The Supplier Master Schedule & Details is a document that:
Demonstrates how the timing for key design, development and production preparation milestones will support the achievement of QCD targets
Monitors overall project timing during supplier internal project meetings
Minimum Content Requirements
The document shall include:
- All key milestones for the Kasai UK project.
- All key milestones for the part being developed. These shall be in line with the Kasai UK project milestones
- Supplier internal project review meeting timing
- Detail design / drawing preparation timing
- Testing timing
- Analysis of Design and Process Potential Failures and Effects timing
- Production tooling development timing
- Production gauging development timing
- Production facilities (inc. test) installation timing
- Control Plan development timing
- Floor plan layout / process flowchart development timing
- Operation sheets / work instructions development timing
- Operator recruitment and training timing
- Capability study timing
- Packaging development and manufacture timing
- Logistics systems implementation timing
- Sub-supplier Management activities timing
- Appearance approval timing
- Parts manufacture and submission timing
- Supplier process audit timing
- PSW sign-off timing
- Ramp-up activities timing
Details sheets should be attached where necessary to provide detailed timing for individual activities e.g. tooling schedule, facility installation & commissioning schedule etc.
The Supplier may use their own document. If the KSPQP blank format is used, the following guideline should be followed:
Item
Completion Instructions
R / N Project
Kasai UK Vehicle / Power train project for which the part is being developed / manufactured.
Document Reference No./ Version
The Suppliers reference no. and version no. for the document.
Document Revision Date
The date of the latest revision of the document.
Document Origin Date
The date when the document was first issued.
Supplier Name
Supplier Company name.
Supplier Plant
Location at which the product will be produced.
Note: If the site supplying off-tool parts for a trial build is different to that supplying off-process parts for a later trial, this should be discussed with Kasai UK and should be reflected in all project management documentation.
Supplier Code
Unique code to each supplier, issued by Kasai UK Purchasing Dept.
Author
The name of the person who created / revised the document.
E-mail
The E-mail address of the person who created / revised the document.
Tel No
The telephone number of the person who created / revised the document.
Part Name
The part name or description as identified on the product drawing.
Part No. & Issue Level
As issued by Kasai UK design department.
Design Note No.
The latest design note number that applies to the product being developed / manufactured.
Trial
These five boxes should designate the trials for which parts will be required.
Delivery Date
These five boxes are to show the date that parts for each specified trial are to be delivered. The delivery dates are given by Kasai UK to the supplier.
Quantity
These five boxes are to show the quantity of parts for each specified trial.
SOP Date
This is the date that production will commence at the relevant Kasai UK plant.
Planned Maximum Annualized Production Build
This figure represents the annual volume assuming that the maximum monthly requirement for the year was required in every month.
E.g. annual volume could be 350,000 units, but with a peak monthly requirement of 35,000 units, the maximum annualized production volume would be 411,250 units (based on 20 days /month and 235 days/ year).
Time Scale
Identify year and months that the timing plan covers. Timing for each element should be shown using a time-scale in months (maximum) to cover the whole of the project life and with reference to the standard set of symbols.
Timing of suppliers internal cross-functional project review meetings. The purpose of these meetings is to confirm progress status to the Master timing / detail action plans and make countermeasure plans for project delays and major risks.
Detail Design/Drawing Preparation
Initial design development period and timing for study of Basic Specification, Product Specification and Drawing preparation/submission for approval.
Testing
Timing for testing as identified on Supplier Test Reports and Design Assurance Plan from Specification Tenders.
Note : Open test issues should be reported at all Kasai UK review meetings. If open items remain unresolved by the first Kasai UK production trial material receiving date (MRD) timing, concessions must be formally requested.
Analysis of Failure and Effects
Timing for conducting / completion of Design and Process Potential Failure & Effects Analysis (FMEA & FTA). Historical Recurrence Prevention data from Warranty and Customer Build concerns shall be reviewed as part of this planned activity.
Production Tooling
Describe the preparation schedule for the completion of the design, manufacture, inspection & buy off of all tooling including additional tool sets and multi-cavity dies. The schedule shall also include the date of tooling design reviews and trials.
Specify the production place of tool/ die (maker name and country name) and trial place.
Production Gauging
Describe the preparation schedule for the completion of the design, manufacture, inspection & buy off for all gauges including additional gauges. Specify the production place of gauge (maker name and country name).
Production Facilities (inc. Test) Installation
Overview timing of all facilities including, modifications, installation and commissioning at final manufacturing site. Timing details should show schedule from Facility design through to Facility commissioning. Ensure historical concerns are reviewed and countermeasures built into the activities.
Control Plan
Timing for deployment of all Design and Process Failure & Effects Analysis items into the development of the pre-production and production control plans and submission / approval of document. Kasai UK requirement items are as per the DCI for this document
Floor Plan Layout/ Process Flowchart
Overview timing for proposed shop floor layout / process flow. Kasai UK requirement items are as per the DCI for this document. Timing details should show schedule from Process design through to document completion. Ensure historical concerns are reviewed and countermeasures built into the activities
Operation Sheets / Work Instructions
Timing for initial preparation of work instructions and planned updates based on the results of pre-production trials.
Operator Recruitment & Training
Timing of recruitment and training activities for trial builds through to SOP requirements. Note: Show how recruitment and training support the planned trial builds.
Capability Study
Timing for study plan, evaluation and submission of capability data from off tool throughout supplier internal trials, concluding with data submission to Kasai UK.
Note: Kasai UK may ask for development capability data for specific parts and projects.
Packaging Development and Manufacture
Timing for specification, submission and approval of packaging specification, including timing for trial evaluation and procurement of packaging. Timing should support production trials using final packaging specification where agreed with Kasai UK.
Logistics Systems Implementation
Timing for specification, submission and approval of Logistics data, including timing for installation.
Sub-supplier Management
Timing for Sub-supplier activities (including Imposed / Module suppliers) from Sub-supplier selection through to sub-component part approval / PSW submission, with supporting sub-component assurance documents.
Appearance Approval
Timing for specification, confirmation, evaluation, reiteration activities, and final submission of reports and master samples or plaques.
Parts Manufacture & Submission
Timing from start to finish of each internal supplier trial build, any reiteration/ feedback activities and trial builds that are supporting submission of parts to Kasai UK. Note: Suppliers should liaise with Kasai UK to confirm requirements and timings.
Supplier Process Audit
Timing for the supplier to validate both his own and sub-suppliers process under SOP conditions, prior to SOP.
PSW Sign-off
Timing for issue of supplier signed-off Parts Submission Warrant to Kasai UK. Confirm Submission timing with Kasai UK QA.
Ramp up activities
Timing for the planning, commencement and duration of the Ramp up activities.
Responsible Person (Supplier)
Name of the person responsible at the supplier for the activity.
Comments
Include any comments relevant to the content of the Master Schedule or details sheets.
Supplier Sign-off (Manager Level)
Each area with a major involvement in the project will be expected to sign-off the Supplier Master Schedule at a senior level to confirm agreement of all areas to the content of the document.
For rules related to document submission, refer to the Submission Rules page.
