*** production capacity investigation Supplier code

Recipient Supplier name

Contact person : Mfg location

e-mail : Department

Writer

TEL

Capacity calculation standard; "Same or less than 95% of load ratio" based on following conditions

1) same or less than 22 working hours per day, 2) same or less than 5 working days per week

Please consider reliable working time length condition.

All blue column should be filled with data and calculation logic

Production capacity and production preparation check sheet by supplier, with referencing Sample comments and logic

Parts name Parts number P/C

1. Requirement and available supplies To consider delivery lead time, and decide N as not customer SOP but your SOP with volume to produce

Unit : EA Sample N N+1 N+2 N+3 N+4 N+5 N+6

Month Feb-2013 Jan-1900 Mar-1900 Apr-1900 May-1900 Jun-1900 Jul-1900

0) Customer requirement volime 11,300

A) Requirement volume as your production 11,300

B) Actual available supplies quantity 11,491 0 0 0 0 0 0 0

C) Load ratio (A/B) 98.3% #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

C) column should be same or less than 95%

If C) is more than 95%, please describe proposed measures and reculculate capacity including them

D) Available supplies quantity with measures 11,947

E) Load ratio with measures (A/D) 94.6% #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

e.g. : D = B + 2(machine) * 5(day) * 1(H) * 60(pcs/H) * 80% * 95% = 11,947 EA

Describe the reason of low capacity and proposed measures

Equipment/line durability for model life (serviceable without renewal until EOP or not) To be selected

Describe the following condition

Actual available supplies quantity

Sample Dec-1899 Jan-1900 Mar-1900 Apr-1900 May-1900 Jun-1900 Jul-1900

1. # of equipment or line 2 line line line line line line line line

e.g. : 2 machine

Ref; using general-purpose equipment/line or not Exclusive use

(producing for other vehicle/parts also or not) e.g. : Exclusive use

Ref; equipment/line total load ratio 90 % % % % % % % %

(including production for other vehicle/parts) e.g. : 90% This total load ratio also should be same or less than 95%

2. # of operation days for this vehicle 21 day day day day day day day day

(excluding operation days for other vehicle/parts) e.g. : 21 day

Ref; # of shift per day 1 shift shift shift shift shift shift shift shift

e.g. : 1 shift

3. # of working hours per day for this vehicle 6 hour hour hour hour hour hour hour hour

(excluding operation hours for other vehicle/parts) e.g. : 6 hour

4. # of job per hour (JPH) 60 EA EA EA EA EA EA EA EA

e.g. : 60 EA

5. Operation ratio (%) 80 % % % % % % % %

(fill latest actual ratio, not wishful ratio) e.g. : 80%

6. Defect ratio (%) 5 % % % % % % % %

(fill latest actual ratio, not wishful ratio) e.g. : 5%

7. Mathematical formula 11,491 EA 0 EA 0 EA 0 EA 0 EA 0 EA 0 EA 0 EA

Describe bottleneck process

PSW (or PPAP) status

Concern & counter measures

Machine :

Tooling :

Man power :

Delivery :

Design change :

Quality :

Material preparation :

e.g. : = 2(machine) * 21(day) * 6(H) * 60(pcs/H) * 80% * 95% = 11,491 EA

L03F production capacity investigation Supplier code

Recipient Supplier name

Mfg location

Department

Writer

TEL

Capacity calculation standard; "Same or less than 95% of load ratio" based on following conditions

1) same or less than 22 working hours per day, 2) same or less than 5 working days per week

Please consider reliable working time length condition.

All blue column should be filled with data and calculation logic

Production capacity and production preparation check sheet by supplier, with referencing Sample comments and logic

Parts name COVER RECESS F RH / F LH / R RH / R LH Parts number BJS7-68424-02 / BJS768454-02 / BJS8-68424-02 / BJS868454-02 P/C 1

1. Requirement and available supplies To consider delivery lead time, and decide N as not customer SOP but your SOP with volume to produce

Unit : EA Sample N N+1 N+2 N+3 N+4 N+5 N+5

Month Mar-2014 Apr-2014 May-2014 Jun-2014 Jul-2014 Aug-2014 Sep-2014 Oct-2014

0) Customer requirement volime 7,200 6,560 7,040 7,520 11,840 14,400 15,120 16,720

A) Requirement volume as your production 7,200 6,560 7,040 7,520 11,840 14,400 15,120 16,720

B) Actual available supplies quantity 24,190 0 0 25,290 25,290 26,389 25,290 25,290

C) Load ratio (A/B) 29.8% #DIV/0! #DIV/0! 29.7% 46.8% 54.6% 59.8% 66.1%

C) column should be same or less than 95%

If C) is more than 95%, please describe proposed measures and reculculate capacity including them

D) Available supplies quantity with measures 24,440 0 0 25,290 28,689 28,788 26,439 26,439

E) Load ratio with measures (A/D) 29.5% #DIV/0! #DIV/0! 29.7% 41.3% 50.0% 57.2% 63.2%

e.g. : D = B + 2(machine) * 5(day) * 1(H) * 60(pcs/H) * 80% * 95% = 11,947 EA

Describe the reason of low capacity and proposed measures

* High scrap ratio at Paint process is the reason of low capacity.

To increase working shift 1 to 2, and add overtime work and working on hpliday.

Equipment/line durability for model life (serviceable without renewal until EOP or not) To be selected

Describe the following condition

Actual available supplies quantity

Sample Apr-2014 May-2014 Jun-2014 Jul-2014 Aug-2014 Sep-2014 Oct-2014

1. # of equipment or line 1 line 1 line 1 line 1 line 1 line 1 line 1 line 1 line

e.g. : 2 machine

Ref; using general-purpose equipment/line or not Exclusive use General-purpose General-purpose General-purpose General-purpose General-purpose General-purpose

(producing for other vehicle/parts also or not) e.g. : Exclusive use

Ref; equipment/line total load ratio 90 % %

(including production for other vehicle/parts) e.g. : 90% This total load ratio also should be same or less than 95%

2. # of operation days for this vehicle 22 day day day 23 day 23 day 24 day 23 day 23 day

(excluding operation days for other vehicle/parts) e.g. : 21 day

Ref; # of shift per day 3 shift shift 3 shift 3 shift 3 shift 3 shift 3 shift 3 shift

e.g. : 1 shift

3. # of working hours per day for this vehicle 22 hour hour 22 hour 22 hour 22 hour 22 hour 22 hour 22 hour

(excluding operation hours for other vehicle/parts) e.g. : 6 hour

4. # of job per hour (JPH) 60 EA EA 60 EA 60 EA 60 EA 60 EA 60 EA 60 EA

e.g. : 60 EA

5. Operation ratio (%) 85 % % 85 % 85 % 85 % 85 % 85 % 85 %

(fill latest actual ratio, not wishful ratio) e.g. : 80%

6. Defect ratio (%) 2 % % 2 % 2 % 2 % 2 % 2 % 2 %

(fill latest actual ratio, not wishful ratio) e.g. : 5%

7. Mathematical formula 24,190 EA 0 EA 0 EA 25,290 EA 25,290 EA 26,389 EA 25,290 EA 25,290 EA

Describe bottleneck process

PSW (or PPAP) status

Concern & counter measures

Machine :

Tooling :

Man power :

Delivery :

Design change :

Quality :

Material preparation :

e.g. : = 2(machine) * 21(day) * 6(H) * 60(pcs/H) * 80% * 95% = 11,491 EA

* Painting process is botleneck. Then to increase shift, add overtime work and working on holiday.