425Glossary
space, shipping/receiving areas, quarantine areas, hold areas, and so
on. The layout will also indicate any proposed areas for expansion
and development.
mapping: a method used to look at the complexity of the extended enterprise
value chain. Mapping details the manufacturing process, transpor-
tation, and other factors that go into component production.
material condition modier: one of three modiers that further dene the
tolerance of a feature in relation to its acceptable size limits.
material requirement planning (MRP): a computerized system used to
determine the quantity and timing requirements for materials used
in a production operation. MRP systems use: (1) a master produc-
tion schedule; (2) a bill of materials listing every item needed for
each product being made; and (3) information on current inventories
of these items in order to schedule their production and delivery.
Manufacturing resource planning (often called MRPII) expands
MRP to include capacity planning tools, a nancial interface to
translate operations planning into nancial terms, and a simulation
tool to assess alternative production plans.
maximum material condition (MMC): the point at which a feature contains
the greatest amount of material within its acceptable size limit. The
smallest acceptable hole and the largest acceptable shaft are exam-
ples of MMC.
median point: a point that is exactly the same distance between two outer
points.
net operating time: the number of hours (normal work pattern) less sched-
uled downtime (breaks, startup, previous maintenance, shared
production, tool changes, shut down) and unscheduled downtime
(estimated, based on historical or projected information). In case
of multiple customer part numbers, the changeover time has to be
considered.
noise-vibration-harshness (NVH): measurable perceptions of vehicle attri-
butes. These items are usually discovered and measured by the
customer’s NVH laboratory facilities. NVH attributes are typically
tuned to a certain frequency and amplitude in order to achieve an
overall vehicle signature frequency. This signature is optimized by
vehicle development for the best customer responses.
non-value-adding: an operation or activity that takes time and resources but
does not add value to the product sold to the customer. Non-value-
adding activities include work-in-process, inspection, defects, wait-
ing, and inefciency.
operator instructions: lists of steps that may contain inspection require-
ments, required tools and gauges, statistical process control (SPC)
applications, sample size and frequency, and acceptance/rejection
criteria. They will communicate all requirements involved in the
process. These are readily available to the operator.
426 Glossary
orientation tolerance: a group of geometric tolerances that limit the direction,
or orientation, of a feature in relation to other features. Orientation
tolerances are related tolerances.
overall equipment effectiveness (OEE): a production system measurable. An
indispensable metric in calculating capacity for any organization. OEE
measures the availability, performance efciency, and quality rate of
equipment, in particular, the constraint operation. OEE is part of any orga-
nization’s total productive maintenance program and improves through-
put by eliminating downtime. OEE = Availability × Performance
Efciency×Quality Rate.
packaging: material that is used to store and ship parts. It provides protec-
tion and containment of parts. It affects ease of handling by manual
or mechanical means. Packaging may consist of returnable or non-
returnable items including dunnage.
parallelism: a three-dimensional geometric tolerance that controls how
much a surface, axis, or plane can deviate from an orientation paral-
lel to the specied datum.
part number: a 10-digit alphanumeric number that represents a production
part number that is assigned to a commodity or part. These numbers
are assembled to describe the customer’s engineering bill of materi-
als used in building a product.
perishable tools: tools that are consumed in the process of producing a
product, and are usually a cost item, for example, drill bits, cutters,
sockets, driver tips, inserts, hobs, broaches, welding tips, and so on.
perpendicularity: a three-dimensional geometric tolerance that controls
how much a surface, axis, or plane can deviate from a 90° angle.
plant operating systems (POS): the part of FPS that encompasses what plants
do. Implementation of the POS involves using ve sequential phases
that take each plant from current state conditions to the improve-
ments envisioned in FPS. The ve phases are stability, continuous
ow, synchronous production, pull system, and level production.
poka-yoke: (1) an error-proong device or procedure used to prevent a
defect during order taking or manufacture. An order-taking exam-
ple is a screen for order input developed from traditional ordering
patterns that questions orders falling outside the pattern. The sus-
pect orders are then examined, often leading to discovery of input-
ting errors or buying based on misinformation. A manufacturing
example is a set of photocells in part containers along an assembly
line to prevent components from processing to the next stage with
missing parts. The poka-yoke in this case is designed to stop the
movement of the component to the next station if the light beam has
been broken by the operator’s hand in each bin containing a part for
the product under assembly at that moment. See also error proong.
(2) A Japanese term that refers to fool proong a design such that all
ambiguity is removed and it becomes virtually impossible to set up
427Glossary
a machine or produce a part or an assembly incorrectly. This is often
accomplished through designing the components of the tools and
the assemblies so they will t together only in the proper orientation
and sequence (Duncan 1995).
position: a three-dimensional geometric tolerance that controls how much
the location of a feature can deviate from its true position.
preproduction sample report (PPSR): a dimensional and performance veri-
cation document, submitted with all part samples used prior to S1
build.
pre-PSO documentation review: a meeting conducted by the PSO team,
chaired and coordinated by the supplier quality specialist with the
supplier and their advanced quality planning project team. The
meeting is conducted at a customer’s selected location prior to the
planned PSO. The purpose is to review all of the supplier’s advanced
quality planning and system plan documents in a sequential way
and determine the supplier’s readiness to demonstrate a rst pro-
duction demonstration run (300 pieces) in the form of a PSO.
preventive maintenance (PM): a planned system of actions performed to pre-
vent breakdown of a machine or equipment as a result of normal use.
primary datum: the datum feature that rst situates the part within the
datum reference frame. The primary datum is the rst feature to
contact a xture or surface during assembly.
problem-solving techniques (PST): methods that are used to identify the
root cause of a problem. The most common forms of PST are correc-
tive action teams, 8D, quality circles, multivari charts and analysis,
design of experiments (DOE), benchmarking, root-cause analysis,
shbone diagramming, quality function deployment (QFD) teams,
Shainan Consultants Inc.’s trademarked PST techniques (Isoplot,
Red“X”, Rank Order ANOVA, etc.), Pareto charts, and many more.
The most successful techniques have employee teams contributing
in some special way to perform root-cause analysis and then perma-
nently solve the issue or problem.
process: a series of individual operations required to create a design, com-
pleted order, or product. It is also a combination of people, equip-
ment, methods, materials, and environment that produces a product
or service. Any aspect of a business may be involved.
process capability: the total range of inherent variation in a stable process.
It is determined using data from control charts. The control charts
will indicate stability before capability calculations can be made.
Histograms are to be used to examine the distribution pattern of
individual values and verify a normal distribution. When analysis
indicates a stable process and a normal distribution, the indices P
p
and P
pk
(or C
p
and C
pk
) can be calculated. If analysis indicates a non-
normal distribution, advanced statistical tools such as transforma-
tion of data analysis will be required to determine capability.
428 Glossary
process failure mode and effects analysis (PFMEA): a structured method
of documenting historical or potential process failure modes, their
effects, and the controls taken to ensure their prevention. The
PFMEA rating system allows quantication of the risk presented by
each failure mode. The risk rating will be used to prioritize failure
prevention. The PFMEA will be developed by a cross-functional
team and will be uniquely developed for each process/product. It
has to be linked to the control plan and process ow diagram.
process ow diagram/chart: illustrates the ow of materials through the
process. Usually starting at receiving, material in process, through
shipping including any special processing which may result from a
nonconformance requiring disposition, rework, or repair operations.
process performance and process capability indices (P
p
, P
pk
, C
p
, and C
pk
):
dened in the statistical process control manual published by AIAG
(2005) as measures of capability. P
p
and P
pk
are preferred.
process sign-off (PSO) on-site visit: a systematic and sequential review of
the supplier’s manufacturing process conducted by a PSO team at
the supplier’s production facilities. Supplier quality is responsible
for team leadership.
processing time: the time a product is worked on in design or production, as
well as the time an order is actually being processed. Typically, process-
ing time is a small fraction of throughput time and lead time. In addition,
processing time includes value-adding and non-value-adding activities.
product assurance plan (PAP): a structured method of dening and estab-
lishing the required steps necessary to assure that a product satises
the customer. It is a checklist to track all engineering, supplier, and
quality planning events required for new products. It lists all the
important tasks to be completed, the persons responsible, the esti-
mated/actual completion dates, and how the individual tasks con-
tribute to the progress of the phases of the product creation process.
product assurance planning manual: a DaimlerChrysler published blue dot
manual that provides requirements to assure that specic activities
occur at the proper time in the product creation process. It also gives
specic instructions on how to develop a product assurance plan. It
involves assurance activities that focus on the areas of quality, reli-
ability, producibility, maintainability, and serviceability.
product family: a range of related products that can be produced interchange-
ably in a production cell. The term is often analogous to platforms.
product specications: the sum total of engineering drawing requirements
including standards referenced on those drawings and within the
contract. Some of these requirements are determined by team con-
sensus during advanced quality planning meetings and design
reviews and can take the form of safety standards, material stan-
dards, temporary standards, process standards, laboratory stan-
dards, reliability standards, or performance standards.
429Glossary
production capacity sheet: a job aid used by team members establishing and
maintaining a quality process system.The form is used to determine
the processing capacity of each machine in the work sequence.
production demonstration run: a production run consisting of 300 or more
parts (2 or more hours of production), from the production line of
record, using trained operators, production-approved piece parts
or materials from production subsuppliers, and run at a rate equal
to the quoted maximum tooling capacity. All special characteristics
will meet or exceed a process performance of P
p
≥P
pk
≥1.67. FTC
shall be calculated for each station and overall. A customer’s repre-
sentative will be on the manufacturing oor during the demonstra-
tion to observe and verify the documented production system. PV
test parts are taken from this run to demonstrate that the production
process has not degraded the design performance that was veried
by DV testing. (The customer representative may change the amount
of samples to less than 300 pieces if required.)
production part approval process (PPAP): process for ensuring that pro-
duction parts are manufactured at the production site using the
production tooling, gauging, process, materials, operators, environ-
ment, and process settings (e.g., feed, speed, cycle time, pressure,
temperature). Parts for production part approval will be taken from
a signicant production run. Customers usually require that this
run is a minimum of 2 h or 300 pieces, whichever is more stringent,
unless otherwise stated in writing by the customer. Parts from each
position of a multiple cavity die, mold, tool, or pattern are to be mea-
sured and representative parts tested.
production validation testing (PV): demonstration tests performed to vali-
date design conformance of initial production parts manufactured
with production tools and processes.
prole: the outline of a part feature within a given plane.
prole of a line: a two-dimensional geometric tolerance that controls how
much the outline of a feature can deviate from the true prole.
prole of a surface: a three-dimensional geometric tolerance that controls
how much a surface can deviate from the true prole.
prole tolerance: a group of powerful geometric tolerances that control the
size, location, orientation, and form of a feature. Prole tolerances
can be either independent or related.
program: the identication of a specic product line and model year.
pull: a system of cascading production and delivery instructions from down-
stream to upstream activities. The upstream supplier only produces
when the downstream customer signals a need. Pull is the opposite
of push.
pull system: a way of managing shop oor (or even ofce-level) activity that
minimizes work-in-process and dramatically improves throughput
time by eliminating interoperation queues. A pull system requires two
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