Supplier Kick-Off Review Document - Yeemak - 20230811
Supplier Kick-Off Review Document - Yeemak - 20230811
Supplier Kick-Off Review Document - Yeemak - 20230811
STATUS OVERVIEW:
Approved
Section #2: Datum's, Critical Dimensions / Characteristics, and Gauges (Supplier Quality Development - SQD)
2.1 Datum's:
2.1.1 Does the supplier understand the "A" Datum as N/A
shown on the drawing? Are there any concerns?
- Can the item be measured on CMM and check
fixture accurately? N/A
- Does the supplier agree with this datum
structure?
2.3 Customer Critical Dimensions: Annual re-certification of customer critical characteristics required per approved control plan
2.3.1 CUSTOMER CRITICAL No issue
C DIMENSION / CHARACTERISTIC:
- Define Critical Dimension/Characteristic Here
(identify location of characteristic on drawing)
- What is supplier's interpretation of requirement
and how it is applied?
Approved
- Are there any issues meeting this functional
requirement? List & explain.
2.4.4 Gage concept to be provided by supplier YEEMAK SIWOO will submit the concept drawing for gage within
2 weeks after K/O (for approval by Inalfa 2weeks after K/O.
Engineering and Supplier Quality). To Be
- Inalfa response shall be provided in 2 weeks. Decided
3.1.3 Mold Flow Analysis: (per applicable No Issue ( Same concept with serial )
manufacturing process for component)
- Has supplier obtained and reviewed (as
applicable) Inalfa Mold Flow analysis worksheet
for MFA requirements
- Will your manufacturing tools conform to the Approved
MFA requirements of the applicable document?
- List all exceptions.
- What is suppliers alternate proposal ?
4.1.7 Has the visual standard and the visual standard No Issue
definition been reviewed and approved?
Approved
4.3.2 What kind of tools / processes will be used for N/A ( Serial tooling )
prototype items? Purchasing to give supplier 1st
dimensionally correct item due date, PPAP due
N/A
date, and SOP date. Purchasing to also provide
approximate quantities required.
4.3.3 What is the intended production location? YEEMAK SIWOO chennai plant
Approved
4.4.2 What is the planned capacity for this item (Hourly, No Issue
Weekly, Annual)? The press facility can produce 200,000 units per month. AY cars
-Has the "EQUIPMENT CAPACITY WORKSHEET" account for 20% capa.
tab been completed? Approved
-What is the planned tool life (item quantity)?
-Are there any issues?
4.4.3 Does this item require the supplier to purchase No need extra equpment
new equipment? If yes, describe. Approved
5.1.2 Is existing returnable packaging planned for this Needs discussion with IGGS
item? Has a study been completed to insure
proper fit of the item? Are there adequate
quantities available to include this item? If no, is To Be
another container available or is new packaging Decided
required?
5.1.3 Supplier required to submit a backup packaging Needs discussion with IGGS
plan for use if returnable packaging is not
To Be
available. Has the backup plan been approved by
Decided
Inalfa?
5.1.4 Does supplier have concerns about shipping Needs discussion with IGGS To Be
containers or item damage in transit? Decided
5.1.5 Does the supplier understand Inalfa's approved Needs discussion with IGGS
criteria for shipping (labeling, etc)? If not, please To Be
review this on the supplier portal. Decided
5.1.6 Supplier is required to supply packaging concept at Needs discussion with IGGS
the time of submitting their final quote. Packaging
Approval Form # IRS PASO-01 to be completed
To Be
and submitted with Quote.
Decided
-Has the "PACKAGING" tab been reviewed?
-Are there any issues?
6.2 Summary:
6.2.1 Summarize the meeting, review open actions. Approved
TIMING PLAN
17 IMDS '24.3.25~'24.3.29
TEST REQUIREMENTS
Plastic Parts
Fill in by Supplier
Specification / Test
Paragraph
Item (A,B,C etc) Test Method Acceptance Criteria
Description of test
FMVSS 302 (MS300-08); FLAMMABILITY of INTERIOR MATERIALS (in occupant compartments of motor vehicles)
Burn Resistance of Interior
- -
Components
IES50.016
CLIMATE CYCLES FOR
TEST PERFORMED
OVERMOULDED STEEL -
INALFA
PARTS
IES60.017
COATINGS FOR METAL
- Min. 240h
PARTS
MS201-01
MARKING OF MATERIALS
C
C - -
FOR AUTOMOTIV PARTS
MS201-02
PROHIBITION AND
C
C REPORTING THE USE OF
- -
HARMFUL SUBSTANCES
PARTS AND MATERIAL
MS300-55
TEST METHOD FOR THE
DETERMINATION OF THE
- -
C EMISSION OF VOCs FROM
VEHICLE PART
MS124-07
Public #_x000D_
Specific program requirements must be added for each new kick-off review
T REQUIREMENTS
STATUS
Plastic Parts
OVERVIEW:
Approved
Kick-Off Review Drive Cable GLASS Not Approved - Major
red will be in grey) Not Approved - Minor
To Be Decided
N/A
Fill in by Supplier
Y A Yes
N/A A Yes
Y A Yes
N/A A Yes
N/A A Yes
Y A Yes
Public #_x000D_
Y A Yes
Test Specifications
Summary
1
0
0
0
0
Fill in by I.R.S. only Set column K to N/A for all greyed out lines
Decision by
Alternate Proposal Remark
IRS
실내 부품
Approved
내화성
Approved
Approved
Approved
Approved
Approved
Public #_x000D_
Approved
AM
J. Rose
EP
J. Rose
APPROVED BY
Public #_x000D_
Example)
Project : Name AY1 YEEMAK SIWOO JONGCHAN OH 010-8533-1293 11-Aug-23
per
(seconds)
PROCESS CAPACITY
ASSUMPTIONS :
Volumes of Roofs
Volumes of Roofs
Volumes of Roofs
H = Main equipment availability
A = Weeks per YEAR (max. 48)
Total Volumes
- 48 weeks per year
always > 1
project X
project Y
- 5 days per week
YEARS
of parts
WK
TT/CT =
Requested volume Working week Requested Volume - 8 hours per shift
D = Number of SHIFT
- 2 shifts per day
max 85% )
week (%)
100%
408.0
48,600 48 1,013 241.8 48 6 7.5 3 1 1 85% 100% 1 11 37.09 48600 48600
2025
Peak 1
10% Increase over
370.9
Nominal 53,460 48 1,114 219.8 48 6 7.5 3 1 1 85% 100% 1 11 33.72 54000 54000
2026
Peak 2
25 % Increase over
326.4
Nominal 60,750 48 1,266 193.4 48 6 7.5 3 1 1 85% 100% 1 11 29.67 56700 56700
2027
59400 59400
2028
59400 59400
PRODUCTION DATA YEAR 2 2029
NOMINAL Volume
367.2
54,000 48 1,125 217.6 48 6 7.5 3 1 1 85% 100% 1 11 33.38 40500 40500
2030
Peak 1
333.8
10% Increased of Nominal
59,400 48 1,238 197.8 48 6 7.5 3 1 1 85% 100% 1 11 30.35 0
2031
Peak 2
293.8
25 % Increased of Nominal
67,500 48 1,406 174.1 48 6 7.5 3 1 1 85% 100% 1 11 26.71 0
2032
0
2033
349.7
56,700 48 1,181 207.2 48 6 7.5 3 1 1 85% 100% 1 11 31.79 0
2035
Peak 1
317.9
10% Increase over
Nominal
62,370 48 1,299 188.4 48 6 7.5 3 1 1 85% 100% 1 11 28.90 0
2036
Peak 2
279.8
25 % Increase over
Nominal
70,875 48 1,477 165.8 48 6 7.5 3 1 1 85% 100% 1 11 25.43
Peak 1
10% Increase over
65,340 48 1,361 180 48 6 7.5 3 1 1 85% 100% 1 11 27.59
303.5
Nominal
Peak 2
25 % Increase over
74,250 48 1,547 158 48 6 7.5 3 1 1 85% 100% 1 11 24.28
267.1
Nominal
Peak 1
10% Increase over
65,340 48 1,361 180 48 6 7.5 3 1 1 85% 100% 1 11 27.59
303.5
Nominal
Peak 2
25 % Increase over
74,250 48 1,547 158 48 6 7.5 3 1 1 85% 100% 1 11 24.28
267.1
Nominal
Bottle Neck
Operations Description Equipment
Y/N
INVESTMENTS Needed I L M N O P
Direct OR Sub-
#
Actions to improve process :
Description of tools / equipment
Estimate /
Fix Cost
supplier
TOTAL : $0 0 #DIV/0!
Public # _x0 0 0D_
LEGEND
F Opposite value of the N° of parts needed in a roof . ( Example If there are 2 parts
1 / parts per roof
every roof then F = 0,5 )
G Efficiency of the process Best utilization of the process time , including all efficiency factors. Max. accepted value
is 0.85 or 85%
Availability of the production machine for this project . ( Example : for an injection
H Equipment availability press , if that is dedicated at this project then H = 1 , if the press is only 50% available
for this project then H = 0.5 or 50%
Minimum value available to be able to produce requested volume , with the
TT Takt Time
production conditions settled
Measured time needed to produce 1 component , including the packaging time . CT
CT Cycle Time
must be measured during R&B . CT must be always smaller then the TT
Factor to recognize if the process is able to produce the requested volume . Must be
TT/CT Process ability
always > 1
Investment required to produce requested volume . Must indicate value for every
I Investment
modification , new tool or equipment to added .
Indicates if the investment is done directly by the Inalfa's supplier or by another
L Direct / Sub-supplier company ( sub-supplier ) that supply some components needed to produce the part
to the Inalfa's supplier . Indicate D or S
M Sub-supplier It indicate the name of the external company
N Lead time It indicate the lead time to start produce new volume including training , prepare new l
O Estimate / Fix It indicate if the value of the investments is an estimation or a fixed price
Factor to indicate if the investment is done only for the project shown or can be used
P % investments for this program
also for other projects.
Available tooling to produce component in subject . Generally it is 1 , but for high
volume production can be 2 or more , depending on cycle time . If this number is
T Number of Tooling Available
more than 1 , need to recalculate H value ( Equipment availability ) considering the
overall average of the availability of all Production machine
INSTRUCTIONS
- Please fill out one entire worksheet for each individual component supplied to Inalfa. If the components have a LH and RH hand, it must be indicated at the top of the format.
- Each worksheet must be completely filled out by supplier in all YELLOW cells. The GREY cells do not have to be filled , because there are in automatic formula.
-There are two requested volume assumptions to be reviewed : Nominal Production and Peak production. Buyer will provide to you volumes in SECTION 1 and value for Peaks .
- To complete the form the actions are as follows;
1) Complete the section entitled "PRODUCTION VOLUME" by filling the yellow cells with the current actual planned process parameters for production. The goal in this section is that your current planned process will cover the NORMAL and
PEAKS requested volumes. In this phase is very important to define correctly the CYCLE TIME. (The cycle time must be EVALUATED based on your quotation). If your current planned process parameters ( A , B , C , .. ) are correct, the value of
TT/CT Must be > 1, and the TT/CT column cells will change to GREEN. If the parameters are incorrect, or do not meet the requested volume, the cells will change to GREY.
- If is not possible to cover whole requested volumes with the current planned process parameters, please define a potential action plane to achieve the goals. Based on these actions, move to the next section and complete.
2) Complete the section entitled "IMPROVED SCENARIO" with the new potential process parameters based on your actions noted above, and verify if the problems are solved.
3) Once the parameters are correct, and the CT/TT column cells are green, start fill the three sections entitled "INVESTMENTS". In the "description tool / equipment" rows note the tools and equipment which is already in place (based on your TCAR)
and used for the forecasted production. In this case, the costs cells only need to be filled if modifications to the existing equipment or tools is necessary. Once if you have listed all current tooling in use, IF REQUIRED, specifically list potential new
tools, equipment, gages, fixtures, etc. which may be needed to cover the related volume. For these items, supplier must indicate the estimated investments and the estimated complete lead time. Supplier have to indicate also if the investment will be
100% dedicated to the program in subject or if will be used also for other programs ( INVESTMENT RATE ) . Lead time should including all necessary work and time spent for each action needed, before to start producing at a new volume (i.e.: pkg,
hire and train of extra shift, material order lead time, ect.
4) In the section entitled "LEGEND" provide a short explanation about the potential actions forecasted above. Provide this description in the appropriate row, in the open cells in the column "explanation". An explanation only needs to be provided in
those cells where there have been changed parameters in order to achieve the requested volumes.
NOTE: PLEASE REVIEW THE SAMPLE WORKSHEETS PROVIDED FOR FURTHER CLARIFICATION ON HOW TO FILL THE FORMS.
NOTE: WHEN EVER YOU SEE A "LETTER" NOTED WITHIN THE FORM, PLEASE REFER TO THE LEGEND SECTION FOR ACTUAL DEFINITIONS AND DESCRIPTIONS.
NOTE:
THE COMPLETED WORKSHEETS MUST BE SUBMITTED TO INALFA BEFORE FIRST KICK-OFF REVIEW
EXAMPLE
EQUIPMENT CAPACITY PLAN
(See bottom for Instructions and Supplier : Completed By: Phone #: Updated on:
Example)
Project : Name Inalfa F. Bonucci 248 371 0901 13-Sep-12
E70
Part Number Part Name
per
(seconds)
PROCESS CAPACITY
ASSUMPTIONS :
CT = CYCLE TIME in sec.
TT = TAKT TIME in sec.
H = Main equipment availability
A = Weeks per YEAR (max. 48)
always > 1
WK
Requested volume Working week Requested Volume - 8 hours per shift
D = Number of SHIFT
week (%)
100%
Peak 1
10% Increase over
97.1
Peak 2
25 % Increase over
85.5
Peak 1
10% Increase over
121,000 48 2,521 97 48 5 8 3 1 1 85% 100% 1 100 1.46
145.7
Nominal
Peak 2
25 % Increase over
137,500 48 2,865 85 48 5 8 3 1 1 85% 100% 1 100 1.28
128.2
Nominal
Public
PART INFORMATION (Digital Photo or Sketch) INTERIOR DESIGN DIGITAL PHOTO (or Sketch) PROGRAM: REVISION NO.
AY1
PLANT(s):
DDS DIMENSIONS TARE
QTY CNTR NAME MATERIALS L W H WT
1600/pallet BOX Container Carton 1100 980 750 271
International- Rail
PHONE: SUPPLIER APPROVAL
FAX:
CONTACT:
TITLE: Supplier Approval: Date:
CONTAINERS PER PALLET EMAIL:
MIN: 1 MAX: 1 DATE:
REMARK 1: REMEMBER, THE RESPONSIBILITY FOR ENSURING COMPONENT QUALITY FROM YOUR PLANT TO THE POINT OF USE REMAINS WITH YOU - THE SUPPLIER OF THE PRODUCT.
REMARK 2: ALL NEW CONTAINERS MUST BE LABELED ACCORDING TO CURRENT INALFA PACKAGING GUIDELINES!
Other List:
Number of Cavities:
Direct on tool
Injection System: Hot Runner / Manifold Cold Runner
On an insert
Drop Valve
Other (Specify):
Other (Specify):
Other (Specify):
Process
Mold Flow Analysis Forecasted NOT Forecasted
Volumes
Peak
See “Marked Print” for parting line locations, gate locations, ejector pin locations and cavity ID locations
identified and approved at initial design review meeting. Any deviation from approved print requires approv
Systems.
YES NO
YES NO
Supplier Toolmaker
Supplier Toolmaker
Solid Shuttle
In:
Gas points (Qty)
Out:
Other (Describe):
Public #_x000D_
Other (Specify):
Chrome plate
Other (Specify):
Chrome plate
Other (Specify):
Chrome plate
Depth (mm):
Max.
PPT-file showing :
Supplier to provide a mold
-shrinkage applied X,Y,Z YES compensation strategy within
3 weeks of purchasing KO
-warpage correction X,Y,Z (position)
Completion Date
Public #_x000D_
Public #_x000D_
K
Defect Type / Definition Photo/Description
Zone “A” Zone “B” Zone “C”
Sink marks
NOT Only 1 max
Acceptable 1mm x 1mm
NOT
Acceptable
NOT
Acceptable
Acceptable
Acceptable
NO
NOT NOT
Silvering Acceptable
Acceptable Acceptable
Acceptable -
NOT To be
Glass fiber Acceptable
Acceptable agreed with
SQD
Zone Definition
Zone A - Moderate to high visibility to vehicle
occupants
Zone B - Moderate to low visibility to vehicle
occupants
Zone C - Low to no visibility to vehicle occupants
Correct Viewing
Directions
Public #_x000D_
Light
Sourc
e
600 MM
( Approximate
Arms Length)
45
Degr
ees
16- Oct-
General Revision AM
11
Added template to
5-May-11 J. Rose
file
ENG.
REVISIO DESCRIPTION OF APPROV
CHANGE
N DATE CHANGE ED BY
NUMBER
Public #_x000D_
NO K
NO K
Example of Silvering (bad
Example of bur or bad injection cutting conditioning of the material)
NO K K
NO
IMPORTANT INFO
NOOKK
N
Example of glass fiber on the
surface (bad flow or bad tool
temperature)
NOOKK
N
Public
Example of glass fiber on the
#_x000D_
NO K
Public #_x000D_
NO K
bad
aterial)
OK
Phase Action
A similar part in production is defined as Master
Sample => all the esthetical areas are defined and
the part is signed by SQD - ENG - Supplier.
KOR
Pictures of the component are taken and will be
part of this document;
The physical part is given to the supplier;
d Definition
Responsability
Step # Process
Process Guidelines
ms with welded coverplates
Included in Process?
Comments (Supplier to complete
using drop list)
No
No
No
No
No
Key Proc
Plastic beams
Step # Process
Included in Process?
Comments (Supplier to complete
using drop list)
No
No
No
No
No
Key Proce
Plas
Step # Process
11
Included in Process?
Comments (Supplier to complete
using drop list)
No
No
No
No
No
Step # Process
10
Public #_x000D_
10
11
12
13
Process Guidelines
ubes for plastic beams
Included in Process?
Comments (Supplier to complete
using drop list)
No
Public #_x000D_
Step # Process
Input the part to cooling jig, and check the fit of part in
11 the cooling jig
Process Guidelines
Plastic Frame
Included in Process?
Comments (Supplier to complete
using drop list)
No
No
No
No
No
Supplier Status
Item Requirement-SEE IRS GSQAP-004-below are highlights only (Supplier to complete
using drop list)
The gage must be dimensionally stable and capable of maintaining stability without the use of unattached elements (such
asbrackets, cross bars, braces) throughout the life of the gage.
1 * Checking fixture base plate should be robust and stable, thickness prefreably >10 mm Not Agreed
* Material: Steel or Aluminium
All details must function freely without the use of excessive force and no allowable play.
2 Not Agreed
* Also keep in mind that the checking fixture is necessary (and should stay stable) during the complete product life time
3 Attaching features must function without binding or kinking and must be attached securely Not Agreed
(90 Newton minimum pull-off requirement, i.e normal operation should not cause details to separate from gage)
All elements locating and checking features must be clearly identified by Inalfa naming convention per Inalfa drawing.
4 * Identification lables should be attached in the right way, so that there is no risk that they will come loose during the life ime of Not Agreed
the checking fixture!
5 All non-gauging surfaces that may be subject to oxidation are to be coated to prevent deterioration through the life of the gage. Not Agreed
6 All sharp corners are to be broken 0.5mm or what is safely practical. Not Agreed
Tooling ball coordinate system required on all gages (x, y, z axis - in body position as required).
7 Not Agreed
* Preferable with tool ball values stamped on tags on non critical surfaces
Required inspection points (variable and attribute) are called out on Inalfa drawing
8 Not Agreed
Not Agreed
Not Agreed
Not Agreed
It is preferred that gage must be capable of being used as a CMM holding fixture
* Checking fixture can be used for checking during production with “Go-nogo features” (Attribute) and measuring clocks
9 Not Agreed
(variables)
* Part can be clamped on the datum points on this fixtures and used for CMM measurements
10 CMM access to underside of item required (minimum of 200mm of clearance to base plate) if doubling as a holding fixture. Not Agreed
11 Gage base plate must be flat within 0.08mm - 0,12 mm Not Agreed
Hardened steel bushings required for all check surfaces (unless otherwise specified by Inalfa).
* On feature 1, a flange can measured with a digital indicator in Z-direction. (“Variable” for checking during production)
12 * On feature 2, a flange can measured with a digital indicator in X-direction. (“Variable” for checking during production) Not Agreed
* With the CMM, the flange can be measured in both Z- and X -direction
13 Gage design must follow functional GD&T from drawings to locate items. Not Agreed
14 Net gauging surfaces and or datums shall be within 0.08 mm of math data Not Agreed
All clamping and swing templates (in open position) shall remain within the confines of the base or have appropriate guarding for
15 Not Agreed
protection of detail.
16 Variable data collection systems must have the ability for real time data review. Not Agreed
17 Gage build will not proceed without written authorization by Inalfa. Not Agreed
18 All gage concept/design drawings and math data must include the component in the section view for full understanding Not Agreed
19 Gage must be designed to function properly for the life of the component program (including service requirements). Not Agreed
Supplier compliance to approved designs, concepts, drawings, GR&R, and uniform gauging specifications are mandatory.
20 Not Agreed
Failure to comply could result in rejection of the gage.
Acceptable gage R&R will be less than 10%. Gage R&R values greater than 10% must be reviewed and signed off by Inalfa
21 (reference AIAG MSA manual for additional information / ANNOVA method is required for all Ford work and may be required by Not Agreed
other customers).
22 Gage certifications must be completed by a accredited metrology laboratory. Not Agreed
24 Detailed gage instructions with visual aids defining use of gage must be permanently attached to check fixture. Not Agreed
25 Gage must have Inalfa identification property tag (see Inalfa purchasing for tags and requirements). Not Agreed
26 See IRS GSQAP-004 gage specification for FULL detail (document available on Inalfa supplier portal). Not Agreed
The number of assigned "C" characteristics, per commodity, shall be determined by Customer Specification, with no limit to quantity (typically, less than 5).
F (Inalfa) Key Functional Characteristics are the key dimensions and tests that determine, with > 90% certainty, if the item/assembly will meet all of it's "fit and function"
requirements. Includes Customer Characteristics (but not identified as Critical Characteristics).
The number of assigned "F" characteristics, per commodity, to be minimal (typically, less than 8).
Ppk / Cpk calculated in accordance with AIAG Statistical Process Control Manual (latest issue).
Within
Within Statistical Specification Per Supplier
C Dimension All ≥30 All ≥30 Ppk ≥1.67 Cpk ≥1
Specification Analysis Control Plan
Pp>2
Within
Within Statistical Specification Per Supplier
F Dimension All ≥30 All ≥30 Ppk ≥1.67 Cpk ≥1
Specification Analysis Control Plan
Pp>2
The supplier shall perform 100% inspection until Capability (Variable, Attribute, and Appearance) is proven with zero defects. Once the supplie
proven capability (long and short term), the Step Down Plan may go into effect with the approval of SQE. If in the event a defective part reaches
during the Safe Launch period, the Safe Launch Plan will re-start at 100% inspection until the Capability with zero defects criteria is proven and t
Step Down plan can be re-started at the beginning.
All "F" characteristics require proof of initial capability to 1.67 for Ppk
All "F" characteristics require long term capability to 1.33 for Cpk
All "F" characteristics require conformance to the typical stepdown chart for verification shown below.
Stage To Be Determined
Initial Delivery 0-100 100% F's All Parts
100-600* 100% F's, 50% of the Parts
600-3000** 2 X's Normal Control Plan
Beyond 1st 3000 pc production Per Normal Control Plan
13-Oct-14 Key Characteristics Flowchart revised to show all applicable FMVSS requirements plus ECE, CNCA, etc. J. Ros
termined by Customer Specification, with no limit to quantity (typically, less than 5).
tests that determine, with > 90% certainty, if the item/assembly will meet all of it's "fit and function"
d as Critical Characteristics).
Requirement
(Results Recorded &
Retained by Supplier;
available by request)
Cpk ≥1.33
Within Specification
Cpk ≥1.33
Within Specification
Within Specification
Within Specification
riable, Attribute, and Appearance) is proven with zero defects. Once the supplier has
y go into effect with the approval of SQE. If in the event a defective part reaches Inalfa
at 100% inspection until the Capability with zero defects criteria is proven and then the
n can be re-started at the beginning.
7 for Ppk
r Cpk
pdown chart for verification shown below.
J. Rose
J. Rose
J. Rose
J. Rose
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