Run at Rate (R@R)

Polaris Supply Chain – Supplier Training

Revised: June 6, 2016

Polaris CONFIDENTIAL
Revision Number: 1
Welcome

Welcome to the Run@Rate Training Module

Add the slide take-away here!

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Agenda

Learning Objectives
Why the Training Topic is Important? When?
Define Training Topic – What is It?
Training Content
Tools and References
Demo / Example
Learning Objectives Recap
Thank you!

Name of Training Topic: Run@Rate Training Module

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Learning Objectives
At the end of this training, participants will be able to:

• Understand importance of the R@R

• Know when to schedule a R@R

• Know how to perform a R@R

Effective R@R Audit

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Why is a R@R Important?
A R@R audit is used to:
Validate the readiness of your manufacturing process.
Comprehensive process review: receipt to shipment.
Demonstrates capability over multiple shifts and production set ups.
Evaluate the process controls with regards to production readiness.

Evaluate capability.
True capacity.
Equipment effectiveness.
Quality systems management.

Expose process variation prior to SOP.

Drive production like requirements

Evaluate sub-tier supplier management.

Review formal selection process.
Review PPAP completion of sub-tier suppliers.

Uncover and address quality risks before SOP.

R@R Audits Determine State Of Production Readiness

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Process Overview

Supplier Pre-R@R Close our Follow up

R@R R@R Perform on
selected for meeting(s) action R@R if
schedule requirements site R@R
R@R held register items needed

Process Usage: Run@Rate The Quality Lifecycle Management process is a

process to ensure product quality assurance.

P
Supplier P Supplier Performance
PDP A
Qualification Monitoring Control Improvement
P

Supplier SOP Serial

Selection …..APQP……
PPAP Volume Ramp…. Maturity ……… …….
Production
……. …… EOL

Supplier On- Product Quality Event

APQP Safe Launch
Boarding Assurance Resolution

R@R Audits Are Key Part Of PDP And APQP

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R@R Selection
Supplier Pre-R@R Close out Follow up
R@R R@R Perform on
selected for meeting(s) action R@R if
schedule requirements site R@R
R@R held register items needed

All suppliers selected for APQP will require R@R audit.

Detail of APQP selection process can be found in this link.

SQE can conduct R@R audit as risk mitigation on any supplier.

Examples:
Validation of process change: sub-tier change, new equipment, etc.
In response to a design change.
Verify process due to seasonal manufacturing schedule.

Suppliers Selected From APQP Process or as Risk Mitigation

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R@R Timing
Supplier Pre-R@R Close our Follow up
R@R R@R Perform on
selected for meeting(s) action R@R if
schedule requirements site R@R
R@R held register items needed

The R@R should be scheduled with PV parts production.

Higher risk parts/suppliers should have pre-audit visits.
Recommended at PI so that suggestions can be given before tooling has been completed.

Schedule R@R Based on Project Timeline

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R@R Requirements
Supplier Pre-R@R Close ou Follow up
R@R R@R Perform on
selected for meeting(s) action R@R if
schedule requirements site R@R
R@R held register items needed

Audit to be performed at production of PV parts.

Timing driven by PV timing.
High risk parts/suppliers will require earlier audit.
Quantities driven by PV volume.
If PV volume too low then use pulse process.
Significant production run(s) should be performed before R@R as well.

Production should be off tool, off process.

Any changes to process after R@R will require PCR.

Should be at planned production volume.

Frozen design must be achieved.

Use PV or Pulse to Drive Requirements

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R@R Preparation
Supplier Close out Follow up
R@R R@R R@R Perform on
selected for action R@R if
schedule requirements preparation site R@R
R@R register items needed

Your preparedness is critical for success.

Steps to ensure you are prepared:
Participate in the pre-audit meetings to set expectations.
• Go through the audit form with the SQE.
• Perform the self assessment and send results back to SQE prior to formal audit.
• Complete capacity tab and send back to SQE before the audit.
Audit is from receipt – shipment. Prepare all processes!

Poor planning will result in a poor

Conduct a significant production run before audit.
Review the agenda before audit.

audit!
Off tool, off process.
Also means operators run the process not engineers.
Make sure the right representatives are present!
• Senior Management (kickoff and wrap up).
• Quality.
• Engineering.
• Manufacturing.

If your schedule changes let SQE know before arriving at audit.

This is meant to help your process be successful.

Preparation is Key to Successful R@R

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Performing the R@R
Supplier Pre-R@R Close out Follow up
R@R R@R Perform on
selected for meeting(s) action R@R if
schedule requirement site R@R
R@R held register items needed

It’s time for the R@R! How are we successful?

Review the agenda.
Have copies of print, control plan, and process flow available.
Make sure production operators are running the processes.
The SQE will Review the entire process
• Receiving – Shipment
• Poke yokes
• Labeling/barcoding
• Doc control
• Rework procedure
Review multiple shifts.
If not enough time to see entire process make sure critical processes are running for audit.
Stage any other processes for general review.
Have a closing meeting.
Work with SQE to complete action register.

Production Readiness & Risk Should be Fully Understood

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Action Register
Supplier Pre-R@R Close out Follow up
R@R R@R Perform on
selected for meeting(s) action R@R if
schedule requirement site R@R
R@R held register items needed

Use the action register tab to:

List any non-conformance items.
Assign responsible person for each item.
Assign due date for each item.
Drive process improvements for production.

Be prepared for all follow up meetings with updates.

As with the audit itself make sure the correct people participate in each meeting.
Complete all tasks on the action register!

Action Register Drives Required Improvement

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Follow Up
Supplier Pre-R@R Close out Follow up
R@R R@R Perform on
selected for meeting(s) action R@R if
schedule requirement site R@R
R@R held register items needed

A follow up R@R will be required if:

The process was not ready when the SQE was present for the first R@R.
• Fixtures
• Machines
Late design change requires process changes.
The process was not able to complete enough parts for a full production run.
• Not enough raw material
• Equipment failure
High risk suppliers/parts as part of safe launch.
Validate any PCRs after R@R.

Preparation Prevents Repeat Audits & Follow-up

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Tools / Other References
R@R form can be accessed via the SQAM.

Standard Work; Use of Form is Required

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Example – Audit Tab

Snap Shot Of Blank To Completed Audit Tab

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Example – Audit Tab
First fill out the top section of the audit tab. Supplier
fills out top portion, SQE fills out bottom portion. All
orange sections must be completed.

Complete All Fields

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Example – Audit Tab
Now it is time to work through the audit process.
Each item is graded on a 0-3 scale. If the item is not
applicable then it can be marked “NA.” The grading
criteria is provided as a guideline for each line. Take
all time required to review each line.

Use Criteria as the Guideline to Score Audit

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Example – Audit Tab
The objective evidence is the section to insert the
detail justifying the rating given for each item. The
criteria gives the guideline for rating but the SQE is
still responsible for giving further detail when
necessary.

Tip: While objective evidence is important for all line items it is especially
important when the supplier and Polaris ratings are different and when giving a 0
or 3.

Utilize Objective Evidence to Justify

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Example – Action Register
There will be some improvement
items with each audit. The AR tab
is the place to capture the CA plan.

Use The AR Tab To Capture Improvement Plan

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Example – Scoring Summary
Once the scoring has been completed
on the audit tab use this summary to
show where most improvement is
needed.

Quick Assessment to Prioritize Improvement Area(s)

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Example – Pre-Run@Rate AR
Prior to each audit the pre-run@rate AR must be completed. This is your checklist
to ensure the supplier is prepared for the audit.

Ensure Your Supplier Is Prepared!

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Example – Capacity
Line capacity is also a crucial part of the success for a supplier’s process. Before
arriving for the run@rate the supplier should have the capacity tab filled out. Make
sure to pay attention to the bottle neck(s) in the process. These should be attacked
for future improvements.

Important to Verify Actual Capacity

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Example – Summary
The summary page is important for giving quick feedback in meetings where the full
detail is not needed. This should give a snapshot of the audit results.

Complete Summary for Concise Reporting

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Learning Objectives Recap
You should understand:
Understand importance of the R@R

Know when to schedule a R@R

Know how to perform a R@R

What you learned from this training

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Thank you!
Thank you for taking the time to complete the Polaris R@R Training Module.

• Please make sure to take the Quiz and provide training feedback.
• Taking the Quiz gives visibility to us that you have read and understand this
training!

Questions? Please contact your Supplier Quality Engineer or Buyer.

Thank you for attending!

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