They’re both "final exams" before mass production, so why do some suppliers breeze through R@R only to be forced into overnight rework by 2TP?
Newcomers often mix them up, thinking, "Isn’t it just running the production line before mass production? How different can it be?"
Very different.
I’ve seen too many suppliers apply their American R@R mindset to a German 2TP audit, only to get schooled by the auditor on the spot.
Let’s break down exactly how these two systems work.
01 The Definition: What is R@R?
Let’s correct a common misconception: R@R stands for Run @ Rate, not Ready for Ramp-up.
While the ultimate goal is "production readiness," the name itself reveals the core logic—running at the required pace.
American OEMs (Ford, GM, etc.) want to verify your production claims. If you say your capacity is fine, prove it by running at the actual production takt time.
The German 2-Tage-Produktion (2TP) is stricter: running for one day isn’t enough. You must run for two consecutive days, and your lower-tier suppliers must run with you.
02 One is an "Exam," the Other is a "Drill"
To visualize it:
R@R is like a scheduled driving test.
The examiner gives you a heads-up, you practice your car, and you drive a set route at a set speed. The focus is on: Can the equipment hold the takt time? Are the operators skilled? Does the yield meet the target?
Hit the key metrics, and you’re generally cleared to go.
2TP is an unannounced military drill.
The auditor from the VW group might show up at your factory gate and demand two consecutive days of non-stop production (at least 6 hours per day). They don’t just check you; they check if your raw materials arrive on time, if your sub-suppliers can keep up, and if your logistics packaging can withstand the pressure.
One tests "capability," the other tests "system robustness."
03 Key Differences Every Supplier Must Know
📌 Time Requirements Differ
R@R usually involves one shift; producing around 300 parts is often enough to prove the point.
2TP has a hard rule: two consecutive days with no major interruptions. Some projects require production based on the OEM’s actual daily demand. If you need to supply 5,000 parts per day, you must produce 5,000 parts.
R@R usually involves one shift; producing around 300 parts is often enough to prove the point.
2TP has a hard rule: two consecutive days with no major interruptions. Some projects require production based on the OEM’s actual daily demand. If you need to supply 5,000 parts per day, you must produce 5,000 parts.
📌 Process Capability is a Hard Threshold
The German requirement for Cpk is ≥1.33 (or 1.67/2.0 for special characteristics). This is a red line. While the Americans also look at process capability, they focus more on whether the overall capacity meets forecasted demand.
The German requirement for Cpk is ≥1.33 (or 1.67/2.0 for special characteristics). This is a red line. While the Americans also look at process capability, they focus more on whether the overall capacity meets forecasted demand.
📌 Supply Chain Scope is Different
This is where most people trip up.
This is where most people trip up.
For American projects, managing your own factory is usually sufficient. For German projects, your Tier 2 and Tier 3 suppliers are in the crosshairs. Auditors will trace raw material batches, ask about your procurement cycle, and demand documentation from sub-suppliers.
I know an injection molding boss who passed R@R on the first try but failed 2TP because a small hardware supplier’s materials didn’t arrive on time.
📌 Documentation Systems are Completely Different
American documentation is relatively flexible, focusing on capacity analysis reports and process parameter records.
American documentation is relatively flexible, focusing on capacity analysis reports and process parameter records.
The German system? You need 19 checklists (E1-E19) and 6 acceptance records (F1-F6). Missing one is an automatic fail. Plus, the scoring is a strict 0/5/10 scale, not a simple pass/fail.
04 Practical Tips for Suppliers
First, don’t use the same materials for all clients.
I’ve seen suppliers change the cover of a Ford R@R report and hand it to VW, only to be called out immediately for not meeting Formel Q requirements. The documentation logic for American and German systems is fundamentally different.
Second, you must "rehearse" before 2TP.
Before the official audit, run a full rehearsal using the 2TP standard. Check: Do you have enough raw materials for two days? Can your sub-suppliers respond instantly? Do you have backup plans for equipment failure?
Third, R@R focuses on pace, 2TP focuses on resilience.
The Americans ask, "How fast can you run?" The Germans ask, "How long can you keep running?" Your preparation strategy must reflect this difference.
05 The Bottom Line
Facing the OEM, suppliers are always the underdog. But knowing the rules versus not knowing the rules leads to completely different outcomes.
At their core, R@R and 2TP are both risk mitigation tools for the OEM.
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