DOCUMENT COMPLETION INSTRUCTION
Supplier Production Preparation Monitoring Plan / Status Report

Key Points

The Supplier Production Preparation Monitoring Plan / Status Report is a document that is used to establish the targets for the 4M (manpower, material, machine, method) at each stage of the project and to report the achievement of these targets at each milestone.

Minimum Content Requirements

The supplier shall complete a Supplier Production Preparation Monitoring Plan / Status Report for each part or part family/group. This document should identify the targets set and results achieved by the supplier for each Kasai UK project milestone.

All targets shall be expressed as a percentage of required SOP condition.

Document Description

Item Completion Instructions
Project Kasai UK Vehicle project for which the product 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 The latest Spec Tender number that applies to the product being developed / manufactured.
Spec Tender No. As issued by Design.
Milestone Enter the Kasai UK project milestone name.
M
A
N 		Manning Requirement Planned Target Indicate the planned total number of personnel (including all shifts) who will manufacture the product at each milestone
Achievement Indicate the actual number of personnel used to manufacture the product at each milestone
Skill Level Planned Target Indicate the planned number of fully trained personnel who will manufacture the product at each milestone
Achievement Indicate the actual number of fully trained personnel who manufactured the product at each milestone
M
A
T
E
R
I
A
L 		Test Achievement Planned Target Indicate the planned number of successfully completed tests (design verification & product/process validation) by the Supplier at each milestone.
Achievement Indicate the actual number of successfully completed tests at each milestone
Process Capability Planned Target Indicate the planned number of features, as shown on the Process Capability Study Plan, which will be capable at each milestone.
Achievement Indicate the actual number of features, as shown on the Process Capability Study Plan, that were capable at each milestone
Straight Through Ratio Planned Target Indicate the planned percentage of good product manufactured without rework at each milestone
Achievement Indicate the actual percentage of good product manufactured without rework at each milestone
OK Ratio Planned Target Indicate the planned percentage of OK product, including rework, manufactured at each milestone.
Achievement Indicate the actual percentage of OK product, including rework, manufactured at each milestone.
Approval of Sub-components Planned Target Indicate the planned number of sub-components fully approved at each milestone.
Achievement Indicate the actual number of sub-components fully approved at each milestone
Part Marking for Mass Production Planned Target Indicate the planned number of parts with mass production marking at each milestone.

NOTE: Component marking includes any marking that is made on the product to aid identification of the product. Typically this includes part number, Material type, traceability identification.
Achievement Indicate the actual number of parts with mass production marking at each milestone
M
A
C
H
I
N
E 		Production Tooling Completion Planned Target Indicate the planned number of tools to be completed at each milestone.
Achievement Indicate the actual number of tools completed at each milestone
Production Gauging Completion Planned Target Indicate the planned number of gauges to be completed at each milestone.
NOTE: Review Kasai UK Gauge timing requirements prior to completion of the Supplier Production Preparation Monitoring Plan / Status Report.
Achievement Indicate the actual number of gauges completed at each milestone
Facilities Commissioned
(including test) 		Planned Target Indicate the planned number of facilities identified on the Floor Plan Layout document, which are to be modified/introduced/ commissioned in their final location at each milestone.
Achievement Indicate the actual number of facilities modified/ introduced/ commissioned in their final location at each milestone.
Production Cycle Time Achievement Planned Target Indicate the planned cycle time to be achieved at each milestone.
Achievement Indicate the actual cycle time achieved at each milestone.
M
E
T
H
O
D 		Packaging Availability Planned Target Indicate the planned quantity of packaging (internal and external) to be available at each milestone
Achievement Indicate the actual quantity of packaging (internal and external) available at each milestone
Work Instructions Planned Target Indicate the planned number of operation sheets to be completed at each milestone.
Achievement Indicate the actual number of operation sheets completed for at each milestone.
Average Score Indicates the average of the percentage results for the planned targets at each milestone
Supplier Sign-off Each area with a major involvement in the project will be expected to sign-off this document at a senior level to confirm the agreement of all areas to the content of the document.
For guidance in sign-off at the supplier, responsibility is intended to be
  • Project Leader - the agreed window within the supplier for the project.
  • Purchasing/Sales - responsibilities may include direct and indirect materials ordering.
  • Production Control - responsibilities may include sales administration, production scheduling, parts ordering, inventory control.
  • QA - responsibilities may include customer quality concerns, supplier quality assurance and in-house quality assurance.
  • Engineering - responsibilities may include tooling specifications, production line layout, process control.
  • Design - responsibilities may include drawing release, design change control.
  • Production - responsibility for all aspects of production.
The relevant name should be clearly printed with signature below.

For rules related to document submission, refer to the Submission Rules page.