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It explains how GPDS Schedule “A” deliverables (#25, #19, #30) map to CAR form sections and phases, and how Overall Equipment Effectiveness (OEE) links Equipment Availability, Performance Efficiency, and Quality Rate to capacity risk. The guide details CAR structure, sheet functions, risk-reduction logic, and shared loading planning assumptions for capacity 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\nFord Motor Company Supplier Technical Assistance (STA)  \nFebruary 2018  \nTABLE OF CONTENTS  \n\n| Topic | Page |\n| --- | --- |\n| Introduction\u003Cbr>􀁸  GPDS Schedule “A” Deliverables \\#25, \\#19, and \\#30\u003Cbr>􀁸  CAR Form Architecture | 3 |\n| Setting up a CAR:\u003Cbr>􀁸  Determining Single Value Streams for CAR Form\u003Cbr>􀁸  In-Process Scrap Loss Considerations\u003Cbr>􀁸  Manual Linking of Multiple CARs (More than 8 processes, various Value Streamsand Sub-tiers)\u003Cbr>􀁸  Grouping a family of parts into a CAR | 12 |\n| CAR Color codes Overview | 17 |\n| Historical Manufacturing Performance | 18 |\n| Shared Loading Plan | 22 |\n| Supplier Declarations and Notes | 26 |\n| Section A of CAR Form –All Phases (For Deliverable \\#25, \\#19, and \\#30)\u003Cbr>~~􀁸 ~~ GPDS Volume Communication | 28 |\n| Section B of CAR Form – Capacity Planning (For Deliverable \\#25 ONLY) Section B of CAR Form – Phase 0 (For Deliverable \\#19 ONLY)\u003Cbr>Section B of CAR Form – Phase 3 (For Deliverable \\#30 ONLY) | 37\u003Cbr>39\u003Cbr>44 |\n| Section C of CAR Form\u003Cbr>􀁸  Gap Analysis-Required OEE vs. Demonstrated\u003Cbr>􀁸  Resolving Potential Capacity Risks | 48 |\n| Record of Revisions | 53 |\n\nINTRODUCTION  \nGPDS Schedule “A” Deliverables, the CAR Form and CAR Form Architecture  \nThis manual is intended to assist in navigating the Ford Motor Company Capacity Analysis Report (CAR) for New Model Launch Capacity, as well as post launch capacity change, including capacity extensions, quarterly Purchased Part Capacity (PPC) reporting, capacity uplifts and mix change studies. Significant updates are highlighted in blue italics. Ford requires that supplier sites demonstrate their ability to satisfy Ford volume requirements (Average Production Weekly and Maximum Production Weekly) and report them as the three deliverables (\\#25, \\#19 and \\#30) of the Global Product Development System (GPDS) . For further description of post launch capacity change, see the full training documentation at the following location: [https://www.lean.ford.com/cqdc/supplier_training.asp](https://www.lean.ford.com/cqdc/supplier_training.asp).  \nFord utilizes Overall Equipment Effectiveness (OEE) to assess the risk associated with the supplier’s plan to demonstrate capacity requirements, as it incorporates three key manufacturing performance elements (Equipment Availability, Performance Efficiency, and Quality Rate) .  \nGPDS begins capacity engagement early in the product development cycle at FDJ; up to 16 months before Job 1. The intention is that, by beginning to look at capacity early on, potential risks can be identified and addressed with significant minimization to launch risk and cost. At Site Visit \\#1 or \\#2 in GPDS, a supplier’s plan for containing production volumes must be validated. Site Visits \\#3 and \\#4 further validate that the supplier's plan is capable of meeting volume requirements, coinciding with Phase 0 PPAP and Phase 3 PPAP.  \nGPDS Supplier Engagement – Process Overview  \nThe CAR form can be used to satisfy the following GPDS Schedule “A” Deliverables:  \n\n| Schedule “A”Deliverable | Supplier Engagement Visit | Phase | GPDS Text |\n| --- | --- | --- | --- |\n| \\#25 | \\#1 or \\#2 | Planning | Capacity Planning:\u003Cbr>Verify Supplier’s Demonstrated OEE (Surrogate) ≥ Required OEE |\n| \\#19 | \\#3 | PPAP Phase 0 | PPAP Phase 0:\u003Cbr>Verify Supplier’s Demonstrated OEE (Run @ Rate) ≥ Required OEE |\n| \\#30 | \\#4 | PPAP Phase 3 | PPAP Phase 3:\u003Cbr>Verify Supplier’s Demonstrated OEE (Capacity Verification) ≥ Required OEE |\n\nSatisfying the deliverables is accomplished through the use of the CAR Form with the same method, regardless of which deliverable is targeted.  \nPhase 3 (CapVer)  \nRisk increases as the amount of time prior to launch decreases. Risks must be addressed with even more urgency, and resolution may  \nPhase 0 (R@R) incur higher cost.  \nRisk increases as the amount of time prior to launch decreases. Risks must be addressed with more urgency, and resolution may incur higher cost.  \nC","cbCaieWWdoFSc52j","https://ap.wps.com/l/cbCaieWWdoFSc52j","pdf",1595422,53,"English","# Introduction\n## GPDS Schedule “A” Deliverables and CAR Form Architecture\n## GPDS Supplier Engagement – Process Overview\n# Setting up a CAR\n## Determining Single Value Streams for CAR Form\n## In-Process Scrap Loss Considerations\n## Manual Linking of Multiple CARs\n## Grouping a family of parts into a CAR\n# CAR Form Details\n## CAR Color codes Overview\n## Historical Manufacturing Performance\n## Shared Loading Plan\n## Supplier Declarations and Notes\n## Section A, B, and C of CAR Form\n## Gap Analysis and OEE Risk Resolution\n# Record of Revisions","[{\"question\":\"What is the purpose of the Ford Capacity Analysis Report (CAR) User Guide?\",\"answer\":\"The guide helps suppliers navigate the CAR process for new model launch capacity and post-launch capacity changes, including how to report quarterly Purchased Part Capacity and other capacity adjustments through GPDS deliverables.\"},{\"question\":\"How do GPDS Schedule “A” deliverables map to CAR form phases?\",\"answer\":\"Deliverable #25 uses Capacity Planning to verify demonstrated OEE (surrogate) meets the required OEE, deliverable #19 uses Phase 0 PPAP to verify demonstrated OEE (run @ rate), and deliverable #30 uses Phase 3 PPAP to verify demonstrated OEE (capacity verification) meets the required OEE.\"},{\"question\":\"How does the CAR form assess capacity risk?\",\"answer\":\"Risk is assessed by comparing new model Required OEE with Demonstrated OEE derived from surrogate or historical data for capacity planning, and from Phase 0 or Phase 3 PPAP run/capacity verification results for the respective deliverables.\"}]","CAR_5_6_User_Guide - Capacity Analysis Report (CAR) User Guide | PDF",1789150943,19]