ALLOCATION WORKSHEET

Time (Enter as
# of Working hours/shift
Factor fraction of an Total
Occurrences (8 hrs max. is standard)
hour)
Shifts/ day
Shift Length (hrs)
(Standard is 3)
Days/ week
Short Breaks (hrs)
(Standard is 5)
Weeks/ year
Meal Break (hrs)
(Standard is 48)

Down Time per Shift (hrs) Number of Lines

WORKING HOURS PER SHIFT Available hours per year

Available Hours per month

A B C D E F G H I
Formula A B C D 3600/D A/E + B*C F*12 G/Total of G (Total Reqmnts H -
Total Reqmnts I)/ Total
Reqmnts H
Part Number Monthly Number of Setup Adjusted Production Total monthly Total Annual Required Maximum Addition
Volume Setups per time/run Cycle Time Rate in pcs/hr working hrs working hrs Allocation % Allocation %
month (hrs) (seconds) required required available to TRW
TRW Part Numbers

Date: 01 Mar 2007 387367480.xls; Allocation % Worksheet Process Owner / Department:

Rev: E R. Spariosu / Supplier Development
Doc No: D_020_4_12 Approved by:
Page 1 of 9 R. Blanchette / Dir. Supplier Development
ALLOCATION WORKSHEET
Time (Enter as
# of Working hours/shift
Factor fraction of an Total
Occurrences (8 hrs max. is standard)
hour)
Shifts/ day
Shift Length (hrs)
(Standard is 3)
Days/ week
Short Breaks (hrs)
(Standard is 5)
Weeks/ year
Meal Break (hrs)
(Standard is 48)

Down Time per Shift (hrs) Number of Lines

WORKING HOURS PER SHIFT Available hours per year

Available Hours per month

A B C D E F G H I
Formula A B C D 3600/D A/E + B*C F*12 G/Total of G (Total Reqmnts H -
Total Reqmnts I)/ Total
Reqmnts H
TRW Part Numbers

Part Number Monthly Number of Setup Adjusted Production Total monthly Total Annual Required Maximum Addition
Volume Setups per time/run Cycle Time Rate in pcs/hr working hrs working hrs Allocation % Allocation %
month (hrs) (seconds) required required available to TRW

0 0 0.00 0.00 0 0.00 0.00 0.00%

TOTAL

TRW Total 0 0 0.00 0.00 0 0.00 0.00 0.00%

Customers
Other

Customer A

Date: 01 Mar 2007 387367480.xls; Allocation % Worksheet Process Owner / Department:

Rev: E R. Spariosu / Supplier Development
Doc No: D_020_4_12 Approved by:
Page 2 of 9 R. Blanchette / Dir. Supplier Development
ALLOCATION WORKSHEET
Time (Enter as
# of Working hours/shift
Factor fraction of an Total
Occurrences (8 hrs max. is standard)
hour)
Shifts/ day
Shift Length (hrs)
(Standard is 3)
Days/ week
Short Breaks (hrs)
(Standard is 5)
Weeks/ year
Meal Break (hrs)
(Standard is 48)

Down Time per Shift (hrs) Number of Lines

WORKING HOURS PER SHIFT Available hours per year

Available Hours per month

A B C D E F G H I
Formula A B C D 3600/D A/E + B*C F*12 G/Total of G (Total Reqmnts H -
Total Reqmnts I)/ Total
Reqmnts H
Part Number Monthly Number of Setup Adjusted Production Total monthly Total Annual Required Maximum Addition
Volume Setups per time/run Cycle Time Rate in pcs/hr working hrs working hrs Allocation % Allocation %
month (hrs) (seconds) required required available to TRW
Customers
Other

Customer B

TOTAL 0 0 0.00 0.00 0 0.00 0.00 0.00%

Overall Utilization

Available Time (hours/yr)

Date: 01 Mar 2007 387367480.xls; Allocation % Worksheet Process Owner / Department:

Rev: E R. Spariosu / Supplier Development
Doc No: D_020_4_12 Approved by:
Page 3 of 9 R. Blanchette / Dir. Supplier Development
Run-at-Rate Verification
(1) Part Number (2) Part Description/Program TRW Annual Capacity Planning 4
Run@Rate Date
Volume (pcs/year)
5 Supplier Name
6 Supplier Address
7 City/State/Postal Code
8 Supplier Country
(3) TOTAL CPV (pcs/year) 0 9 Supplier Vendor Code

10 Process Step STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6

11 Process Description
Units
12 Working hours/shift (8 hours is requirement) hours
I - Supplier

Shifts/ day (3 shifts is requirement) shifts

Standards

13
Working

14 Days/ week (5 days is requirement) days

15 Weeks/ year (48 weeks is requirement) weeks
16 Number of lines, presses, etc. units
17 Total hours/year (12*13*14*15*16) hours
18 % of line for TRW parts (Allocation %) %
II - Supplier Quoted

19 Quoted Production Rate pcs/hour

Capacity Data

20 Quoted % scrap %
21 Quoted process efficiency %
22 Adjusted production rate (19*(1-20)*21) pcs/hour
23 Available capacity ((19*21*(1-20)*17*18)) pcs/year
24 Utilization % (3/24) %
25 Quoted Status (28) % Unacceptable Unacceptable Unacceptable Unacceptable Unacceptable Unacceptable
26 Bottleneck operation X
27 Trial run duration (8hrs is default) hours
28 Total parts produced pcs
29 Number of bad parts pcs
30 First time capability % ((28 - 29)/28) %
31 Number of good parts (28-29) pcs
III - RUN at RATE Results

32 Net output (31/27) pcs/ hour

33 Takt Time Rate (Target) (3/(17*18)) pcs/ hour
34 Downtime hours

35 Reason text

36 Availability ((27-34)/27) %
37 Quality (31/28) %
38 Perfomance (((28/27)/((27*3600)*28))*100) %
39 Overall OEE (36*37*38) %
40 Run-Off utilization % % 0.00% 0.00% 0.00% 0.00% 0.00% 0.00%
41 Bottleneck operation X X X X X X X
42 Net Output-Weeks (32*12*13*14) pcs/week #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE!
43 Net Output-Months ((32*12*13*14*15)/12) pcs/month #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE!
SHADED CELLS ARE CALCULATED and protected 45 44
44 Run at Rate Conducted by: Overall Process TRW Reviewer
Status
Utilization % Name:
Product Line:
0.00% Acceptable
Location:
Comments

46

47
Supplier representative name printed Supplier representative signature Date
Date: 01 Mar 2007 387367480.xls; Run at Rate Form Process Owner / Department:
Rev: E R. Spariosu / Supplier Development
Doc No: D_020_4_12 Approved By:
Page 4 of 9 R. Blanchette / Dir. Supplier Development
 Run at Rate Exception Form
DATE OF REQUEST: RUN AT RATE DATE:

ORIGINATOR: NUMBER OF LINES:

SUPPLIER: ANNUAL CPV:

SUPPLIER CODE: STANDARD CALCUATION: [3 Shifts; 8 hours; 5 Days (120 hour maximum rate)]

SDE: CALCULATION: Shifts Hours Days

COMMODITY MANAGER: UTILIZATION PERCENTAGE:

PART NUMBER: SUPPLIER PLANNED SCHEDULE:

PROGRAM: CALCULATION: Shifts Hours Days

PART NAME: UTILIZATION PERCENTAGE:

RUN AT RATE CONDUCTED BY: RED/YELLOW/GREEN STATUS:

SDE REASON FOR THIS EXCEPTION:

COMMODITY MANAGER EXPLAIN COST IMPLICATION:

APPROVED: YES NO

PRODUCT LINE PROGRAM MANAGER SIGNATURE: DATE:

PRODUCT LINE PURCHASING SENIOR MANAGER SIGNATURE: DATE:

PRODUCT LINE PURCHASING DIRECTOR APPROVAL SIGNATURE: DATE:

APPROVAL COMMENTS:

Date: 01 Mar 2007 387367480.xls; Exception Form Process Owner / Department:

Rev.: E R. Spariosu / Supplier Development
Doc No.: D_020_4_12 Approved By:
Page 5 of 9 R. Blanchette / Dir. Supplier Development
ALLOCATION WORKSHEET
Time (Enter as 7.50
# of Working hours/shift
Factor fraction of an Total
Occurrences (8 hrs max. is standard)
hour)
Shifts/ day 3.00
Shift Length (hrs) 8.00
(Standard is 3)
Days/ week 5.00
Short Breaks (hrs) 0.25 2 0.50
(Standard is 5)
Weeks/ year 48.00
Meal Break (hrs) 0.00
(Standard is 48)
5400.00
Down Time per Shift (hrs) Available hours per year

450.00
WORKING HOURS PER SHIFT 7.50 Available Hours per month

A B C D E F G H I
Formula A B C D 3600/D A/E + B*C F*12 G/Total of G (Total Reqmnts H -
Total Reqmnts I)/ Total
Reqmnts H
Monthly Number of Setup Adjusted Production Total monthly Total Annual Required Maximum Addition
Volume Setups per time/run Cycle Time Rate in pcs/hr working hrs working hrs Allocation % Allocation %
month (hrs) (seconds) required required available to TRW

TRW Part A 25,000 4 0.5 7 514.29 50.61 607.33 27.30%

TRW Part B 25,000 4 0.5 7 514.29 50.61 607.33 27.30%

TRW Part Numbers

Date: 01 Mar 2007 387367480.xls; Allocation % Example Process Owner / Department:

Rev: E R. Spariosu / Supplier Development
Doc No: D_020_4_12 Approved by:
Page 6 of 9 R. Blanchette /Dir. Supplier Development
ALLOCATION WORKSHEET
Time (Enter as 7.50
# of Working hours/shift
Factor fraction of an Total
Occurrences (8 hrs max. is standard)
hour)
Shifts/ day 3.00
Shift Length (hrs) 8.00
(Standard is 3)
Days/ week 5.00
Short Breaks (hrs) 0.25 2 0.50
(Standard is 5)
Weeks/ year 48.00
Meal Break (hrs) 0.00
(Standard is 48)
5400.00
Down Time per Shift (hrs) Available hours per year

450.00
WORKING HOURS PER SHIFT 7.50 Available Hours per month
TRW Part Numbers

A B C D E F G H I
Formula A B C D 3600/D A/E + B*C F*12 G/Total of G (Total Reqmnts H -
Total Reqmnts I)/ Total
Reqmnts H
Monthly Number of Setup Adjusted Production Total monthly Total Annual Required Maximum Addition
Volume Setups per time/run Cycle Time Rate in pcs/hr working hrs working hrs Allocation % Allocation %
month (hrs) (seconds) required required available to TRW

50,000 8 1.00 14 1028.57 101.22 1214.67 54.60% 81.30%

TOTAL

TRW Total 50,000 8 1.00 14 1028.57 101.22 1214.67 54.60%

Customers

Customer A
All

15,000 3 0.50 10 360.00 43.17 518.00 23.28%

Customer B 12,000 2 0.50 12 300.00 41.00 492.00 22.12%

TOTAL 77,000 13 2.00 36 1688.57 185.39 2224.67 100.00%

Overall Utilization 41.20%
Available Time (hours/yr) 3175.33

Date: 01 Mar 2007 387367480.xls; Allocation % Example Process Owner / Department:

Rev: E R. Spariosu / Supplier Development
Doc No: D_020_4_12 Approved by:
Page 7 of 9 R. Blanchette /Dir. Supplier Development
Run-at-Rate Verification
(1) Part Number (2) Part Description/Program TRW Annual Capacity Planning 4
Run@Rate Date 5-Jul-2006
Volume (pcs/year)
31367943B Tube 300000 5 Supplier Name Acme Stamping Company
6 Supplier Address 12345 S. North Blvd.
7 City/State/Postal Code Wayout, ID 56565
8 Supplier Country USA
(3) TOTAL CPV (pcs/year) 300000 9 Supplier Vendor Code September 20, 2048

10 Process Step STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6

11 Process Description Weld Seam Endform Holes Flats Bend Gage/Label/Pack
Units
12 Working hours/shift (8 hours is requirement) hours 7.50 7.50 7.50 7.50 7.50 7.50
3.00 3.00 3.00 3.00 3.00 3.00
I - Supplier

Shifts/ day (3 shifts is requirement) shifts

Standards

13
Working

14 Days/ week (5 days is requirement) days 5.00 5.00 5.00 5.00 5.00 5.00
15 Weeks/ year (48 weeks is requirement) weeks 48.00 48.00 48.00 48.00 48.00 48.00
16 Number of lines, presses, etc. units 1.00 1.00 2.00 2.00 1.00 1.00
17 Total hours/year (12*13*14*15*16) hours 5400.00 5400.00 10800.00 10800.00 5400.00 5400.00
18 % of line for TRW parts (Allocation %) % 50% 28% 50% 50% 100% 100%
II - Supplier Quoted

19 Quoted Production Rate pcs/hour 720.0 500.0 150.0 150.0 120.0 100.0
Capacity Data

20 Quoted % scrap % 0.0% 1.0% 1.0% 1.0% 1.0% 1.0%

21 Quoted process efficiency % 85.00% 90.00% 90.00% 90.00% 90.00% 85.00%
22 Adjusted production rate (19*(1-20)*21) pcs/hour 612 446 134 134 107 84
23 Available capacity ((19*21*(1-20)*17*18)) pcs/year 1,652,400 673,596 721,710 721,710 577,368 454,410
24 Utilization % (3/24) % 18% 45% 42% 42% 52% 66%
25 Quoted Status (28) % Acceptable Acceptable Acceptable Acceptable Acceptable Acceptable
26 Bottleneck operation X X
27 Trial run duration (8hrs is default) hours 10.00 2.00 10.00 10.00 10.00 10.00
28 Total parts produced pcs 5790 1080 1288 1283 855 743
29 Number of bad parts pcs 0 4 5 1 15 10
30 First time capability % ((28 - 29)/28) % 100.00% 99.63% 99.61% 99.92% 98.21% 98.64%
III - RUN at RATE Results

31 Number of good parts (28-29) pcs 5790 1076 1283 1282 840 733
32 Net output (31/27) pcs/ hour 579 538 128 128 84 73
33 Takt Time Rate (Target) (3/(17*18)) pcs/ hour 111.11 198.41 55.56 55.56 55.56 55.56
34 Downtime hours

35 Reason text

36 Availability ((31-38)/31) % 100.00% 100.00% 100.00% 100.00% 100.00% 100.00%

37 Quality (35/32) % 100.00% 99.63% 99.61% 99.92% 98.25% 98.65%
38 Perfomance (((28/27)/((27*3600)*28))*100) % 258.67% 225.00% 12.80% 12.70% 5.64% 4.26%
39 Overall OEE (40*41*42) % 258.67% 224.17% 12.75% 12.69% 5.54% 4.20%
40 Run-Off utilization % % 19.19% 36.88% 43.30% 43.34% 66.14% 75.79%
41 Bottleneck operation X X
42 Net Output-Weeks (32*12*13*14) pcs/week 8246
43 Net Output-Months ((32*12*13*14*15)/12) pcs/month 32985
SHADED CELLS ARE CALCULATED and protected 45 44
44 Run at Rate Conducted by: Overall Process TRW Reviewer
Status
Utilization % Name: B. Jones
Product Line: Steering
75.79% Acceptable
Location: Shirley
Comments

46

47 Runyon Wraitt Runyon Wraitt 5-Jul-2006

Supplier representative name printed Supplier representative signature Date
Date: 01 Mar 2007 387367480.xls; Run at Rate Form Example Process Owner / Department:
Rev: E R. Spariosu / Supplier Development
Doc No: D_020_4_12 Approved By:
Page 8 of 9 R. Blanchette / Dir. Supplier Development
 Run at Rate Exception Form
DATE OF REQUEST: 10-Jan-2007 RUN AT RATE DATE: 9-Nov-2006

ORIGINATOR: R. U. Kedding NUMBER OF LINES: 1 Line

SUPPLIER: S. Claus Manufacturing ANNUAL CPV: 5.5 Million Annually

SUPPLIER CODE: 57389 STANDARD CALCUATION:[3 Shifts; 8 hours; 5 Days (120 hour maximum rate)]

SDE: Runyon Wraitt CALCULATION: 3 Shifts 8 Hours 5 Days

COMMODITY MANAGER: Les Kost UTILIZATION PERCENTAGE: 94.80%

PART NUMBER: 42568799B SUPPLIER PLANNED SCHEDULE:

PROGRAM: Various CALCULATION: 3 Shifts 8 Hours 7 Days

PART NAME: Widget UTILIZATION PERCENTAGE: 67.70%

RUN AT RATE CONDUCTED BY: Runyon Wraitt RED/YELLOW/GREEN STATUS: Yellow

SDE REASON FOR THIS EXCEPTION:
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: X YES NO

PRODUCT LINE PROGRAM MANAGER SIGNATURE: DATE:

PRODUCT LINE PURCHASING SENIOR MANAGER SIGNATURE: DATE:

PRODUCT LINE PURCHASING DIRECTOR APPROVAL SIGNATURE: DATE:

APPROVAL COMMENTS:

Date: 01 Mar 2007 387367480.xls; Exception Form Example Process Owner / Department:
Rev.: E R. Spariosu / Supplier Development
Doc No.: D_020_4_12 Approved By:
Page 9 of 9 R. Blanchette/ Dir. Supplier Development