Ford Capacity Analysis Report User Guide

Ford Motor Company
Capacity Planning Analysis (CPA) User Guide

Capacity Planning Analysis (CPA)

User Guide
Ford Motor Company
Supplier Technical Assistance (STA)
January 2010

2010.01 CPA Release 4 User Guide

1

Ford Motor Company
Capacity Planning Analysis (CPA) User Guide

TABLE OF CONTENTS
Topic
Introduction
• GPDS Deliverables #17, #19, and #44
• The CPA Toolset
•GPDS Supplier Engagement Process Timeline
• CPA Toolset Architecture
Section A of CPA Toolset (For Deliverable #17, #19, and #44)
• GPDS Volume Communication
• Shared – Loading Plan / Total Allocation Description
Section B of CPA Toolset (For Deliverable #17 ONLY)
• Including Surrogate OEE Summary Description
Section B of CPA Toolset (For Deliverable #19 ONLY)
Section B of CPA Toolset (ForDeliverable #44 ONLY)
Section C of CPA Toolset
• Including Demonstrated OEE vs. Required OEE Analysis
• Resolving Potential Capacity Risks
Reference
• OEE Calculation Worksheet
Process Flow Charts
• Capacity Planning – GPDS Deliverable #17
• Phase 0 PPAP (Run @ Rate) – GPDS Deliverable #19
• Phase 3 PPAP (Capacity Verification) – GPDS Deliverable #44

Page
3

7

13
15
17
19

2122
23
24

2010.01 CPA Release 4 User Guide

2

Ford Motor Company
Capacity Planning Analysis (CPA) User Guide

INTRODUCTION
GPDS Deliverables, the CPA Toolset, and CPA Toolset Architecture
This manual is intended to assist in navigating the Ford Motor Company Capacity Planning Analysis (CPA)
Toolset for New Model Launch Capacity. Ford’s Global Product Development System (GPDS)requires
the supply base to demonstrate their ability to contain Ford volume requirements as three deliverables
of the GPDS process. Utilizing Overall Equipment Effectiveness (OEE), suppliers must show that they
have plans in place to contain volume requirements, considering all potential losses.
Ford utilizes OEE as the measure of capacity as it incorporates three key manufacturing performanceelements. Equipment availability, performance efficiency, and quality rate must be evaluated to
understand a supplier’s ability to deliver volumes on a consistent basis.
GPDS begins capacity engagement significantly earlier in the product development cycle; up to 24months before Job 1. The intention is that, by beginning to look at capacity early on, potential risks can
be identified andaddressed with significant minimization to launch risk and cost. At Site Visit #1 in
GPDS, a supplier’s plan for containing production volumes must be validated. Site Visits #3 and #4
further validate that the supplier's plan is capable of meeting volume requirements, coinciding with
Phase 0 and Phase 3 PPAP.

GPDS Supplier Engagement – Process Overview

Supplier Sourcing
Begins

CapacityPlanning
Deliverable #17

→ → CAPACITY IMPROVEMENTS → →

Phase 0
PPAP Deliverable
#19

Phase 3
PPAP Deliverable
#44

Priority Suppliers
Selected

Resolve Open Issues
Cross-Functional
Teams Formed

Team Kick-Off
Meetings Begin

On-Site
Evaluation #1

On-Site
Evaluation #2

Decision to
Proceed to
Run-At-Rate

On-Site
Evaluation #3

On-Site
Evaluation #4Supplier APQP/PPAP Readiness
Assessment (Schedule A)

2010.01 CPA Release 4 User Guide

3

Ford Motor Company
Capacity Planning Analysis (CPA) User Guide

The CPA Toolset can be used to satisfy the following GPDS Deliverables:
Schedule A
Deliverable

Supplier
Engagement
Visit

Phase

#17

#1

Planning

#19

#3

PPAP Phase 0

#44

#4

PPAP Phase 3

GPDS TextCapacity Planning:
Verify Supplier’s Demonstrated OEE (Surrogate) ≥ Required OEE

PPAP Phase 0:
Verify Supplier’s Demonstrated OEE (Run @ Rate) ≥ Required OEE

PPAP Phase 3:
Verify Supplier’s Demonstrated OEE (Capacity Verification) ≥ Required OEE

Satisfying the above deliverables is accomplished through the use of the CPA Toolset in the same
method, regardless of which deliverable is being...