CAPACITY VERIFICATION FORM
PART NAME(S) Pulley SUPPLIER Central Yoshida Japan
MANUFACTURING LOC Aichi, Japan
PART NUMBER(S) TN021042-7400 SUPPLIER CODE
EQUIPMENT Slugformer
CHANGE LEVEL(S) VERIFICATION DATE
PROGRAM AUDITOR(S)
Calculation Witnessed information Input information
Data input from production P.O.:
A) QUOTED DAILY PARTS FOR DENSO
Common Process Group (CPG)? Yes or No - Other DENSO parts on this process with the same production rates?
Shared Line? Yes or No - Is this line used for other Customers or DENSO products at a different production rate?
A1) P.O. Daily Quantity Part Number TN021042-7400 1,000 Pieces/day
A2) P.O. Daily Quantity Part Number TN021042-7410 1,000 Pieces/day
A3) P.O. Daily Quantity Part Number TN021042-7420 1,000 Pieces/day
A4) P.O. Daily Quantity Part Number TN021042-7430 1,000 Pieces/day
A5) P.O. Daily Quantity Part Number Pieces/day
Total (A1 + A5) 4,000 Pieces/day
B) P.O. Shift Pattern
B1) Number of shifts per day 2 shifts
B2) Production hours per shift 12 hours
B3) Number of production days per week 6 days
Data input from manufacturing process (Requires Supplier Input):
C) Downtime per shift
C1) Lunches 1.00 hours/shift
C2) Breaks None - slugformer is run through staggered breaks 0.00 hours/shift
C3) Changeover and/or set-up 4 hours per day 2.00 hours/shift
C4) Operating time dedicated to other customers 4.34 hours/shift
Comments: 700,000/ month @ 70 SPM
C5) Scheduled/unscheduled downtime (as applicable) 0.17 hours/shift
Comments: Weekly Kaizen Circle - 1 hour/shift/week
D) Parts attempted during the Capacity Verification Run (CVR) 1932 attempted parts
E) First time through fallout during the CVR 185 failed parts
F) Length of CVR in hours Start: 11:35 Finish: 12:30 0.92 hours
G) Acceptable parts witnessed at the CVR 1740 pieces
In process calculations:
H) Available production hours/shift [B2-(C1+C2+C3+C4+C5)] 4.49 hours/shift
I) Available production hours/day [B1*H] 8.98 hours/day
J) Required parts per hour at the CVR [A/I] 445.5 parts/hour
K) Witnessed parts per hour at the CVR [G/F] 1891.3 parts/hour
Requirements:
L) FTC calculation [((D-E)/D)*100] Minimum requirement of 90% 90.42 %
M) Difference between witnessed parts/hour and required parts/hour [K-J] 1445.8 pieces
Must be 0 or greater for approval 44.55
CAPACITY VERIFICATION FORM
PART NAME(S) SUPPLIER
MANUFACTURING LOC
PART NUMBER(S) SUPPLIER CODE
EQUIPMENT
CHANGE LEVEL(S) VERIFICATION DATE
PROGRAM AUDITOR(S)
Calculation Witnessed information Input information
Data input from production P.O.:
A) QUOTED DAILY PARTS FOR DENSO
Common Process Group (CPG)? Yes or No - Other DENSO parts on this process with the same production rates?
Shared Line? Yes or No - Is this line used for other Customers or DENSO products at a different production rate?
A1) P.O. Daily Quantity Part Number Pieces/day
A2) P.O. Daily Quantity Part Number Pieces/day
A3) P.O. Daily Quantity Part Number Pieces/day
A4) P.O. Daily Quantity Part Number Pieces/day
A5) P.O. Daily Quantity Part Number Pieces/day
Total (A1 + A5) 0 Pieces/day
B) P.O. Shift Pattern
B1) Number of shifts per day shifts
B2) Production hours per shift hours
B3) Number of production days per week days
Data input from manufacturing process (Requires Supplier Input):
C) Downtime per shift
C1) Lunches hours/shift
C2) Breaks 0.00 hours/shift
C3) Changeover and/or set-up hours/shift
C4) Operating time dedicated to other customers hours/shift
Comments:
C5) Scheduled/unscheduled downtime (as applicable) hours/shift
Comments:
D) Parts attempted during the Capacity Verification Run (CVR) attempted parts
E) First time through fallout during the CVR failed parts
F) Length of CVR in hours Start: Finish: hours
G) Acceptable parts witnessed at the CVR pieces
In process calculations:
H) Available production hours/shift [B2-(C1+C2+C3+C4+C5)] 0.00 hours/shift
I) Available production hours/day [B1*H] 0.00 hours/day
J) Required parts per hour at the CVR [A/I] #DIV/0! parts/hour
K) Witnessed parts per hour at the CVR [G/F] #DIV/0! parts/hour
Requirements:
L) FTC calculation [((D-E)/D)*100] Minimum requirement of 90% #DIV/0! %
M) Difference between witnessed parts/hour and required parts/hour [K-J] #DIV/0! pieces
Must be 0 or greater for approval #DIV/0!
700,000
÷ 24
= 29,166
70
X 60
÷ = 4200
X 0.8
= 3,360
8.68
÷ 2
= 4.34
35
X 60
= 2100
X 0.92
= 1932
pcs/month
days/month
pcs/day
spm (strokes per minute)
minutes per hour
pcs/hour
80% efficiency
pcs/hour
hours/day
shifts/day
hours/shift
spm (strokes per minute)
minutes per hour
pcs/hour
hours (length of trial)
Attempted parts in trial
CAPACITY VERIFICATION FORM
EXAMPLE
SUPPLIER
MFG LOCATION
SUPPLIER CODE
EQUIPMENT/PROCESS
PROGRAM
AUDITOR(S)
VERIFICATION DATE
Instructions:
- Please complete the form below by completing all of the Yellow, "Supplier Input Items", cells.
- Ideally your APW calculations would be for a standard 5 day week. For MPW, this could be a 6 day week, or remain a standard 5 day week, but with added shift(s), or
increased shift lengths.
Planned Condition Definitions
Time Spent on Non-DENSO Parts
2 APW: Average Parts per Week
[Hrs / Week]
MPW: Maximum Parts per Week
APW Conditions MPW Conditions IPR: In Process Rejects
Running Days / Week 5 Running Days / Week 6 CT: Cycle Time
Running Shifts / Day 2 Running Shifts / Day 2 CT = Hand Time + Machine Time +
Scheduled Time [Hrs / Shift] 8 Scheduled Time [Hrs / Shift] 8 Movement Time
Breaks / Lunch [Min / Shift] 60 Breaks / Lunch [Min / Shift] 60 Chokotei: Any unplanned idling or
Start Up / Meetings [Min / Shift] 0 Start Up / Meetings [Min / Shift] 0 minor stop(s) <1min
Part Changeover [Min / Shift] 15 Part Changeover [Min / Shift] 15
Avg. Misc. Downtime [Min / Shift] 5 Avg. Misc. Downtime [Min / Shift] 10 Supplier Input Items
Chokotei / Shortstop [Qty / Shift] 5 Chokotei / Shortstop [Qty / Shift] 12 DENSO Provided Information
IPR / Defects [Qty / Shift] 20 IPR / Defects [Qty / Shift] 25 Auto Calculated Values
DENSO Provided Information Auto Calculated
APW MPW
APW MPW CT
Part DENSO Part Number DENSO Part Name [#] [#] [Sec / Part] Theoretical Good Theoretical Good
% Allocation % Allocation
Parts / Week Parts / Week
1 TN123 Pulley 9565 11080 18 12637.4 75.69% 14838.1 74.67%
2 TN456 Shaft 1855 2558 25 9098.9 20.39% 10683.4 23.94%
3
4
5
APW - Weighted Average Cycle Time 19.14 Target OEE 96.08% Target OEE 98.62%
MPW - Weighted Average Cycle Time 19.31
CAPACITY VERIFICATION FORM
EXAMPLE
Input Items
Auto Calculation
Part Number(s) Observed
Observed Conditions TN123 TN456 TN789 TOTAL
Total VerificationTime [Min]
(Total amt. of observed time / PN, incl. items below) 52 87 45 184
Breaks / Lunch [Min]
(Observed time for all breaks / PN) 9 0 0 9
Start Up / Meetings [Min]
(Observed time of start up & misc. meetings / PN) 5 0 0 5
Changeover / Setup [Min]
(Time for changover INTO observed part) 0 10 12 22
Misc. Downtime [Min]
(Unplanned Machine / Process stops > 1 min.) 3 0 5 8
Chokotei / Shortstop [Qty]
(# of unplanned Machine / Process stops < 1 min.) 2 1 2 5
IPR / Defects [Qty]
(# of In Process Rejects or defects witnessed) 2 5 10 17
Confirmed Total CT (Stopwatch) [Sec]
(Time from one finished good pack to the next) 22 20 20 23.4
Total GOOD Parts Produced [Qty] 90 250 95 435
Auto Calculated
DENSO Part Efficiency
Theoretical Load
Part Number Availability Performance Quality Demonstrated
[#]
Produced (Time) (Part) (Part) OEE
1 TN123 91 92.1% 99.2% 97.8% 89.4%
2 TN456 255 100.0% 98.2% 98.0% 96.3%
3 TN789 107 84.8% 88.8% 90.5% 68.2%
4
5
TOTAL 452 94.6% 96.2% 96.2% 87.6%
Demonstrated OEE should meet or exceed the "Target OEE" calculated on the < APW Target OEE
"Equipment Planning OEE" worksheet. >= APW Target OEE
APW MPW >= MPW Target OEE
Target OEE =
96.08% 98.62%
CAPACITY VERIFICATION FORM
SUPPLIER
MFG LOCATION
SUPPLIER CODE
EQUIPMENT/PROCESS
PROGRAM
AUDITOR(S)
VERIFICATION DATE
Instructions:
- Please complete the form below by completing all of the Yellow, "Supplier Input Items", cells.
- Ideally your APW calculations would be for a standard 5 day week. For MPW, this could be a 6 day week, or remain a standard 5 day week, but with added shift(s), or
increased shift lengths.
Planned Condition Definitions
Time Spent on Non-DENSO Parts
APW: Average Parts per Week
[Hrs / Week]
MPW: Maximum Parts per Week
APW Conditions MPW Conditions IPR: In Process Rejects
Running Days / Week Running Days / Week CT: Cycle Time
Running Shifts / Day Running Shifts / Day CT = Hand Time + Machine Time +
Scheduled Time [Hrs / Shift] Scheduled Time [Hrs / Shift] Movement Time
Breaks / Lunch [Min / Shift] Breaks / Lunch [Min / Shift] Chokotei: Any unplanned idling or
Start Up / Meetings [Min / Shift] Start Up / Meetings [Min / Shift] minor stop(s) <1min
Part Changeover [Min / Shift] Part Changeover [Min / Shift]
Avg. Misc. Downtime [Min / Shift] Avg. Misc. Downtime [Min / Shift] Supplier Input Items
Chokotei / Shortstop [Qty / Shift] Chokotei / Shortstop [Qty / Shift] DENSO Provided Information
IPR / Defects [Qty / Shift] IPR / Defects [Qty / Shift] Auto Calculated Values
DENSO Provided Information Auto Calculated
APW MPW
APW MPW CT
Part DENSO Part Number DENSO Part Name [#] [#] [Sec / Part] Theoretical Good Theoretical Good
% Allocation % Allocation
Parts / Week Parts / Week
1
2
3
4
5
APW - Weighted Average Cycle Time Target OEE Target OEE
MPW - Weighted Average Cycle Time
CAPACITY VERIFICATION FORM
Input Items
Auto Calculation
Part Number(s) Observed
Observed Conditions TOTAL
Total VerificationTime [Min]
(Total amt. of observed time / PN, incl. items below)
Breaks / Lunch [Min]
(Observed time for all breaks / PN)
Start Up / Meetings [Min]
(Observed time of start up & misc. meetings / PN)
Changeover / Setup [Min]
(Time for changover INTO observed part)
Misc. Downtime [Min]
(Unplanned Machine / Process stops > 1 min.)
Chokotei / Shortstop [Qty]
(# of unplanned Machine / Process stops < 1 min.)
IPR / Defects [Qty]
(# of In Process Rejects or defects witnessed)
Confirmed Total CT (Stopwatch) [Sec]
(Time from one finished good pack to the next)
Total GOOD Parts Produced [Qty]
Auto Calculated
DENSO Part Efficiency
Theoretical Load
Part Number Availability Performance Quality Demonstrated
[#]
Produced (Time) (Part) (Part) OEE
1
2
3
4
5
TOTAL
Demonstrated OEE should meet or exceed the "Target OEE" calculated on the < APW Target OEE
"Equipment Planning OEE" worksheet. >= APW Target OEE
APW MPW >= MPW Target OEE
Target OEE =
CAPACITY VERIFICATION FORM
SUPPLIER
MANUFACTURING LOC
SUPPLIER CODE
EQUIPMENT
PROGRAM
AUDITOR(S)
VERIFICATION DATE
Items Will Auto-Populate from Equipment Target OEE Tab
Planned Condition
Time Spent on Non-DENSO Parts 0
[Hrs / Week]
APW Conditions MPW Conditions
Running Days / Week 0 Running Days / Week 0
Running Shifts / Day 0 Running Shifts / Day 0
Sheduled Time [Hrs / Shift] 0 Sheduled Time [Hrs / Shift] 0
Breaks / Lunch [Min / Shift] 0 Breaks / Lunch [Min / Shift] 0
Start Up / Meetings [Min / Shift] 0 Start Up / Meetings [Min / Shift] 0
Part Changeover [Min / Shift] 0 Part Changeover [Min / Shift] 0
Avg. Misc. Downtime [Min / Shift] 0 Avg. Misc. Downtime [Min / Shift] 0
Chokotei / Shortstop [Qty / Shift] 0 Chokotei / Shortstop [Qty / Shift] 0
IPR / Defects [Qty / Shift] 0 IPR / Defects [Qty / Shift] 0
DENSO Provided Information Auto Calculated
APW MPW
Part DENSO Part Number DENSO Part Name APW MPW CT
[#] [#] [Sec / Part] Theoretical Good % Allocation Theoretical Good % Allocation
Parts / Week Parts / Week
1
2
3
4
5
APW - Weighted Average Cycle Time Target OEE Target OEE
MPW - Weighted Average Cycle Time
DENSO SPECIALIST VERIFICATION
Part Number(s) Observed
Observed Conditions TOTAL
Total VerificationTime [Min]
(Total amt. of observed time / PN, incl. items below)
Breaks / Lunch [Min]
(Observed time for all breaks / PN)
Start Up / Meetings [Min]
(Observed time of start up & misc. meetings / PN)
Changeover / Setup [Min]
(Time for changover INTO observed part)
Misc. Downtime [Min]
(Unplanned Machine / Process stops > 1 min.)
Chokotei / Shortstop [Qty]
(# of unplanned Machine / Process stops < 1 min.)
IPR / Defects [Qty]
(# of In Process Rejects or defects witnessed)
Confirmed Total CT (Stopwatch) [Sec]
(Time from one finished good pack to the next)
Total GOOD Parts Produced [Qty]
