What is a Run&Rate Audit?
Run&Rate is a test under real serial conditions to verify throughput, capacity and quality of a line before (or during) delivery to the customer. Its objective: to confirm that the process complies with the agreed volume and parameters, to detect bottlenecks and to prevent deviations with early actions.
The purpose of a Run&Rate manufacturing test is to verify that the production line is capable of producing correctly, in serial production conditions, with the required rate and complying with the necessary and previously defined parameters, verifying that the manufacturing process complies with the quality parameters, and that the production volume is the one planned to meet the demand contracted by the customer.
Key Benefits
The main benefits of using Run&Rate are:
- Verify the consistency of the information contained in the PPAP (Production Part Approval Process) presented by the company to the customer.
- Provide the team with prior information and data to forecast product availability.
- Evaluate the company’s ability to achieve the production volume required by the customer.
- To provide a consistent mechanism for verification of a company’s actual production process, allowing action to be taken prior to mass production, in case of deviation from quality and production capacity.
“Kapture.io QMS allows data from Run&Rate audits to be collected, and analyzed so that the results can be immediately applied in process optimization.”
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Before you start: Minimum requirements
In order to carry out a Run&Rate audit, several essential prerequisite issues must be considered:
- In high-speed production, what is the right quantity of parts to produce?
- What are the bottlenecks within the production process, including warehousing and internal transportation?
- What is the total production yield, and what risks would lower yields entail for the customer?
- What is the capacity of each process?
- What are the capabilities of the run controllers and have they been evaluated by Run at Rate studies?
- General quality-related issues such as control plan, instructions, training, traceability, etc.
- It is important that these control measures are linked to an FMEA. FMEA.
How to perform a Run&Rate test?
1. Planning
Define volume (e.g., ≥ 1,000 pcs), time horizon, resources and simultaneous quality observations.
2. Execution in cadence
Draw up a plan indicating the estimated time required for each stage of the process, as well as the expected performance. Any possible disturbances that may appear within normality must be taken into account in the execution time. Produce as fast as possible (within a normal target), adapting the processes to the bottleneck.
3. Real-time registration
Set aside and retain defective or rejected parts leading to production losses so that they can be analyzed.
4. Issue List / CAPA
Record the results and define an Issue List if necessary.
5. Parallel audits
Simultaneously perform quality audits(Audits Kapture) and verify Control Plan, traceability, training and compliance with instructions.
How to interpret the results?
- It will be necessary to fill in reports of the results and to elaborate Action Plans(Issue List Kapture) in case of incomplete or failed part.
- It is advisable to have a production, manufacturing and quality representative to discuss the final results and determine the actions to be taken in this regard.
Kapture.io QMS allows you to collect data from Run&Rate audits, and analyze it so that the results can be immediately applied to process optimization.
Frequently asked questions
Content reviewed by:
Xavier Conesa Foix, CGO and Co-Founder of Kapture.io QMS
With more than 30 years dedicated to industrial quality improvement, Xavier combines technical expertise and strategic vision to transform quality control and incident management in the plant.
