GSQT-004 Husqvarna Full run test report template revision 0 Issued: Johan Rosenlund 2012-04-19

Approved Fredrik Währborg 2012-04-19

Full run test report template

Supplier name Part number Drawing number Customer representative Date

Part description Drawing revision level Supplier representative Update

Process 1 Process 2 Process 4 Process 5 Process 6 Process 7 Process 8 Process 8 Process 9 Process 10

process name process name process name process name process name process name process name process name process name process name

Shift duration hours

Working time calculations

Breaks & allowances minutes / shift

Shift pattern shifts / day
Non working days per year non-working days / year
Other product commitments working days / year
Number of machines number

Working time working days / year 0 0 0 0 0 0 0 0 0 0

Working time minutes / year 0 0 0 0 0 0 0 0 0 0

Capacity parts / year

Cycle time seconds / part
Targets

Right first time %

Scrap parts %
OEE, target %

Theoretical Capacity parts / year #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

Trial duration minutes

results input
Full run test

Parts made (total) parts

Rejects parts
Scrap parts parts
Downtime (incl breaks) minutes

Cycle time seconds / part #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

Right first time % #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!
Full run test results

Scrap % #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

OEE % #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

Full run test capacity at targeted OEE parts / year #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

CONCLUSION #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

Comments:

Are Full run test results acceptable to customer? Yes Supplier representative signature

No - Corrective actions required and new Full run test required Customer representative signature
 GSQT-004 Husqvarna Full run test report template revision 0 Issued: Johan Rosenlund 2012-04-19
Approved: Fredrik Währborg 2012-04-19

Full run test report template, instructions

White fields to be filled in

Example 1 Example 2
Shift duration hours How long is each shift? (normally 8 or 12 hours) 8 12
Breaks & allowances mins / shift How many minutes are allowed for breaks, start of shift, cleaning, handover, etc ? 50 70
Working time calculations

Shift pattern shifts / day How many shifts per day ( normally 1,2 or 3) are used? 3 2
Number of planned non-working days, when the plant is closed. Includes weekends, summer / Christmas holidays, National
Non working days per year non-working days / year holidays etc. 116 12
Other product commitments working days / year Number of days per year that the line will run other product. 0 0
Number of machines number Number of machines used for this process 1 2

Working time working days / year 249 706

Working time minutes / year Calculated automatically 321210 917800

Capacity parts / year What is the target for annual capacity? 500,000 1,200,000
What is the calculated cycle time for the equipment? If more than one cavity, then cycle time need to be divided by number of
Targets

Cycle time seconds / part cavities. 32 19

Right first time % What is the minimum for right first time product? ( no rejects, rework or scrap) 97.0% 97.0%
Scrap parts % What is the maximum allowable scrap rate? (not reworkable) 1.0% 1.0%
OEE, target % What is the minimum acceptable Overall Equipment Efficiency 80.0% 80.0%

Theoretical Capacity parts / year Field calculated automatically. Purple is OK, Red is Not OK 481,815 2,318,653

Trial duration minutes The total duration of the trial from start to finish 480 720
results input
Full run test

Parts made (total) parts Total number of parts made (including any rejects, rework and scrap) 1023 1000
Rejects parts Total number of all rejects (including rework & scrap) 21 88
Scrap parts parts Total number of scrap parts made (ie non-reworkable rejects) 7 26
Downtime (incl breaks) minutes Total number of minutes when the process was not working 34 56

Cycle time seconds / part 26.2 39.8

These fields are calculated automatically
Full run test results

Right first time % They will turn Purple if the result is acceptable compared to the target 97.9% 91.2%
They will turn Red if the result is unacceptable compared to target
Scrap % 0.7% 2.6%

OEE % Field calculated automatically. Purple is OK, Red is Not OK 111.3% 40.1%

Full run test capacity at targeted

OEE parts / year Field calculated automatically. Purple is OK, Red is Not OK 585,380 1,077,033

CONCLUSION Field calculated automatically. Green is OK, Red is Not OK OK NOT OK

OEE Definition (using Availability, Performance and Quality):

OEE, Overall Equipment Effectiveness

OEE % = Availability X Performance X Quality %

OEE Example : Availability, Performance and Quality

Assume Machine A is a single product machine and is

theoretically capable of producing 1,500 units every hour.

In a 16 hour scheduled production day (e.g. 2 x 8 hour shifts)

Machine A could theoretically produce 24,000 good units.

On a particular day the equipment/process recorded downtime of 1,5 hours

(e.g. equipement breakdown, waiting on materials etc..)

Scheduled Production Time = 16 Hrs (2 x 8Hr Shift)

Downtime (Planned & Unplanned)= 1,5 Hrs
Available Time (Uptime) = 16 Hrs – 1,5 Hrs = 14,5 Hrs

Available Time / Scheduled Time = 14,5Hrs/16Hrs = 91% Availability

In this example we will record throughput on the equipment/process

as 19,228 units (cycles) for the 14,5 hrs of Available Time. Also remember
that the Machine can produce 1,500 units an hour

Available Time = 14,5 Hrs

Total Product Produced (Throughput) in Available Time = 19,228 units
Theoretical time to produce 19,228 units = 19,228 /1,500 = 12.82 Hrs

Theoretical Time / Available Time = 12.82Hrs / 14,5Hrs = 88% Performance

Out of the 19,228 units (cycles), it was found that only 18,652 of the
units were deemed good units (i.e. shippable units). The other 576 are
accounted as scrapped and/or rework cycles to make shippable.

Performance Time = 12.82 Hrs

Good Units (expressed in time) = 18,652 units / 1,500 per Hour = 12,43 Hrs

Good Units / Performance Time = 12.43Hrs / 12,82 Hrs = 97% Quality

Availability x Performance x Quality = 91% x 88% x 97% = 78% OEE

Therefore there are losses totalling 22% for the day

OEE is about looking at the root causes compiling the 22%,

and taking corrective action to reduce the losses and increase the OEE %