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CPG & CMS: Common Process Groups & Capacity Management
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Common Process Groups (CPG) & Capacity Management Systems (CMS) 2/6/2023 COURSE OBJECTIVES ● Define Common Process Groups ● Capacity Management System (CMS) overview ● Understand required supplier actions on the Capacity Management System (CMS) ● Create/Modify CPGs ● Real-world/complex example NOTE: If you have not already taken the Volume Variance Course, please take that one prior to this one. Table of Contents • • • • • • • • • • • • • Defining Common Process Groups (CPG) - Unique vs Grouped System Overview - Navigating the Capacity Management System (CMS) Actionable Items - Steps for responding to actionable items Non-Actionable Items - Steps for responding to non-actionable items Creating CPG - Loading new CPGs Modify CPG - Adding parts and breakpoints to CPGs Real World Example - In-depth example on creating CPGs COMMON PROCESS GROUPS (CPG) Understanding and defining what a CPG is 2/6/2023 Common Process Group (CPG): What is a CPG? What is a Common Process Group (CPG)? A group of parts with a shared constraint within their supply chain Constraint Examples: • Contractual: labor regulations • Material: resin, steel • Process: painting, plating, heat treat Why are Common Process Groups Important? • Contracts are individual part based and do not have the ability to capture shared capacity • CPGs are required to identify process shortfalls by generating volumes variances and highlight constraints on Traplines 2/6/2023 Capacity Planning Common Process Group (CPG): Grouped vs. Unique Parts in CPGs must be identified as Grouped or Unique by Supplier *System’s default is Unique, remember to update to Grouped if needed Grouped: • Parts are interchangeable from a production/material standpoint • Supplier can make any combination of parts in a CPG as long as it does not exceed the total max CPG capacity • Each part can achieve the full CPG capacity if none of the other parts were produced • Grouped parts in a CPG are not evaluated individually. Only the CPG will get a Volume Variance Unique: • Individual part capacity is constrained lower than the CPG capacity • UNIQUE parts in a CPG are evaluated individually AND as part of the group • The individual part can get a Volume Variance while CPG might not Why updating POs to CPG capacity is important: • Captures the true part capacity/flexibility • Allows Stellantis to contractually document shared capacities 2/6/2023 Capacity Planning Common Process Group (CPG): Grouped Illustration GROUPED Parts in the same press CPG 400 JPW Part 1 = 50 JPW (G) Part 1 = 400 JPW (G) Part 2 = 200 JPW (G) Part 3 = 150 JPW (G) Paint Process Painter can only output a max of 400/week with full flex Part 4 = 100 JPW (G) Total parts PO sourced individually equal to 500 JPW 2/6/2023 Capacity Planning Part 2 = 400 JPW (G) Part 3 = 400 JPW (G) Part 4 = 400 JPW (G) Example: Supplier can make 400 JPW of Part 1 if they make zero of any other part Created to capture painter bottleneck Parts PO updated to 400 JPW Common Process Group (CPG): Unique Illustration UNIQUE Parts in the same press CPG 400 JPW Weld Process Part 1 = 50 JPW (U) Part 2 = 200 JPW (G) Part 3 = 150 JPW (G) Part 4 = 100 JPW (G) Only 1 part gets welded and can only reach 50 JPW Press Process Part 1 = 50 JPW (U) The press can run CPG capacity 400 JPW Part 2 = 400 JPW (G) Based on welding constraint supplier can only output a maximum of 50 JPW for Part 1 and it will be identified as Unique (U) Part 3 = 400 JPW (G) Part 4 = 400 JPW (G) Created to capture press capacity with unique constraint 2/6/2023 Capacity Planning COMMON PROCESS GROUP (CPG) → Basic CPG examples. All Grouped parts. Common Process Group (CPG): Basic CPG Example #1 Example: Supplier for headliners manufactures 4 parts which were sourced individually at 200/week. Supplier’s final assembly line is only capable of a total of 200/week for all parts. Supplier can make any combination of the 4 parts as long as it does not exceed 200/week. One CPG is needed including the 4 parts, labeled as Grouped, with a total maximum capacity of 200/week. Part 60000001AA Part 60000002AA 200/week 200/week Part 60000003AA Part 60000004AA 200/week 200/week CPG - CP00011111 Actual Weekly = 200/week Note: All CPG #s begin with “CP000” followed by a 5 digit number. (EX: CP00025123) Assumed Weekly = 800/week Any combination of releases cannot exceed 200 pieces weekly (CPG Weekly Max) Releases Example: Releases Example: Releases Example: Releases Example: Part 1 Part 2 Part 3 Part 4 Total Part 1 Part 2 Part 3 Part 4 Total Part 1 Part 2 Part 3 Part 4 Total Part 1 Part 2 Part 3 Part 4 Total 50 50 50 50 200 50 0 50 100 200 Note: Each part PO will be updated to 200/week once the CPG is created. 2/6/2023 Capacity Planning 0 150 0 50 200 0 0 0 200 200 Common Process Group (CPG): Basic CPG Example #2 Example: Supplier for axles manufactures 8 parts which were each sourced separately. Supplier’s final assembly line is only capable of a total of 300/week for all parts. However, the Supplier also has 3 additional constraints prior to the final assembly. Within these constraints the supplier has full flexibility between the parts. Therefore, these parts are all Grouped. A few CPGs will need to be created for these constraints. CPGs 1,2, and 3 (below) capture constraints prior to the final assembly line. CPG 4 captures the final assembly constraint for all parts up to 300/week The original part PO/sourced capacity will be updated to CPG capacity if Grouped CP00044444 CP00011111 CP00022222 Part 60000001AA – 100/wk → 100/wk Part 60000004AA – 100/wk → 100/wk Part 60000006AA – 50/wk → 200/wk Part 60000002AA – 50/week → 100/wk Part 60000005AA – 50/week → 100/wk Part 60000007AA – 100/wk → 200/wk CP00033333 Part 60000008AA – 200/wk → 200/wk Part 60000003AA – 50/week → 100/wk Part 60000001AA - 100/week Part 60000002AA - 100/week Part 60000003AA - 100/week Part 60000004AA - 100/week Part 60000005AA - 100/week CPG Capacity - 100/week CPG Capacity - 100/week CPG Capacity - 200/week Since all parts are “Grouped” all part POs will be Since all parts are “Grouped” all part POs will be Since all parts are “Grouped” all part POs will be updated to CPG capacity of 100/week updated to CPG capacity of 100/week updated to CPG capacity of 200/week Part 60000006AA - 200/week Part 60000007AA- 200/week Part 60000008AA- 200/week CPG Capacity - 300/week Assumed Weekly = 400/week 2/6/2023 Capacity Planning Actual Weekly = 300/week These are the final part PO capacities that are reflective of the lowest CPG capacity COMMON PROCESS GROUP (CPG) → Basic CPG example. Unique part. Common Process Group (CPG): Basic CPG Example #2 Example: Supplier for steering columns manufactures 5 parts which were each sourced separately. Supplier’s final assembly line is only capable of a total of 200/week for all parts. However, the Supplier also has 2 additional constraints prior to the final assembly. Within CPG CP00011111, part 6000000AA has a unique bottleneck and does not share this constraint with another part. Therefore, this part is considered Unique within the CPG. The original part PO/sourced capacity will be updated to CPG capacity if Grouped CP00011111 CP00022222 Part 6000001AA – 100/wk → 150/wk Part 60000004AA – 100/wk → 100/wk Part 6000002AA – 50/wk → 50/wk (Unique) Part 60000005AA – 50/week → 100/wk Part 6000003AA – 50/wk → 150/wk CP00044444 Part 60000001AA - 150/week Part 60000002AA - 50/week (Unique) Part 60000003AA - 150/week Part 60000004AA- 100/week CPG Capacity - 150/week CPG Capacity - 100/week Since part 60000002AA is “Unique” the PO will Since all parts are “Grouped” remain at 50/week All parts will be updated to CPG capacity of 100/week All “Grouped” parts will be updated to 150/week Part 60000005AA - 100/week CPG Capacity - 200/week Part 60000002AA remains “Unique” in all CPGs it belongs in Assumed Weekly = 250/week 2/6/2023 Capacity Planning These are the final part PO capacities that are reflective of the lowest CPG capacity OR its Unique constraint Actual Weekly = 200/week Parts are either “Grouped "or “Unique” A part that is Grouped in one CPG is Grouped in ALL CPGs it is in A part that is Unique in one CPG is Unique in ALL CPGs it is in Common Process Group (CPG): Key Questions To Ask Before creating CPGs, always ask yourselves these questions: ➢ Do these parts share any capital equipment/tooling (bottlenecks/constraints)? ➢ Sub-tier supplier bottlenecks NEED to always be considered. Confirm your tier 2 suppliers can support the capacities you are committing to. Even if they are directed components from Stellantis you must manage capacity. ➢ Can supplier make any combination of these parts as long as it does not exceed the total maximum capacity? ➢ In other words, does supplier have full flexibility between the group of parts? ➢ Do these parts have to go through any secondary processes (painting, plaiting, machining, heat treatments) that have their own constraints? (If yes, sub CPG may be needed) Note: If you have any questions on CPGs or you are unsure if a part should be in a CPG please contact your capacity specialist. 2/6/2023 Capacity Planning Common Process Group (CPG): Team Responsibilities for CPGs Constraint Specialist • • Subject matter expert on plant and program capacity requirements Buyer’s touch-point for all capacity questions CPG Specialist • • Subject matter expert on capacity database and CPG creation process Works with supplier to validate CPG capacity upon submission Supplier • • Process expert identifies need to create CPGs in the capacity database system Works with CPG Specialist to validate CPGs Buyer • • Authorizes new capacity on the contract Manages commercial aspects and capacity tooling Supplier Operations • • Calculates the required line speed for the PDR. Daily tooling capacity for CPG is used rather than adding up the daily tooling capacity for all parts in that CPG 2/6/2023 Capacity Planning SYSTEM OVERVIEW Learn to navigate the Capacity Management System (CMS) 2/6/2023 System Overview: Capacity Management System Importance The Capacity Management System (CMS) is a repository for all production parts with released contracts (POs) It serves 5 main purposes: 1. Holds suppliers capacity information 2. Allows suppliers to communicate changes to awarded capacity 3. Flags potential capacity issues and when they will occur 4. Helps identify shared capacities/bottlenecks (CPGs) 5. Uses stated capacities to calculate Trapline Studies 2/6/2023 Capacity Planning System Overview: Accessing Capacity Management Database 1. Go to www.eSupplierConnect.com 2. LOGIN 3. Select NAFTA → Applications 4. Select Capacity Management NOTE: Suppliers get access to the Capacity Management System through THEIR IT department/system administrator 2/6/2023 Capacity Planning System Overview: Home Page/Supplier Dashboard Below is the initial screen you will see when you first login Note: The yellow boxes for your reference in the following slides Joe Smith 2/6/2023 Capacity Planning System Overview: Navigation Column The Navigation Column is used to switch between: Joe Smith Training Material Message Board Part/CPG Search Supplier Dashboard 2/6/2023 Capacity Planning System Overview: Training Material Training Material: 2/6/2023 Capacity Planning • Volume Variance Training – Learn where to see/answer volume variances for CPGs and parts. This training course should be taken prior to this one. • Trapline Training • CPG and Capacity Management Supplier Course – Learn what CPGs are, how to create CPGs in CMS, and navigating CMS (this training). • 6 Month Validation One Pager – Learn how to answer your 6 month CPG/annual part capacity validation under “Actionable Items.” System Overview: Message Board Message Board: Recent Messages • Current information to be aware of show here • The first message shown is the Capacity Planning Contact Roster (downloadable excel format). Use this contact roster to find out who your Capacity/CPG specialists are. 2/6/2023 Capacity Planning System Overview: Part/CPG Search Part/CPG Search allows for user to view all data associated with a specific Part/CPG number Note: Yellow boxes below show important information for the part/CPG. 2/6/2023 Capacity Planning System Overview: Supplier Dashboard Supplier Dashboard contains the Actionable & Non-Actionable item information for their assigned supplier code If responsible for multiple codes, user can toggle between codes by utilizing the drop down bar. 2/6/2023 Capacity Planning System Overview: Supplier Dashboard → Actionable vs Non-Actionable Items Actionable Items: Non-Actionable Items: The left side of the screen indicates specific system actions required from the supplier. The right side of the screen includes all parts and CPGs tied to the supplier code. You will use this section when creating/modfying CPGs. These items must be addressed within 13 days before CMI score is impacted 2/6/2023 Capacity Planning Responses do not affect CMI score. ACTIONABLE ITEMS Responding to Actionable Items and their purpose 2/6/2023 Actionable Items: Key Terminology Key Terms to Know when responding to Actionable Items: ➢ Temporary Breakpoint – A Temporary Breakpoint is created within a part/CPG by the supplier to reflect an uplift in capacity. • Note: This does NOT mean “temporary capacity.” It is simply a breakpoint that is considered “temporary” until the breakpoint is “validated” by a capacity/CPG specialist. Once reviewed/validated, the breakpoint will then switch from “temporary” to “validated” status • This temporary breakpoint capacity overrides the PO capacity and is used to calculate variances and trapline studies. This breakpoint capacity can only be higher than the PO capacity, unless approved by the Capacity Specialist & Buyer. • The “Expiration Date” field shown when creating a temporary breakpoint is when the 6 month validation is due. ➢ In-Progress Breakpoint – An In-Progress Breakpoint is created within a part/CPG by the supplier to reflect a future uplift in capacity. • The “Effective Date” filed when creating this breakpoint is the date when the supplier will have capacity in place. These breakpoints are used primarily when new tooling is kicked off. 2/6/2023 Capacity Planning Actionable Items: Overview Note: Click on ANY light blue bar for the specific data subset • Suppliers are required to resolve ALL actionable items to avoid a negative CMI score impact. • E-mail notifications are sent to all supplier “employees of record” indicating there are actionable items that need to be resolved. • Supplier has 13 calendar days from initial notification to resolve actionable items. • Unanswered actionable items reduce the supplier CMI score after 13 calendar days from initial notification • Unanswered actionable items can cause a risk of shutting down our plants resulting in CLS/CLD $ costs. • Potential escalation to supplier senior leadership for resolution 2/6/2023 Capacity Planning ACTIONABLE ITEMS → NEW PARTS Actionable Items: New Parts New Parts: Newly sourced parts will appear here. Click on the bar for the list of parts/details and to answer Actionable Item. To answer “New Parts” Actionable Item, suppliers must choose from the following options. No Change Required – Part does not belong to a CPG and capacity is correct. If capacity is incorrect, contact your buyer. Create CPG – If multiple parts listed in “New Parts” share a bottleneck, select the parts and button will be available to create a CPG Add Part CPG – If CPG exists for commodity and part belongs to it, select this option and choose CPG. 2/6/2023 Capacity Planning ACTIONABLE ITEMS → IN-PROGRESS CAPACITY Actionable Items: In-Progress Capacity In-Progress Capacity: Parts/CPGs that have In-Progress breakpoints which have reached their “effective date” will show up here. To answer “In-Progress” Actionable Item follow the steps below: 1. Select part/CPG number. It will highlight green. 2. If the tooling is ready, select “Implement Capacity” If the tooling is NOT ready by the “impact date” committed, reach out to your capacity or CPG specialist ASAP. 2/6/2023 Capacity Planning ACTIONABLE ITEMS → REJECTED BY SPECIALIST Actionable Items: Rejected by Specialist Rejected by Specialist: Parts/CPGs that your Capacity Specialist or CPG Specialist has rejected will show up here CPGs that are rejected are typically because they have been requested for deletion with no previous communication with Stellantis or, Supplier has been unresponsive pertaining to a CPG needing to be updated. To answer “Rejected by Specialist” Actionable Item: Suppliers should reach out to the CPG Specialist to resolve any rejected CPGs 2/6/2023 Capacity Planning ACTIONABLE ITEMS → VOLUME VARIANCE Actionable Items: Volume Variance Volume Variance: Parts/CPGs with volume variances will appear here. A Volume Variance is a release that exceeds the supplier’s stated PO (for a Unique part) or the CPG breakpoint capacity. The Capacity Management System is designed to identify potential capacity shortfalls to prepare an action plan. Volume Variance Releases are refreshed on a weekly basis 2/6/2023 Capacity Planning Volume Variances are identified as releases are compared to PO, breakpoint, or CPG capacities Supplier has 13 days to respond to variance before CMI score is impacted Responses trigger further investigation by Capacity Specialist Actionable Items: Volume Variance To answer “Volume Variance” Actionable Item follow the steps below: 1. Click on the “Volume Variance” bar in the Actionable Items graph 3. Locate the weeks with the variance (highlighted in red) and click on the “Select” drop down bar to pick the response 2. Select part/CPG (it will highlight green) and click on the “Volume Variance” button on the bottom left of the page to view and respond to all weekly and monthly variances 4. Scroll to the bottom of the page and click the “Save Response” button. NOTE: For additional information on volume variances, take the Volume Variance Course or access the presentation deck via CMS under Message Board → Training Material 2/6/2023 Capacity Planning ACTIONABLE ITEMS → TEMPORARY EXPIRATION DATE REACHED Actionable Items: Temporary Expiration Date Reached Temporary Expiration Date Reached: Temporary Breakpoints contain an “Expiration date” For CPGs they are valid for a maximum duration of 6 months & for parts they are valid for 1 year CPGs/Parts in which suppliers have created temporary breakpoints but have not yet been validated by the “Expiation Date” will appear here Note: Temporary Breakpoints do NOT mean “temporary capacity.” It is simply a breakpoint that is considered “temporary” until the breakpoint is “validated” by a capacity/CPG specialist. Once reviewed/validated, the breakpoint will then switch from “temporary” to “validated” status To answer “Temporary Expiration Date Reached” Actionable Items: For parts NOT in CPGs, contact your buyer if the PO needs to be updated. Buyer name is listed on the right of each part # For CPGs, reach out to your CPG Specialist 2/6/2023 Capacity Planning ACTIONABLE ITEMS → 6 MONTH CPG/ANNUAL PART CAPACITY VALIDATION Actionable Items: 6 Month CPG/Annual Part Validation 6 Month CPG/Annual Part Capacity Validation: Suppliers are required to validate capacity; Every 6 months for CPGs Every 1 year for unique parts NOT in CPGs This is to ensure accuracy of information in Capacity Management System. To answer “6 Month CPG/Annual Part Capacity Validation” Actionable Items, follow the steps in the next slide → 2/6/2023 Capacity Planning Actionable Items: 6 Month CPG/Annual Part Validation To answer “6 Month CPG/Annual Part Capacity Validation” Actionable Items follow the steps below: 1. Click on the “6 Month CPG” bar in the Actionable Items graph 3. Ask yourself the following questions: ✓ Is the shift pattern and capacity correct? ✓ Is the CPG still necessary/accurate? ✓ Are all affected parts included in the CPG? ✓ Are all parts in the correct status within the CPG (grouped vs unique)? If there are any concerns with the accuracy of a part or CPG, please contact your assigned Capacity Specialist for assistance in resolving. If the part or CPG is still accurate, proceed to step 4. 2. Select part or CPG (it will highlight green) and click the “Breakpoint” button on the bottom left of the page. 2/6/2023 Capacity Planning 4. If part/CPG is correct, click the “Validated Capacity” button. ACTIONABLE ITEMS → MONTHLY SUPPLIER VALIDATION OF IN-PROGRESS BREAKPOINT - NEW! Actionable Items: Monthly Supplier Validation of In-Progress Breakpoint What is this Actionable Item for? Allows for better tracking of In-Progress breakpoints (future capacity). This will minimize the risk of overlooking potential shortfalls of future stepped-capacity that suppliers are working toward. FYI: This is a new enhancement to Capacity Management beginning 8/1/22. Please see the next couple of slides for additional information. In-Progress Breakpoint Date in the future: • Supplier will be required to respond monthly to In-Progress breakpoints with two new options: “Capacity on Track” or “Capacity Not on Track • If “Capacity On Track” • Actionable Item is removed • No further action necessary • If “Capacity Not on Track” • Pop-up Box: Note that a response of “Capacity Not On Track” does NOT release the supplier from the previously committed capacity on the In Progress date. This is simply a means to notify our team who will reach out to you shortly for additional information. • CPG team/SO/Lead Constraint Analyst/Buyer notified • CPG becomes “unvalidated” • Supplier will work with appropriate Stellantis teams to identify reasons for failure to support, shortfalls, risks, etc. Further escalation may be required. • If no response (after 2 weeks) • DRIVE score impacted • CPG becomes unvalidated • Supplier receives weekly notifications until response is provided In-Progress Breakpoint Date in the present or past: • • • • Once the date of the In-Progress hits, the supplier gets an Actionable Item to respond Supplier must respond “Implement Capacity” If no response, the Supplier receives weekly reminders and DRIVE Score is affected every week of no response Variance volume reverts to the latest validated capacity immediately 2/6/2023 Capacity Planning Actionable Items: Monthly Supplier Validation of In-Progress Breakpoint Monthly Supplier Validation of In-Progress Breakpoint: Suppliers are required to respond monthly to In-Progress breakpoints (future capacity uplift) as “On Track” or “Not on Track” This minimizes the risk of overlooking potential shortfalls for future stepped-capacity that suppliers are working toward. To answer “Monthly Supplier Validation of In-Progress Breakpoint” Actionable Items, follow the steps in the next slide → 2/6/2023 Capacity Planning Actionable Items: Monthly Supplier Validation of In-Progress Breakpoint To answer “Monthly Supplier Validation of In-Progress Breakpoint” Actionable Items follow the steps below: 1. Click on the “Monthly Supplier Validation of In-Progress Breakpoint” 2. Select the CPG and click on either “On Track” or “Not on Track” Note that a response of “Not On Track” does NOT release the supplier from the previously committed capacity on the In-Progress date. This is simply a means to notify our team who will reach out to you shortly for additional information. 2/6/2023 Capacity Planning NON-ACTIONABLE ITEMS Defining Non-Actionable items 2/6/2023 Non-Actionable Items: Overview Note: Click on ANY light blue bar for the specific data subset All Parts – All parts tied to supplier code All Temporary Parts – Parts in which the Supplier/CPG specialist has added a temporary breakpoint (different capacity than PO) All NIK Parts – Parts with new NIK. If a part is already in a CPG, the new NIK will automatically be added to it All CPG – All CPGs tied to supplier code All Temporary CPG – CPGs that have a new temporary breakpoint added to it (typically showing a capacity uplift) or a new CPG that has not yet been validated by CPG specialist CPG Awaiting Approval – CPGs waiting to be reviewed/validated by CPG specialist. Supplier is NOT penalized for a CPG awaiting approval but you must still complete actionable items for CPG while it is approved. New NIK Modified CPG - Lists all CPGs which have had new NIK parts automatically added. 2/6/2023 Capacity Planning CREATING CPGs A step-by-step guide to CPG creation 2/6/2023 Creating CPGs: Step 1 → Select parts Step 1 → Select Parts: 1. Go to “Supplier Dashboard” 2. Under the “Non- Actionable Item” bar graph, click on the “All Parts” bar to open list of parts 3. Select all parts that belong in CPG (they will highlight green) 4. Click the “Create CPG” button on the bottom right corner of the page 2/6/2023 Capacity Planning Creating CPGs: Step 2 → Fill out fields Add brief/high level CPG description of CPG based on bottleneck Field is automatically updated. The date shown is when the 6 month validation is due. DO NOT CHANGE. Default is “Unique” Change status to “Grouped” if necessary using drop down bar Default work pattern is 2/8/5. Change if necessary Insert daily rate here. Example: If weekly rate is 2,500 and supplier has a 5 day work pattern. The daily rate is 500. Field is automatically updated after work pattern and daily rate added Add detailed bottleneck description 2/6/2023 Capacity Planning Click Save when done Creating CPG: Step 3 → Confirm CPG Step 3 → Confirm: 1. After clicking “Save” (previous slide) the following pop-up (below) will appear. Click “Yes.” 2. A second pop-up will appear (below). Click “Agree.” 2/6/2023 Capacity Planning Creating CPG: Important Notes/Takeaways Important Things to Note When Creating a CPG: ➢ • It is essential to create CPGs for new parts if necessary as soon as they are added to CMS. (If part DOES NOT belong in a CPG, do not add it to one) This allows both suppliers and Stellantis to accurately identify capacity available, flexibility b/w parts, and any capacity shortfalls ➢ It is especially important to be proactive in creating CPG for new programs (even if there are no releases yet) ➢ Adding the bottleneck in the comment section is imperative • This allows new supplier/Stellantis team members to understand the purpose of the CPGs. The comments remain in the CPG for future reference and they are tied to the SID/TID of the creator. ➢ New NIK level parts (AA to AB) should automatically be added to CPGs in which the old NIK part is. • Suppliers do not have to manually add them. ➢ Old NIK level parts should automatically drop/fall off from the Capacity Management System within 2 weeks ➢ Old NIK level parts should automatically drop/fall off from the from the CPG within 1 month • Suppliers do not have to manually delete them. ➢ Supplier can add parts with multiple supplier codes to a CPG. 2/6/2023 Capacity Planning MODIFY CPG A step-by-step guide to updating a current CPG 2/6/2023 MODIFY CPG → ADDING PARTS TO EXISITING CPG Modify CPGs: Add Parts to Existing CPG → Step 1 Step 1 → Select Parts: 1. Go to “Supplier Dashboard” 2. Under the “Non- Actionable Item” bar graph, click on the “All Parts” bar to open list of parts 3. Select all parts that belong in CPG (they will highlight green) 4. Click the “Add Part to CPG” button on the bottom right corner of the page 2/6/2023 Capacity Planning Modify CPGs: Add Parts to Existing CPG → Step 2 - 5 Step 2 → Select CPG: Step 4 → Fill out comment field: 1. Select the CPG you want to add parts to by clicking on the dot to the left of the CPG # 1. 2. Click “Continue” on the bottom right of the page. Change part status from “Unique” to “Grouped” if necessary and click “Save” on the bottom right of the page Step 3 → Update part status: Step 5 → Confirm: 1. 1. Change part status from “Unique” to “Grouped” if necessary 2/6/2023 Capacity Planning The following pop-up (below) will appear. Click “Agree.” MODIFY CPG → ADDING PARTS WITH MULTIPLE SUPPLIER CODES Modify CPGs: Add Parts with Multiple Supplier Codes → Step 1 Step 1 → Select CPG: 1. Go to “Supplier Dashboard” 2. Under the “Non- Actionable Item” bar graph, click on the “All CPG” bar to open list of CPGs 3. Select the CPG you want to add part to (it will highlight green) 4. Click “View CPG” on the bottom left of the page 2/6/2023 Capacity Planning Modify CPGs: Add Parts with Multiple Supplier Codes → Step 2 - 4 Step 2 → Add Part: Step 4 → Fill out Part # on blank field 1. 1. Manually add the part # you want to add in the blank field under “OTHER” 2. Manually add the supplier # associated with the part 3. Change part status from “Unique” to “Grouped” if necessary Click on the “Add Part” button Step 3 → Select “Other” 1. Click on the “Select” drop-down bar 2. Scroll all the way down and select “OTHER” Step 5 → Confirm: 1. 2/6/2023 Capacity Planning The following pop-up (below) will appear. Click “Agree.” MODIFY CPG → CREATE TEMPORARY BREAKPOINT Modify CPGs: Create Temporary Breakpoint → Step 1 - 2 Step 1 → Select CPG: Step 2 → Select “Breakpoint” Option 1. Go to “Supplier Dashboard” 1. 2. Under the “Non- Actionable Item” bar graph, click on the “All CPG” bar to open list of CPGs Select the CPG you want to create a temporary breakpoint to (it will highlight green) 2. Click “Breakpoint” on the bottom left of t the page 3. Click “Add Breakpoint” on the top right of the page 2/6/2023 Capacity Planning Modify CPGs: Create Temporary Breakpoint → Step 3 Step 3 → Fill out Fields Fill out ONLY fields highlighted in red below. Do NOT change/fill out any other fields. ONLY include any OT if previously discussed with CPG Specialist. This is rare. Note: A Temporary Breakpoint does NOT mean “temporary capacity.” It is simply a breakpoint that is considered “temporary” until the breakpoint is “validated” by a capacity/CPG specialist. Once reviewed/validated, the breakpoint will then switch from “temporary” to “validated” status 2/6/2023 Capacity Planning MODIFY CPG → CREATE IN-PROGRESS BREAKPOINT Modify CPGs: Create In-Progress Breakpoint → Step 1 - 2 Step 1 → Select CPG: Step 2 → Select “Breakpoint” Option 1. Go to “Supplier Dashboard” 1. 2. Under the “Non- Actionable Item” bar graph, click on the “All CPG” bar to open list of CPGs Select the CPG you want to create a temporary breakpoint to (it will highlight green) 2. Click “Breakpoint” on the bottom left of t the page 3. Click “Add Breakpoint” on the top right of the page 2/6/2023 Capacity Planning Modify CPGs: Create In-Progress Breakpoint → Step 3 Step 3 → Fill Out Required Fields Fill out ONLY fields highlighted in red below. Do NOT change/fill out any other fields. ONLY include any OT if previously discussed with CPG Specialist. This is rare. 2/6/2023 Capacity Planning REAL-WORLD EXAMPLE In-depth example of a supplier’s CPGs 2/6/2023 Real-World Example: Supplier Commodity Understanding the commodity Supplier manufactures visors for program X Each vehicle takes 2 visors (1 left and 1 right) There are 2 types of left hand visors offered ➢ Standard version ➢ “HomeLink” version. • This is a feature used to open garage doors HomeLink A vehicle gets either a left hand visor with HomeLink or a standard version visor (without HomeLink) Standard All right hand visors are standard 2/6/2023 Capacity Planning Real-World Example: Bottlenecks Understanding the bottlenecks Stellantis requires 10,000 visor sets for the program per week • 10,000 right and 10,000 left, which equals to 20,000 pieces per week Final Production Line/Final Assembly The supplier’s final production line is capable of 23,000 pieces per week • This is sufficient overall capacity but other bottlenecks need to be considered The left and right hand visors are not made in sets (at the same time side-by-side) • Both left and right parts run on the production lines back-to-back with full flex Although the final production line is capable of 23,000 total pieces per week, the supplier has additional bottlenecks for both standard and HomeLink visors. Injection Mold for Standard Visors The standard visors (left and right) have an injection tooling/cavity mold constraint with a capacity of 20,000 pieces per week with full flex HomeLink Installation The left hand visors with HomeLink are made in a separate line with longer cycle time. This limits the capacity to 12,000 pieces per week with full flex. HomeLink Tier 2 The supplier ALSO has a sub-tier constraint that limits the HomeLink feature to 10,000 pieces per week Although the Tier 1 supplier can support 12,000 pieces per week, their Tier 2 constraint matters Note: Sub-tier supplier bottlenecks NEED to always be considered. Confirm your tier 2 suppliers can support the capacities you are committing to. Even if they are directed components from Stellantis you must manage capacity. 2/6/2023 Capacity Planning Real-World Example: CPG Set-Up Setting up the CPGs CP00011111 CP00022222 CP00033333 Standard Visors (LT/RT) Visors with HomeLink (LT) All Visors (LT/RT) 20,000/week 10,000/week 23,000/week Bottleneck – Injection mold Bottleneck – Tier 2 All parts will be “Grouped” and All parts will be “Grouped” and POs updated to 20,000/week POs updated to 10,000/week Bottleneck – Final assembly line All parts will be “Grouped” and POs will reflect the bottleneck capacities in CPGs 1 &2 This CPG is important because it captures the final assembly line capacity of 23k/week Without it, Stellantis will assume the supplier can make 20k standard visors + 10k HomeLink visors = for a total of 30k pieces per week. This is not the case in this example. 2/6/2023 Capacity Planning Real-World Example: Bottlenecks CPG Matrix Example We encourage suppliers to use a matrix template like this to set up CPGs prior to loading them into the system. Suppliers can reach out to their CPG Specialists for the CPG matrix template and help on filling it out. Note: CPGs can get much more complex than the examples presented. Please reach out to your CPG specialist for help. 2/6/2023 Capacity Planning Thank You! Questions?
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