Download pdf - Manufacturability Assessment & Process Plan

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Supplier MAPP Overview Training

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Training Goals

� Communicate Nexteer’s new approach to launch

� Understand what Nexteer is doing differently to improve launch performance

� Understand Nexteer’s new Manufacturability

Assessment & Process Plan (MAPP) process

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GSM Launch Objectives

� Proactive Risk Assessment throughout Launch Process− Cross Functional BOM Risk Assessment (Nexteer)

− Internal Print Reviews (Nexteer)

− Internal Key Stakeholder Meeting (Nexteer)

− Manufacturability Assessment & Process Plan (Nexteer-Supplier)

− 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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Nexteer GSM Launch Goals

� Foster a Nexteer-Supplier Collaborative Culture

− Goal: Name a Target Supplier 6 weeks after issuing RFQ

− Engage the supplier earlier to allow for supplier input into thedesign

� Improve Launch Performance

− PPAP On-time

− Run at Rate On-time

− Delivery On-time

− Zero problem cases during launch

− Achieve cost targets

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What is Nexteer Doing Differently?

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

Source Supplier

Implement Mfg System

Validate Mfg System

Supplier Quotes

Team Feasibility

Final

Negotiations

Sourcing

Approval

PPAP Approval

Run at Rate

Approval

APQP Review

Engineering Development

Technical

Reviews

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What is Nexteer Doing Differently?

� The Collaborative Sourcing Process & Concurrent Engineering Philosophy brings the Target Supplier into the

development phase to obtain supplier input into the design

Develop Business

Case

Develop Business

Case

Develop Sourcing

Strategy

Indentify Target

Supplier

CollaborateSource SupplierSource Supplier

Implement Mfg

System

Implement Mfg

System

Validate Mfg

System

Validate Mfg

System

Strategic

PartnershipsSupplier Quotes

Team Feasibility

Characteristic

Summary

Process Flow

Diagram

Technical

Review

PE-AQE Target

Supplier Input

Final

Negotiations

Sourcing

Approval

PPAP Approval

Run at Rate

Approval

Line Side

Reviews

Category

Strategies

Internal Tech

Review

PE&AQE Bid

List Approval

Pre-Bid

Approval

Technical

Reviews

Agreed Upon

Design/Process

FMEAReviews

Initial PFMEA

Initial

Gaging Plan

Pre-PPAP

PFMEA

Pre-PPAP

Control Plan

Pre-PPAP

Process Flow

APQP Review

Supplier MCA

Risk

Assessment

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What We are Doing Differently?

Question: What is Nexteer Going to do Differently?

Answer: Identify & Mitigate Risk

� Rigorous Internal Risk Reviews

� Identify Target Supplier Early

� Implement the Manufacturability Assessment & Process Plan (MAPP)

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What is the “MAPP”?

MAPP = Manufacturability Assessment & Process Plan

� 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-

461b-47e2-9fb1-93167e2a67f8&groupId=107759

Microsoft Excel

Worksheet

Click on excel

icon for an

example MAPP

Template

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Why do we need the MAPP?

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.

� If we don’t win new business,

our suppliers won’t win new

business

� Encourages a collaborative relationship between the supplier and the Nexteer

Buyer, Supplier Quality and PECollaboration 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 & Supplier Selection

Mechanism to Identify the Target Supplier

� 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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MAPP Process Timeline

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1. Supplier eSigns MAPP with MAPP Submission

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.

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Nexteer Sourcing Activity

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MAPP Contents

1. Team Feasibility **

2. Supplier Assessment **3. Manufacturability Assessment ▼

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

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� 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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MAPP Instructions

� Instructions with document links are included in the MAPP Template

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MAPP Directions & Information

� Detailed comments are

included in the

MAPP Template for additional

information and support for the

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

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� 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 shouldbe 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

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� 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

See comments in the column headers for further instruction

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Example

� Example provided for

the supplier

within the MAPP

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

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� Internal Nexteer Signoff & Approval

� Nexteer Buyer names Target Supplier

� 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


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� SUPPLIER: Complete the APQP Project Contact List during the Design and Supplier Process Collaboration Activity.


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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

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� 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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� The Nexteer Buyer obtains Final Sourcing Approval and issues POs to kickoff the supplier to tool for production

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Supplier Frequently Asked

Questions

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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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Supplier FAQs

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

Question: Does my company have to have Covisint access to obtain a copy of the MAPP?

Answer: No. The MAPP is stored on the Supplier Portal and anyone can access this via the web. The link to Supplier Portal is included in the RFQ template. Please remember that Covisint Registration is required for all Nexteer Suppliers.