right first time dar submissions
TRANSCRIPT
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Right First Time DAR
Submissions Issue 1
August 2016
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Contents 1) Contents ................................................................................................................................. 2
2) Scope ..................................................................................................................................... 3
3) Associated Documents .......................................................................................................... 3
4) Definition of Terms ................................................................................................................. 3
5) Generic Standard Information ............................................................................................... 3
6) Roles ...................................................................................................................................... 3
7) DAR Form – Cover Sheet ...................................................................................................... 4
7.1 DAR Tracking Header .......................................................................................... 4
7.2 Register / Requested By (Requestor to Complete) ............................................. 4
7.3 Supplier Information (Sponsor to Complete) ....................................................... 4
8) Export Control ........................................................................................................................ 5
Required for Successful Submission (Sponsor) ............................................................ 5
8.1 UK (Internal) .......................................................................................................... 5
8.2 Rolls-Royce North America .................................................................................. 5
8.3 Rolls-Royce Deutschland ..................................................................................... 5
9) Definitions Affected ................................................................................................................ 6
10) Reason for Alteration ............................................................................................................. 8
11) Actions Requested ............................................................................................................... 10
Required for a Successful Submission ........................................................................ 10
11.1 Good Example .................................................................................................... 10
11.2 Poor Examples.................................................................................................... 11
12) Alteration Effect Summary ................................................................................................... 12
Required for Successful Submission (Requestor/Sponsor) ........................................ 12
12.1 Supplier Use on Supplier Designed Parts ........................................................ 12
13) Cash Benefit ......................................................................................................................... 13
Required for Successful Submission ........................................................................... 13
13.1 Benefits Calculator.............................................................................................. 13
13.2 Good Example .................................................................................................... 17
14) Technical Justification .......................................................................................................... 18
14.1 Good Examples .................................................................................................. 18
14.2 Poor Examples................................................................................................... 19
15) Supporting Documents ........................................................................................................ 20
15.1 Referenced Documents ...................................................................................... 20
15.2 Relating Documents ........................................................................................... 20
16) Steps to Submitting the DAR + Contacts ............................................................................ 21
16.1 Requestor Key steps to completing Submission ............................................... 21
16.2 Sponsor Key Steps to completing Submission .................................................. 21
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1) Scope
This guide is to assist raising the standard of DAR submissions with the necessary information to achieve Right First Time.
The views/pictures used within this document reflect typical issues often found within a DAR submission. Where different or additional features are required this document is to be used to determine the format and content for a DAR submission.
This guide sets out the requirements for the typical information needed from the requestor and sponsor for DAR input into Rolls-Royce, which will improve the number of DARs raised Right First Time.
For features not covered in this guide, refer to generic standard information or the Guidance & Rules for completion of the Definition Alteration Request (DAR) Form as a minimum requirement.
2) Associated Documents For the external supply chain, SABRe is to be followed
For the domestic plants, GQP C.4.55/WI1.3-3 is to be followed.
For additional information, consult ‘Guidance & Rules for completion of the Definition Alteration Request (DAR) Form’ in SABRe under B4.6.
3) Definition of Terms Re-work is defined as the repeat of already authorised standard operations to make
the product conforming.
4) Generic Standard Information
Consider the implications of the submission of the DAR for employees in different roles (eg. MEs & DEs).
Highlight drawing sheet and/or schematic identifying location(s) of alteration(s).
Clear and good quality photograph(s) or image(s).
Standard of measurement used; JES 160 or RRES90004.
5) Roles
DAR Requestor - The person who has identified the business opportunity – this can
be anyone within the supply chain, Rolls-Royce or otherwise.
DAR Sponsor - Typically the Technical Programme Manager or Manufacturing
Engineer Purchasing. Must be a Rolls-Royce employee.
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6) DAR Form – Cover Sheet 6.1 DAR Tracking Header
Ensure that the REQUEST No. is included on All Sheets and is noted by the Requestor/Sponsor for future reference.
This should follow a sensible naming convention in accordance to the internal tracker controlled by the requestor.
DEFINITION ALTERATION REQUEST (DAR)
SECURITY CLASSIFICATION:
ALL SHADED SECTIONS ARE FOR ROLLS-ROYCE USE ONLY
DAR No.: TRACKING No.: Page 4 of
23 Pages REQUEST No.: ABC12345 DISTRIBUTION:
6.2 Register / Requested By (Requestor to Complete)
Ensure the Date & Requestor information is complete and correct.
6.3 Supplier Information (Sponsor to Complete)
1. DAR REGISTER 2. REQUESTED BY
DATE REQUESTED 01/01/2016 REQUESTOR'S NAME Steve Smith
DATE APPROVED REQUESTOR’S PHONE
No. 07971123098
REQUESTOR’S E-MAIL: [email protected]
DATE ISSUED
SUPPLIER OF ROLLS-ROYCE DESIGNED PART(S)
PROJECT/ACCOUNT No./
FUNDING SOURCE
SUPPLIER OF SUPPLIER DESIGNED PART(S)
SPONSOR/CONTROL ACCOUNT MANAGER
ROLLS-ROYCE
4. SUPPLIER INFORMATION
AB Brackets
645 Tampines Central Singapore
SUPPLIER/VENDOR CODE: ABCD/1234
PHONE No. 07507101065
E-MAIL: [email protected]
ROLLS-ROYCE PERSONNEL CONTACT DETAILS (NAME, PHONE NUMBER & EMAIL)
Reece Matthews 07715072961 [email protected]
Ensure that the Supplier Information is complete, including Vendor code and supplier contact details. The Vendor code can be found on SAP, or through the MEP or Buyer.
The Sponsor MUST insert his/her own contact details in the Rolls-Royce Personnel details area.
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7) Export Control
Required for Successful Submission (Sponsor)
Identify the correct export control classification required for the document.
Ensure that the correct classification is applied to all sheets within the DAR Form which
contain export controlled data.
Ensure that the DATE is outlined as the Date the part was rated, not the date which the
DAR was created or otherwise.
7.1 UK (Internal)
For UK Submissions Internal to Rolls-Royce Plc, consult COGNOS (https://edw.portal.rolls-
royce.com/ibmcognos/) to determine/confirm the correct Export Control classification.
If the correct classification cannot be found here, consult your local Export Point of Contact
(EPOC) for further guidance and information.
7.2 Rolls-Royce North America
For DAR Submissions which may be distributed within the Country, to the EU, or distributed
Globally, please consult EPIC (https://eic.rolls-royce.local/EPIC/PartSearchPage.aspx) to
determine/confirm the correct Export Control classification.
If the correct classification cannot be found here, consult your local Export Point of Contact
(EPOC) for further guidance and information.
7.3 Rolls-Royce Deutschland
For DAR Submissions which may be distributed within the Country, within the EU, or
distributed globally, please consult UK COGNOS, SAP Material Master MM03, or the
Current Drawing to determine the correct Export control classification.
3. EXPORT CONTROL AUTHORISATION
JURISDICTION EXPORT CONTROL CLASSIFICATION DATE (DD/MMM/YYYY)
UK PL9009.c 21/07/2012
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8) Definitions Affected
The majority of the details required for this section can be found on the component
definition:
The following details can be found in the Title Box in the bottom right hand corner of
the drawing:
The following details can be found in the
Issue Box in the top right hand corner of the
drawing:
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8.1.1 For the remaining details:
Supplier Definition Number is the drawing number found on a supplier’s drawing (if applicable).
The Definition Re-issue Status is given when the DAR has been approved as it is the Definition Issue that the component takes on once the alterations have been put in place (ie. the up-rev issue of the definition). NOTE: This does not require Requestor/Sponsor Completion
The Definition Master Source is the location of the master document, as decided by
Rolls-Royce (either Teamcentre, Optegra, or as a physical master). NOTE: This does not require Requestor/Sponsor Completion
The Export Control Technical Classification can be found through the standard
Export Control source. Rolls-Royce Casting/Forging Definitions Affected. If yes, the applicable definition has
to be included in the table. Ensure that Purchasing are informed of the effect on a forging or casting which might affect a 2nd tier supplier.
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9) Reason for Alteration
For this section, please only tick the box(es) that apply to the request you are submitting.
9.1.1 Cost – Reduction in Financial Outlay for the Business
1a. Actual recurring products cost benefit – i.e. Unit cost / build hours reduction, reduce manufacturing time, remove rework / scrap, improve streamline processes
1b. Actual non-recurring cost benefit – i.e. Prevent new tooling costs, unable to amortize one off cost due to low volume
1c. Cost Avoidance – i.e. Prevent new dies & tooling, result of material/ process availability, product of tool/ process capability
9.1.2 Manufacturing Non-Conformance - Concessions / Deviation Permits
2a. To reflect proven manufacturing capability on Non-right first time features (RFT) – i.e. Process capability, meets (CPK) Process capability indices values
2b. Concession Reduction 2c. To reflect the agreed Feature Inspection Plan / Conformance Matrix (CM) – i.e. Result
of Design for Manufacture / Single Week Improvement Process (SWIP) workshops 2d. Failure of supplier acceptance standard (SAS) – i.e. Features bought off but unable to
achieve actual (MAS – Manufacture Acceptance Standards) 2e. “Fourth Instance of a repeat Concession” – i.e. Repeat Concession/ Deviation Permits
retirement GP QI 2.3
9.1.3 Proactive (Improvement)
3a. Concession Avoidance – i.e. Prevent known non-conformance issues (read across from similar parts)
3b. Alternative Material – i.e. New/change to equivalent material availability 3c. Supplier transfer – i.e. Result of moving manufacturing source
9.1.4 Definition Error
4a. Mistake in the definition – i.e. Spelling mistake, missing dimension, incorrect spec, model error
4b. Mistake in document – i.e. Supplier definition 4c. Mistake in Model environment – i.e. Reference sets, wavelink errors, incorrect mass
reference
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9.1.5 Obsolescence – Include corporate initiatives (REACh requirements)
5a. Alternative material or component – i.e. Source difficulties, material or sub assembly parts (rivets)
5b. Alternative process – i.e. New/change to equivalent process availability
9.1.6 Routine Update & Campaigns
6a. Build definitions (config only) – i.e. Changes affecting fitting instructions, arrangement definitions, build packs
6b. Component proving – i.e. Updates to Key Characteristic Features (KCF) or equivalent 6c. Part marking - i.e. Direct Part Marking Introduction 6d. Convert definition to PLM – i.e. Legacy Migration 6e. Source - i.e. Updates to company names in Source Control Definition (SCD) or
equivalent
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10) Actions Requested
Required for a Successful Submission
All Actions requested indicated as individual Line Items.
Each Line Item concisely indicating the exact Action Requested, referencing any
Technical Documentation, e.g. Drawing sheets, which may apply.
If applicable, include diagrammatical references to give a visual aid to indicating
changes. Preferably this should be presented in a ‘before and after’ format.
The NDA box should also be completed prior to submission.
10.1 Good Example
If Multiple Actions are requested: Outline individually (Allows Individual Assessment).
Actions clearly and concisely stated.
Referenced locations shown in screenshots, Sheet No. and Grid references also given.
A screenshot for before and after the change has been included.
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10.2 Poor Example
No reference to Drawing sheets and/or Grid location of where the action should be
applied.
Information is not sufficient to allow for acceptance to be determined.
Actions themselves do not state exactly what is required.
Images are not clear and could possibly be misread.
NDA Number has not been entered.
Export control classification has not been entered.
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11) Alteration Effect Summary
Required for Successful Submission (Requestor/Sponsor)
The Requestor & Sponsor are to complete any sections of the form which he/she
believes they can answer accurately or gain accurate answers.
Sections including (*) which are answered with YES, must be supported with a valid
Technical Justification (Section 15).
If any sections without (*) are answered YES, consider that the submission may be a
MODIFICATION rather than a DAR.
11.1 Supplier Use on Supplier Designed Parts
Requestor (Supplier) has the responsibility to complete all sections of the form
accurately.
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12) Cash Benefit
The Benefits Calculator section, although not mandatory, is very useful for the justification
of any quoted value for the DAR. The section is split into different sub-sections relating to
the different types of waste that might be present in the manufacture of the component.
Note: If the DAR has a cost benefit, it is recommended that the calculator should be
completed. However it is not mandatory for DARs which do not have an associated cost
benefit e.g. Document error correction.
Required for Successful Submission
A justified cash benefit.
(Highly recommended) A complete Benefits Calculator.
(Highly recommended) A calculated Engine Set Value (ESV).
12.1 Benefits Calculator
12.1.1 Assumptions
Standard Cost of Part: Only required for Cycle Time and Lead Time Reductions. Can
be found in SAP at the transaction MM03 (Display Material) section Accounting 1.
Working Days per Week: Only required for Cycle Time and Lead Time Reductions.
12 Months Demand from Date of Implementation: See local MRPC for more
information.
Exchange Rate to Convert to GBP: The sheet is to be completed in local currency and
then converted into GBP for the total benefit. If the costs are already in GBP then
enter 1.
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12.1.2 Concession Reduction
This section is to be filled in if there is going to be a reduction in the number of concessions
produced during manufacture once this DAR has been implemented.
Line Item/Concession Reduction: The difference between the Line Item/Concession
per unit before and after the implementation of the DAR.
Value of Each Line Item: See local TPM or ME for guidance, it is possible to both use
an agreed flat rate or not.
12.1.3 Rework Reduction
This section is to be filled in if the quantity of rework that has to be performed on the
component can be reduced by implementing the DAR.
Variable Cost Rate: See local TPM or ME.
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12.1.4 Scrap-rate Reduction
Scrap-rate reduction produces two types of benefits:
- Hard tangible if the scrap rate allowance is reduced.
- Cost avoided if the number of parts scrapped reduces which does not impact the
scrap allowance.
12.1.5 Raw Material Saving
Raw material saving produces hard tangible benefits as it has an impact on the unit cost.
12.1.6 Consumable Reduction
A reduction in consumables produces tangible (cost rate) benefits when the consumable
reduction is below budget and cost avoidance when it is above budget.
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12.1.7 Cycle Time Reduction
Cycle time reduction produces three types of benefits:
- Hard Tangible (CRISP) due to a SAP cycle time reduction that is below budget.
- Tangible (Cash) from an inventory reduction due to a cycle time reduction.
- Cost Avoidance due to a cycle time reduction in order to achieve the budget.
12.1.8 Lead Time Reduction
Reducing the lead time creates a benefit by reducing the amount of inventory that’s stored.
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12.2 Good Example
At least one of the Benefits Calculator sections should be filled in to provide
justification for the value quoted as the value of the DAR.
The value of the DAR should also be quoted later in the Technical Justification
section.
14. BUSINESS JUSTIFICATION (QUALIFY SECTION 10)
CRiSP No: ARM no: If other, please specify below:
Value of DAR (£); 15,000
Use the benefits calculator located online on InfoCentre - Producibility OR If you cannot access the link please use the benefits calculator shown below.
Benefits Calculator:
Assumptions
v. Standard Cost of Part y. 12 months demand from date of implementation 45
w. Working days per week z. Exchange rate to convert to GBP 1
Improvement Activity Scenarios (Complete only relevant sections)
Concession Reduction YES NO Raw Material Saving YES NO
a. Line item/Concession Reduction 1 a. Cost of the raw material per unit before
b. Line item/Concession per unit BEFORE 2 b. Cost of the raw material per unit after
c. Value of each Line item 1000 Hard Tangible (CRiSP): (a – b) * y * z
d. Average number of parts per concession 3
Cost Avoidance: (b – a) * y/d * c * z 15,000 Consumable Reduction YES NO
a. Total cost of consumable in the last 12 months
Rework Reduction YES NO b. Expected total cost of consumable in the next 12 months
a. Rework Per Unit before c. Cost of consumable reduction below budget
b. Rework Per Unit after Tangible (Cost rate): c * z
c. Hours per rework Cost Avoided: (a – b – c) * z
d. Variable cost rate
Cost Avoidance: (a – b) * c * d * y * z Cycle time reduction YES NO
a. Actual cycle time before (hours)
Scrap rate Reduction YES NO b. Actual cycle time after (hours)
a. No Parts scrapped in the last 12 months c. SAP cycle time reduction (hours)
b. Expected number of parts scrapped in the next 12 months
d. FTE variable cost rate
c. Cost of part up to the point of scrapping Hard Tangible (CRiSP): c * d * 2 * y * z
d. Scrap rate allowance before Tangible (Cash): y/(52 * w) * v * z *
(a – b)/24
e. Scrap rate allowance after Cost Avoidance: (a – b) * d * y * z – Hard Tangible
Hard Tangible (CRISP): (d – e) * c * y * z
Cost Avoided: (a – b) * c * y * z – Hard Tangible Lead Time Reduction YES NO
a. Numbers of concessions
b. Lead time saving due to concession reduction (working days)
c. Number of rework eliminated
d. Lead time saving due to rework reduction (working days)
Tangible (Cash): y
/(52 * w) * v * z * (a * b + c * d)
QUALITY:
DELIVERY:
Any quality or delivery benefits gained from the DAR should be
described in these boxes.
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13) Technical Justification
Required for Successful Submission
Clear concise text
Clear Justification stating exactly why the DAR should be accepted e.g. Cost benefit
(Engine set Value & Annual Saving) stated with calculator references.
Examples of supporting documents & any capability data stated for reference and
attached in the supporting documents.
13.1 Good Examples
Use statistics to justify your argument where possible, as used in the example above.
Make sure to provide evidence for these statistics.
Structure the justification well with distinct sections and paragraphs in order to keep
your argument succinct and easily understandable.
Referenced locations shown and attached, as shown in the example overleaf.
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13.2 Poor Examples
Keep the explanations clear and ensure they are still understandable for colleagues
who have less experience of the specific area.
Specifics should be given such as contacts who have been involved, e-mail threads,
reasons behind conclusions.
Don’t reference other files unless they are attached as supporting documents or
directly referenced e.g. Concession numbers.
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14) Supporting Documents
14.1 Referenced Documents
All documents that are referenced throughout the document should be included in the
supporting documents in order to help the investigator to understand the reasoning behind
the request.
14.2 Relating Documents
Any documents relating to the subject matter of the DAR should also be attached. For
example, in this case the DAR has been raised to correct an error in a definition so an
approved Deviation Permit (DP) for the component was included in the supported
documents.
14.3 Embedding Documents
When files are embedded within the DAR, or within the supporting documents, make sure
that the files are also attached to the DAR in order to make sure that all the necessary
documentation is printed.
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15) Steps to Submitting the DAR + Contacts
15.1 Requestor Key steps to completing Submission
Complete Personal and Company Contact Details.
Complete the DAR Form as outlined by the Guidance Material.
Record the Request No. on local database for future reference.
Send the Request to the associated Sponsor within Rolls-Royce. This will be the
associated ME (Manufacturing Engineer) / MEP (Manufacturing Engineer Purchasing).
15.2 Sponsor Key Steps to completing Submission
Check that all the information provided by the Requestor has been completed
correctly.
Complete Personal Contact Details including Telephone and E-mail.
Complete the DAR Form as outlined by the Guidance Material.
Send the complete request to the submission inbox associated with the DAR.
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16) DAR Form RACI Chart
DAR FORM RACI
Process
Steps
R - Responsible - Actually completes this task
A - Accountable - Ultimately responsible
C - Consults - Prior to a decision
I - Informs - After a decision is made
DA
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DA
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Su
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DAR Number R A I I
Request Number C A R
Tracking Number R/A I I
Distribution R C
Date Requested I A R
Date Approved R A
Date Issued R A I I
Project/Account no I R/A C
Sponsor/CAM I R/A
Person to be informed once the component definition(s) is changed R A I I
Requestor's Name C A R
Requestor's Phone C A R
External supplier of RR designed part(s) C A R
Supplier of supplier designed part(s) C A R
Internal RR supplier C A R
Section 3 Export Licence Check C A R
Supplier (vendor) Code C A R
Supplier Name & Address C A R
Supplier's phone C A R
Supplier's E-mail address C A R
RR Personnel contact details C A R
Initial Engineering Disposition R/A I I C
Notification to requestor R/A I I C
Section 6 DAR Approvals R/A I I C
Section 7 Confirmation of Release & Approval to Archive Altered Definition R/A I I C
RR Definitions & Suppliers Definitions affected C R/A
RR Casting/Forging definition affected C R/A
Section 9 Approvals A C R
Section 10 Reason For Alterations I C A R
Section 11 Action Requested (Define Proposed Alterations) I C A R
Section 12 Alteration Effect Summary A R C
Section 13 Alteration Instruction I A R
Appendix A - Section
14Business Justification I R/A C
Appendix B - Section
15Technical Justification I A R R
Section 4
Section 5
Section 1
Section 2
Section 8
General
Rolls-Royce
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Change History
Issue Date Description of Change Authors Owners Approver
1 Issue 1 R Matthews
S Hutchinson
K Bonner T Hussain
© Rolls-Royce plc 2016
The information in this document is the property of Rolls-Royce
plc and may not be copied, communicated to a third party or used for any purpose other than that for which it is supplied,
without the express written consent of Rolls-Royce plc.
While the information is given in good faith based upon the latest information available to Rolls-Royce plc, no warranty or
representation is given concerning such information, which must not be taken as establishing any contractual or other
commitment binding upon Rolls-Royce plc or any of its
subsidiary or associated companies.