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Manufacturability Assessment & Process Plan

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Microsoft PowerPoint - MAPP Supplier Training.ppt Understand what Nexteer is doing differently to improve launch performance
Understand Nexteer’s new Manufacturability
Assessment & Process Plan (MAPP) process
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Proactive Risk Assessment throughout Launch Process − Cross Functional BOM Risk Assessment (Nexteer)
− Internal Print Reviews (Nexteer)
− PFD, PFMEA & Control Plan Submission prior to PPAP (Supplier)
Identify Target Supplier prior to Design Validation − Supplier input for Design Validation
− Production intent process for Design Validation to mitigate risk
− Production intent supplier for High Priority Parts to mitigate risk
Emphasis on Collaborative relationships − Buyer-AQE-PE-Supplier are responsible for flawless launch of product
− Nexteer-Supplier teamwork approach to achieve quality & cost targets
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− Goal: Name a Target Supplier 6 weeks after issuing RFQ
− Engage the supplier earlier to allow for supplier input into the design
Improve Launch Performance
− Achieve cost targets
Question: What is Nexteer Going to do Differently?
Answer: Collaborative Sourcing & Concurrent Engineering
Traditionally, Nexteer Product Engineering worked independently to develop the product design
Develop Business Case
The Collaborative Sourcing Process & Concurrent Engineering Philosophy brings the Target Supplier into the
development phase to obtain supplier input into the design
Develop Business
Implement Mfg
Question: What is Nexteer Going to do Differently?
Answer: Identify & Mitigate Risk
Rigorous Internal Risk Reviews
Identify Target Supplier Early
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Global Supply Management’s “MAPP to a Flawless Launch”
Based on the “Compliance Matrix” that is required by our customers to
be submitted with our new business
pursuit quotes
The MAPP template is located in the Nexteer Supplier Portal: Home > Frequently Used Documents >
Supplier Standards > Direct Material Sourcing Requirements
or copy & paste the link:
https://sss.portal.covisint.com/c/document_library/get_file?uuid=06330c8b-
Take Action for Quality: It’s everyone’s job
We must eliminate any Customer perception that
Nexteer is a risky supplier
during the Launch Phase.
our suppliers won’t win new
business
Encourages a collaborative relationship between the supplier and the Nexteer
Buyer, Supplier Quality and PE Collaboration is the act of working
with others on a joint project
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How is the MAPP Used?
MAPP: Risk Identification & Mitigation Tool
Communicate expectations to the supplier
Guides the Supplier, AQE, PE & Buyer to identify risk as early as possible
Allows the team to assess risk to use their
experience & judgment whether a supplier is capable to make the part
Documents risk mitigation plans
The MAPP requires the supplier to consider each dimension, feature or requirement on the drawing, or in
the product spec, and document how the it will be
manufactured, measured and controlled in production.
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MAPP Template is sent out with RFQ
Supplier is encouraged to use the
MAPP as a tool to generate their Quote
Supplier MAPP must be provided to Nexteer prior to the Supplier Capability & Selection Review (first tech review)
Open issues should be expected and welcomed
Goal is to identify a Target Supplier 6 weeks from RFQ issue
date; in some cases, multiple suppliers may be selected.
Identifies issues so that Nexteer can select a Target Supplier
to allow collaboration to begin earlier in the process
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2. PC&L, PE & AQE/SQE Sign MAPP after Capability & Selection
Review(s)
3. Buyer identifies a Target Supplier
4. Supplier signs MAPP. PC&L, PE and/or SQE/AQE sign if there
are exceptions. Required for Final Sourcing Approval & Supplier
Kickoff.
4. Process Flow Diagram **
5. APQP Contact List **
6. Supplier Kickoff Information **
7. Approval Sheet ** 8. APQP Open Issues List (at AQE discretion)
9. Supplemental Technical Review Questions (at AQE discretion)
** Required for Supplier Capability & Selection Review
Pilot Only: Required for Supplier Capability & Selection Review
** Completed by Nexteer
Supplier submits Sections 1, 2, 4 & 5 of the MAPP
NOTE: Section 3 will be required on pilot programs as directed by the Nexteer Buyer/AQE
Supplier eSigns the MAPP and emails Excel file to the Buyer prior to the Supplier Capability & Selection Review (1st Tech Review)
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Instructions with document links are included in the MAPP Template
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supplier
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SUPPLIER: Answer each Team Feasibility question in Section 1. Add comments are as required.
NEXTEER: The Buyer assigns a status for each item. Each item should be marked “Closed & Approved” before kicking off supplier tooling. “Open” items must have a mitigation plan completed before closing out the item.
1. Team Feasibility Requirements
SUPPLIER: Answer 44 questions pertaining to your Manufacturing Site, Outside Processing, Quality, Program Management, Timing, etc.
NEXTEER: The Buyer/AQE assigns a status for each item. Each item should be marked “Closed & Approved” before kicking off supplier tooling. “Open” items must have a mitigation plan completed before closing out the item.
2. Supplier Assessment
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SUPPLIER: Attach a high level process flow diagram in the SECTION 4 - SUPPLIER PFD workbook tab.
The Process Flow Diagram should be a sketch that adequately defines the process quoted. This may be a handwritten PDF file pasted into the workbook tab.
4. Supplier Process Flow
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SUPPLIER: Complete the highlighted fields in the APQP Project Contact List in the SECTION 5- CONTACT LIST worksheet tab.
5. APQP Contact List
SUPPLIER: Fill out the Process Operation Number & Process Concept/Method
SUPPLIER: Road Map the print and enter the Road Map #, the Requirement, Dimension, Note or Spec and the Class & Characteristic Number of each
SUPPLIER: Complete a Manufacturing Process Feasibility Assessment for each dimension/process step.
3. Manufacturability Assessment
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SUPPLIER: Select whether the process will be completed In-House or at a Sub-Supplier
SUPPLIER: The required Process Indices automatically populates based on the class of the dimension. Select whether or not there is a commitment to meet the required indices.
SUPPLIER: Enter the control method for each item and the verification method
3. Manufacturability Assessment
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Example
Template
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Supplier eSigns the MAPP by entering the date and Name of their team responsible to address open issues and strive to achieve Nexteer business (cost and quality) targets
Excel file emailed to the Buyer prior to the Supplier Capability & Selection Review
Supplier MAPP eSign
Nexteer AQE, PE & Supplier begin the Design & Supplier Process Collaboration Activity
Buyer completes the Supplier Kickoff and APQP Contact List; Supplier completes the APQP Contact List
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NEXTEER: Buyer completes the APQP Project Contact List during the Design and Supplier Process Collaboration Activity
5. APQP Contact List
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SUPPLIER: Complete the APQP Project Contact List during the Design and Supplier Process Collaboration Activity.
5. APQP Contact List
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NEXTEER: Buyer, with PLPL support, fills out the QTC and Timing information during the Design & Supplier Process Collaboration Activity
6. Supplier Kickoff Information
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The AQE will document APQP Open issues within the MAPP Document
8. APQP Open Issues
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Commodity Technical Supplement questions are included in the MAPP and used at the AQE/SQE’s discretion
9. Supplemental Questions
Nexteer Sourcing Activity
Initial PFMEA & MAPP Review in preparation for Supplier Kickoff of production tooling
Upon completion of the MAPP review, the Supplier prints the “Sections 1, 2, 3, 6 & 7 – MAPP” excel tab and the Supplier’s Key Stakeholders date & sign the MAPP.
PDF scan of signed document is emailed to the Nexteer Buyer & AQE.
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SUPPLIER: Prior to Supplier Kickoff, the Supplier prints the “Sections 1, 2, 3, 6 & 7 – MAPP” excel tab and the Supplier’s Key Stakeholders date & sign the MAPP.
SUPPLIER: A signed PDF copy is emailed to the Buyer and AQE.
Supplier MAPP Signoff for Kickoff
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Nexteer Sourcing Activity
The Nexteer Buyer obtains Final Sourcing Approval and issues POs to kickoff the supplier to tool for production
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Supplier FAQs
Question: Why is Nexteer burdening my company with this additional work?
Answer: This may appear to be a burden but this is all work that is completed during the launch process. This appears to be a burden because we are shifting from a reactive organization to a proactive organization. This also prepares the supplier for their PFD & Control Plan.
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Supplier FAQs
Question: What if my company refuses to fill out the MAPP?
Answer: If your company wants our business, then you will need to comply with our request and use the MAPP. Keep in mind the intent of this document will help both of our organizations to flawlessly execute the program and minimize launch costs.
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Supplier FAQs
Question: What if my company won’t provide this information without a PO?
Answer: Our policy is that we do not issue suppliers with a Purchase Order until our Design Validation is complete.
Nexteer will communicate the planned Supplier Kickoff Date to the supplier.
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Supplier FAQs
Question: What if I am being pressured to provide a quote? Won’t this delay my RFQ response?
Answer: No. You can provide a quote without completing the MAPP.
The MAPP and SPI must be submitted to Nexteer prior to any tech reviews.
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Supplier FAQs
Question: What if I am asked to support a Tech Review as soon as possible?
Answer: Nexteer should give you adequate time to prepare the MAPP for the Supplier Capability and Selection Review (1st Tech Review). However, there may be special circumstances. If you have concerns, please contact your Buyer or AQE/SQE.
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Question: What about a print with hundreds of dimensions?
Answer: In cases where there are many dimensions, you may group a large quantity into one line item. Example: If there are 50 non-critical cast dimensions, give them all the same road map number and document control method. Please contact your AQE if you have any questions regarding the MAPP.
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Supplier FAQs