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    Chapter8

    Uploaded by

    suraj
    The document outlines Pak Suzuki Motor Co. Ltd.'s process for conducting Peak Production Verification Trials (PPVT). It details that PPVTs are conducted to identify any quality, productivity, or process issues before the start of mass production under peak conditions. The key steps are: (1) Conducting a 2-hour PPVT using the same conditions as mass production; (2) Determining if the results are satisfactory - if not, taking countermeasures and retesting; (3) Conducting an additional 4-hour trial to ensure consistency. The vendor must then submit a PPVT report including any countermeasures.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Chapter8

    Uploaded by

    suraj
    171 views6 pages
    The document outlines Pak Suzuki Motor Co. Ltd.'s process for conducting Peak Production Verification Trials (PPVT). It details that PPVTs are conducted to identify any quality, productivity, or process issues before the start of mass production under peak conditions. The key steps are: (1) Conducting a 2-hour PPVT using the same conditions as mass production; (2) Determining if the results are satisfactory - if not, taking countermeasures and retesting; (3) Conducting an additional 4-hour trial to ensure consistency. The vendor must then submit a PPVT report including any countermeasures.

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    peak production

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    000000168 - Chapter8

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    The document outlines Pak Suzuki Motor Co. Ltd.'s process for conducting Peak Production Verification Trials (PPVT). It details that PPVTs are conducted to identify any quality, productivity, or process issues before the start of mass production under peak conditions. The key steps are: (1) Conducting a 2-hour PPVT using the same conditions as mass production; (2) Determining if the results are satisfactory - if not, taking countermeasures and retesting; (3) Conducting an additional 4-hour trial to ensure consistency. The vendor must then submit a PPVT report including any countermeasures.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    171 views6 pages

    Chapter8

    Uploaded by

    suraj
    The document outlines Pak Suzuki Motor Co. Ltd.'s process for conducting Peak Production Verification Trials (PPVT). It details that PPVTs are conducted to identify any quality, productivity, or process issues before the start of mass production under peak conditions. The key steps are: (1) Conducting a 2-hour PPVT using the same conditions as mass production; (2) Determining if the results are satisfactory - if not, taking countermeasures and retesting; (3) Conducting an additional 4-hour trial to ensure consistency. The vendor must then submit a PPVT report including any countermeasures.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 6

    PAK SUZUKI MOTOR CO. LTD.

    CHAPTER 08
    PEAK PRODUCTION
    VERIFICATION TRIAL

    PEAK PRODUCTION VERIFICATION TRIAL

    Conduct Peak Production Verification Trial


    (generally for 2 hours) or 100 Pieces using the
    same process conditions (tools/ dies/ equipment/
    machines/ process flow/ raw materials/ standards/
    gauges/ manpower etc.) with which regular mass
    production shall be carried out

    Take Countermeasures NG Is it
    & carry out PPVT again satisfactory
    ?

    OK

    Conduct additional trial for 4 Hours to ensure consistency

    Submit PPVT Trial report with countermeasures (if any)

    Doc. # QAD-MAN-01 Rev: 00, Feb - 2011


    SUPPLIER QUALITY ASSURANCE MANUAL 52
    PEAK PRODUCTION
    VERIFICATION TRIAL PAK SUZUKI MOTOR CO. LTD.

    8. PEAK PRODUCTION VERIFICATION TRIAL


    8.1 SCOPE
    The purpose of “Peak Production Verification Trial” or PPVT is to capture any Quality,
    Productivity or Process related problem, before start of mass production under stimulated
    peak production conditions so that these problems can be identified and countermeasures
    taken well in advance.

    8.2 CONDITIONS FOR PPVT


    8.2.1 PPVT shall have to be carried out at the vendor's premises as per the timing decided in
    Specification meeting.

    8.2.2 In principle, PPVT shall be carried out after approval of mass production samples by SCM.
    SCM Members can choose to participate & observe PPVT at vendor's premises at their
    discretion in presence of PLD and PID Concerned Engineer.

    8.2.3 This trial shall be an exact replica of Mass Production Conditions i.e. the conditions in which
    this trial is done, must be same under which the Mass Production of parts will be carried out.
    Few examples of these conditions (which need to be same as those during Mass Production)
    are as follow :
    · All the Tooling/equipments and Facilities used.
    · Man Power or Operators (It should cover operators for all the shifts).
    · Process Flow & Sequence/Production Method.
    · Operation Standards & Quality & Productivity Targets.
    · Product Quality Assurance System.
    · Raw Material.
    · Gauges used etc.

    8.2.4 Process Capability study should be carried out during Peak Production Verification Trial for
    important parameters as decided in Specification meeting or listed in Process control
    standards(if required by PSMCL).

    8.3 PPVT RATE CALCULATION


    The rate at which the parts are to be produced i.e. parts/hour, shall also be calculated by
    SCM(PSMCL). This rate indicates the maximum no. of parts that can be produced under
    Doc. # QAD-MAN-01 Rev: 00, Feb - 2011
    SUPPLIER QUALITY ASSURANCE MANUAL 53
    PEAK PRODUCTION
    VERIFICATION TRIAL

    given condition by the vendor in a shift. This production rate must match the PSMCL
    maximum production requirement.
    In principle, the rate of production for PPVT shall be calculated as follows- PSMCL peak daily
    requirement.

    · PPVT Rate = PSMCL peak daily requirement


    Net operating time available per day for the part (in hours)

    Net Operating Time = Total production time available for the part in a day - {Time for
    breaks (lunch, tea, rest etc) + Time for planned maintenance activities + Time for
    Quality Checks}

    8.3.1 PSMCL shall decide that for how many hours (in principle for 2 hours); this run has to be
    carried out. If the rate is not achievable or at the PPVT rate it is not possible to match PSMCL
    requirement for Quality specifications as set in drawings/PSIS/Process control standards
    etc., then the vendor along with PSMCL shall review the conditions and shall take necessary
    countermeasures. After taking the countermeasures, parts have to be produced again and
    PPVT rate has to be revalidated.

    8.3.2 Once the desired rate has been achieved, an additional trial should be conducted.

    8.3.3 The additional trial should be conducted for at least 4 hours, to ensure the consistency of the
    process conditions and effectiveness of countermeasures and prevention controls.

    8.3.4 The vendor shall submit the PPVT reports to SCM, PID and PLD along with the
    countermeasures taken and the process capability study results.

    Doc. # QAD-MAN-01 Rev: 00, Feb - 2011


    SUPPLIER QUALITY ASSURANCE MANUAL 54
    PEAK PRODUCTION
    VERIFICATION TRIAL PAK SUZUKI MOTOR CO. LTD.

    available

    PSMCL’s peak production requirement per day (will be informed by PSMCL)

    Is the Production rate matching or exceeding with PSMCL’s PPVT Rate (Z)?

    Doc. # QAD-MAN-01 Rev: 00, Feb - 2011


    SUPPLIER QUALITY ASSURANCE MANUAL 55
    PEAK PRODUCTION
    VERIFICATION TRIAL

    Cp*

    CpK*

    * If Cp & Cpk is not found as per PSMCL’s requirement, then please enclose the contingency plan.

    Doc. # QAD-MAN-01 Rev: 00, Feb - 2011


    SUPPLIER QUALITY ASSURANCE MANUAL 56

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