2.4
NF ALI . . . . . . . . . ATR LI UN
10
6.3 NOTIFICATION OF RUN .............................................................................. ATRATERESULT

10
6.3.1
PA S . . . . . . . . . . .
10
6.3.2
O PEN . . . . . . . . . . .
10
6.3.3
... .... .......... .... .... .......... .... .... .......... .... .... .......... .... .... .......... .... .... .......... .... .... .......... .... FAIL
11
REFERENCES............................................................................................(RELATEDDOCUMENTS)
11
APPENDICES ..........................................................................................................................................
11
Doc. No: 1005108 Rev. 3 Page 3 pyof printed:11 07

KSS Global Standard
Introductio
n
Systems
This uirements(KSS
Key )Standardrelat
Rate
Safety Processanyne
Supplier wwhicompone
his PPAP
Run at approval.
number
prior to
Purpose
To ensure the
suppliersss
actualiscapablemanufac
of components that
meet KSSntson
-atgoingquotedqualit
capacity for a
specifiedtyrequperireme
ntsodoftimear KSS
Quality First Supplioner
PMartnual,Approvathe
(PPAP) Manual, and the
mostductionrecentdrawi
nKSS
Scope
This procedure shall

be used by all KSS A
Run at Rate self
assessmentofeachis
PPAPamandle
submission. KSS
shouldforbe
anypreseRunt at Rt
rated CLD 3.
Responsibility
The CLD level for

3.1 SQE
each gpartthe
numberESImee
KSS SQE Dept. shall

participateandtransfe
rin level to the APQP-
Trackertyof.theItSQEi
s D assure each part
number
trackedhasCLDin-l
defined.
KSS SQA Dept. is
SQA
reviewinggularthebasis
APQP
setting up the Run at

yRate.TheparticipRunat
be conducted prior
to,PAPor
Productioinconjun KSS
SQA Dept reserves
erthep roductiightton
Run at Rate of all
partsere
ratdeemedCLDne for
parts rated CLD 1
orTheCLDsupplier2att
notified in advance of
KSS particip
3.3
attentionThersupplierbeingmustpaidinclud
Suppli
etomblyatbottleRaandte,llnewprocewithcksp
facilities or cells. theAllcorrectpocesses
notations made to indicatetobeanyrunproco
to new model / old modelquirementsbuildout.
Doc. No: 1005108

Rev. 3 Page 4 pyof
printed:11 07
KSS Global Standard
Definitions / Abbreviations
CLD Control Level Definition
PPAP Pre Production Approval Process
Process Map
Prepare resources following
> Run at Rate Worksheet,
Necessary
resouces
the listed steps below:
> Supplier Planning Data
Supplier
Trials, Materials, CapacityQuantityRequiremeOperationts, Quality &
for Run at Rate

> KSS required data (section 6.1.5)
Targets, Documentation, and Participation
>
Run at Rate Worksheet

> Written Work Instructions
Trials must be representative of Mass Production:
Related equipments
> Visual Manufacturing Aids
> Facilities, tooling, equipment complete

and parameters
>
> Mass Production Quality Control Plan
Fixtures, gages, controls complete
Supplier
>
Operations>Tool changes and set up instructions and
sheets
last trial runs
Trained Operators same as in Mass> Pr ducti
Line Speed (tact time)
>
Production method mustctionbe the same
Mass
>
Mass Production tool and machine capacities, as
and include the points listed in "Outpu "
quoted
>
All materials used duringss Run at Rate must be ma
Purchasing orders
production materials.ubricants,Including direct material, l

>
Mass Production compatible material
Supplier
cleaning material and any otherOperationssupprt mat rial.
sub suppliers
>
>
Preventive Maintenance Plan

Repair and maintenanceper parts shall be a ailable
preventive maintenance plan
>
Process Flow
Diagram
>
>
Process Control Plan, with Reaction Plan
Supplier must prove Customer's Quality>DFMEACapacity/PFMEA
Capacity requirements
Requirements prior to Run at Rate
>
Master Parts
(if available)
Supplier
>
Requested documents shallOperationsbeavailable>DeptOperator. Instructions
from KSS
>
Controls shall be ateriinplalceuntiltoisolateit> Inspectionincomingm Instructions
has been approved
>
Packaging / Labeling Plan

>
Preventive Maintenance Plan
>
Quality Parts produced must satisfy the approv
SupplierrequirementsQualityandquantityfrom
production drawing and ble)boundary samples (if applica
and quantity target
>workQuantityallowed) Themustratebeoofclearlyreconsecutive-OperationsspecifiedgoodDept..partsQuality(n
This quantity shall betherreached without impacting o
production lines or processes.
Related documents
> The completed SectionsRateAand B of> Suppplier RunPlanning Data & KSS required Data
Worksheet shall be availablete. prior tolistthed Runi sectionatRa
6.1.5
Supplier
Operations Dept.
requested by KSS
> Completed Sections eC atthroughthe F shall>Runbe atavailablRateWorksheet
end of the Run at Rate.

> Supplier operations
> A representative fromentKSSforSQA Dept. shall be pres
Suppliermanager and quality
the entire Run at Rate.
Operations>KSS monitored Run at Rate
KSS SQA
>
The lead supplier representativersQuality
and the supplie

KSS Plant>Supplier monitored Run at Rate
>KSS SQA
Manager shall attend the Run at Rate and approve th
results.

KSS Global Standard

> Run at Rate
> Run the processes accordinge to the KSS Run at Rat
Worksheet
Sheet
> Supplier Planning
Requirements
>Capacity
Supplier
> Review all
Run at Ratend contentsthenOperationsduring running,Caculation
Data
> Run a Rate Summary Sheet
> KSS Required

record all datas and prionsblemsforaccordingly,
take act
the problems
Supplier Production
> Production
must be continuousSpeed
Mass Production
Operations
Output of the proces constantly recorded
with output contstantly recorded

> Process shall be stoppedof1 afterhour production period
> Countermeasures shall be applied
Output of
> Process shall be repeatediaare until
he >targetCapacitycriterCalculation Sheet of the Run at Rate

Supplier
achieved
Operations
Worksheet.
constantly
> Results must be recordedion on the Capacity Calculat
Sheet of the Run at Rate Worksheet

To verify that supplier'slan, processthe is according to p
following shall be proven:

> Net output from each operation can support quoted
capacity
> Tooling meets the quoted up time requirements

> Any unexpected downtimeingmust be documented includ
Capacity Calculation
the corrective action(s) taken
SupplierSheet of the Run
> Any regular maintenancewedandOperationsotherdowntime is Runrevat Rate Worksheet.
Rate Worksheet.
and recorded in the Run at Rate Worksheet

> All line changeovers,thifn theany, can be performed wi
quoted Tooling Capacity Requirements

> Monitor the use and effectivenessixtures, of all checking
gages and controls per Process Control Plan.
> Workability, safety andpartergonomicof
issues shall be
the review.
>
In-Process and Final Shipment Packaging shall be
Supplier
reviewed for preservationomicsof
quality
and ergon
>
Op rations
Packaging and Handling Specs
>Packing materials
The suppliers methodthemust
effectively
eliminate
potential for process errors or mixed stock

Capacity caculation!
An additional trial shallhalf bea shiftconducted for
at least
Supplier
Operations
Additional Trial
OK
to establish consistencyct levelsofoutput. and confirm reje

> Capacity
"
Send the notification plantofRunSQA,OperationsRateresult to KSS
Sheet
Supplier/SQA
SQA
will verify the Run at RateKSS Plant SQA

> Run at Rate
Summary Sheet
Capacity
Run at Rate result willationbe judgOperationsdbyCapacity C cul
Supplier/SQASheet
Sheet
KSS Plant
SQA
Run at Rate results
Capacity
some minor non-conformances to the requirements wer

#
found that need to be corrected.
Run at Rate Worksheet including Corrective
SupplierSheet
Operations
Actions
Corrective Action shallt Ratebedefined in the KSS Run a

Worksheet.
Run at Rate
Once the Corrective Actionpleted,Plan is successfully com
verification will be ncedone by Operationsthesupplier and evide

Supplier/SQAincluding
Completed
Corrective Action Plan
Actions
provided to KSS SQA Dept. KSS Plant SQA

In most cases another Run at Rate is not required
Fail indicates a serioust non-conformance exists tha
Capacity Caculation
requires significant ectaction. by the supplier to corr
Run at Rate Worksheet including Corrective

SupplierSheet
An additional Run at Rate willOperationsberequired
Actions
Corrective Actions shallat Ratebedefined in the KSS Run
Worksheet.
Completed Corrective
Once the Corrective Actionpleted,Plan is successfully com
"
the KSS SQA Dept. will scheduleo a new Run at Rate t
Supplier
KSS SQA
New
Run at Rate
Action Plan
verify the successful iveimplementationaction
of the correct
plan
SQA
All Run at Rate Requirements were met
RunKSSat SQARate
Passed
Doc. No: 1005108 Rev.

3
Page
6 pyof printed:11 07
KSS Global Standard
Procedure
Preparation for Run at Rate
Trials must be representative of Mass Production
Facilities, tooling,eteand. equipm
All process checkings shallfixtures,bec functional and in placesual.

aids,Operato available.
Operators must be trawillnedbeandusem Mass Production. The trialfrom

shall
Production method mustctionbetheands include:
Written Work Instructions

Visual Manufacturing Aids
Mass Production Quality Contr
Tool changes and set up instr
Mass Production line speed (t
Mass Production toolquotedandmach
Materials
All materials used duringproductionRat Ram This does not
only includeelllubricantsdirectm material and any
otherdsupportmaintenancmate shall be available per
Preventive M
Supplier
Prior to the Run at Rate,rmhistheabilitysuppl

customers quality capacitytionofrequirethesu
manufacturing processes ghsh allRunbe atac
conducted by the suppliersted. inAllChaptdoc shall be
available fromd duringthesuppliethe Controls shall be
in placerial untiltoisolait approved.

KSS Global Standard
6.1.4 Quality and Quantity Targets
Quality Parts producedproductionmstsatisdr boundary

samples (if applicable). Quantity The rate ofe
-consecutiveworkallowe satisfy KSS mass
productionstbevolumeclearl specified. This
quantityimpactingshall othebe production lines or
processes.
6.1.5 Documentation
At the time of the RunenatationRate,shalthe available:
a) Process Flow Diagram

b) Process Control Plan, with React c) DFMEA / PFMEA
d) Master Part(s) (if available) e) Operator Instructions
f) Inspection Instructions g) Packaging / Labeling Plan
h) Preventive Maintenance Plan Note: The

completed sectionsrRun atA andRat
Worksheet shall be avateilable. pr Completed
sections C throughatthe F end of the Run at
Rate.
6.1.6 Participation
KSS Monitored
A representative from KSSforSQAtheDepten. Rate. No portion of

thermedRun wiathouR personnel present.
An exemption may be grantedssrunsif thefor days and

therefore the completeitnessed proin In this case, KSS SQA
shalldocumentatnsur provided by the supplierent.
KSStheirSQAo participation, and includeintothetheirsupp
documentation.
Supplier Monitored
The lead supplier representativectmanager isor appointee.

In addition,agertheor suppldesi attend the Run at Rate and
approve Note: Equipment suppliersay beandasked/or
participate.

KSS Global Standard
KSS will inform the suppliLDervelin ofadve component

and as a resultheRunof atheRatepa
Performing the Run at Rate
Production Trial Run
During each individualntinuoustrial, produatma production

speeds with nstantlytheoutputreco If it becomes clear
that,hetheprocesstarget stopped after a productionur.
Countermeperiod improve the
performanceocessshallrepeatebeap the target criteria
forved .theTheprocessresul recorded on the Capacityun
CalculatioRateWo Note: All parts
manufacturedbeuseddurinfor
production shipment, implyingngesor ot tuning have
occurred. ovReworkedbyK SQA prior of being
shippedction. to K
6.2.2 Run at Rate Review Content and Documentation
The Run at Rate is a ofverificationthesuppliet

manufacturing process meetroncustomer-goingq
and at the quoted tooledthatcapacitythesupp.
process is to plan requires:
a)
Net output from eachd operationcapacity c
b)
Tooling meets the quoted up time
c)
Any unexpected downtimedingmustthebeco
action taken
d) Any regular maintenanceviwedandandother
in the Run at Rate Worksheet
e)
All line changeovers,ith inf theany,quoca
Capacity Requirements
f)
Monitor the use andg effectivenesfixtures,g
controls per Process Control Plan
g)
Workability, safetye andpartergonomiofthe
6.2.3 Packaging and Handling
In-process and final shvipmewentd forpackapr of part

quality and erghodnomicsforin. -prTh final shipping
packagingely andelimihanatedli potential for process
errors or mix

KSS Global Standard
6.2.4 Final Trial Run
Once the targets for quantityatRateandpartq been achieved,

an additionaledfor attrialleas and a minimum number
ofsistency300units,of confirm reject levels process(these
trialscapab Note: All parts manufacturedbeuseddurinfor
production shipments providedngesor ot tuning have

occurred. ovReworkedbyK SQA prior of being
shippedction. to K
Notification of Run at Rate Result
When the trial is completed,alltheareasu KSS Run at

Rate Worksheetl.be Thisincluddo the PPAP
documentation andt. submittewithin working days of the
Runate canRatehavedat three results: pass; open or
fail.
6.3.1 Pass
Pass indicates that allreRunmetat. RateThe demonstrated

the capabilityeettheto qualiprod requirements at quoteda
ctuapalcitymanufa(ne process matches the
ManufacturingAllkey pra characteristics were
monitoredequirementsand. systems were documented
tationandpracticwas and updated.
6.3.2 Open
Open indicates that sometheminorrequiremnon-were found

that need tothisbe correctearethat output meets volume
requiremenacity;thatsbu systems have minor
deficmaienciesntenance(e.s lacking, lack of
errorequateproofing,operatoin instructions /
visualomplete,aids,operatominor in meeting customer's
ongoing. quali Corrective Action shallt
beRatedefinedWorksh Once the Corrective
Actionpleted,Planverifis be done by the supplierS andSQA
evidencDepart In most cases another Run at Rate i
Doc. No: 1005108 Rev. 3 Page 10opyof printed:11 0

KSS Global Standard
Fail
Fail indicates a serioust requiresnon-conforsi action by

the supplierun toat corrRate ctwil. Corrective Action
shallt beRatedefinedWorksh Once the Corrective
Actionpleted,Plantheis K Dept. will schedule a
newsuccessfulRunat Ra implementation of the
Corrective Ac
References (Related Documents)
KSS Run at Rate Worksheet (Document#

KSS Early Supplier Involvementent#1012767)(ESI)
Quality First Supplier Manual(Docume

AIAG PPAP Process Manual
Appendices
None
Doc. No: 1005108 Rev. 3 Page 11opyof printed:11 0

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KSS Global Standard

Supplier Run at Rate Procedure

KSS GLOBAL STANDARD

Supplier Run at Rate Procedure

Document No: 1005108

Revise Responsible Depar

Revise document to refle

Doc. No: 1005108 Rev. 3 Page 1 pyof printed:11 07Unc-J

(KSS template no. 10338

(KSS template no. 10338

Supplier Run at Rate Procedure

DEFINITIONS / ABBREVIATIONS .............................................................................................................

6.1 PREPARATION FOR RUN AT RATE ............................................................................................

6.1.1 TRIALS MUST BE REPRESENTATIVE .................................. OFMASS PR

QUALITY AND QUANTITY .............................................................................. TARGETS

PRODUCTION ................................................................................................ TRIALRUN

RUN AT RATE REVIEW CONTENT........................................ANDDOCUMENTA9

6.3 NOTIFICATION OF RUN .............................................................................. ATRATERESULT

Doc. No: 1005108 Rev. 3 Page 3 pyof printed:11 07

(KSS template no. 103

Supplier Run at Rate Procedure

This procedure shall

The CLD level for

KSS SQE Dept. shall

setting up the Run at

Doc. No: 1005108

Supplier Run at Rate Procedure

PPAP Pre Production Approval Process

> Run at Rate Worksheet,

> Supplier Planning Data

Trials, Materials, CapacityQuantityRequiremeOperationts, Quality &

for Run at Rate

Targets, Documentation, and Participation

Run at Rate Worksheet

Trials must be representative of Mass Production:

> Visual Manufacturing Aids

> Facilities, tooling, equipment complete

> Mass Production Quality Control Plan

Fixtures, gages, controls complete

last trial runs

Trained Operators same as in Mass> Pr ducti

Line Speed (tact time)

Production method mustctionbe the same

Mass Production tool and machine capacities, as

and include the points listed in "Outpu "

All materials used duringss Run at Rate must be ma

production materials.ubricants,Including direct material, l

Mass Production compatible material

cleaning material and any otherOperationssupprt mat rial.

Preventive Maintenance Plan

preventive maintenance plan

Process Control Plan, with Reaction Plan

Supplier must prove Customer's Quality>DFMEACapacity/PFMEA

Requirements prior to Run at Rate

Requested documents shallOperationsbeavailable>DeptOperator. Instructions

Controls shall be ateriinplalceuntiltoisolateit> Inspectionincomingm Instructions

has been approved

Packaging / Labeling Plan

Preventive Maintenance Plan

Quality Parts produced must satisfy the approv

production drawing and ble)boundary samples (if applica

and quantity target

Worksheet shall be availablete. prior tolistthed Runi sectionatRa