某汽車階段性PPAP(英文)

1、GLOBAL PURCHASINGSupplier Technical AssistanceEdition 1, October 2002Phased PPAP Phased Production Part Approval ProcessPhased PPAPã Ford Motor CompanySupplier Technical AssistanceOctober, 2002Table of ContentsAcknowledgements Foreword CONTENTSPhased PPAP Introduction3PPAP Milestones4Phased PPA

2、P Overview5Phased PPAP Process Flow6Run-at-Rate7Phase 1 PPAP Quality Verification8Phase 2 PPAP Production Verification9Phase 3 PPAP Capacity Verification10Customer Disposition of the PSW13Expectations14Appendix A15Appendix B21Appendix C22Appendix D24AcknowledgementsThe development of Phased PPAP and

3、 the supporting systems has represented a substantial undertaking. We would like to thank the members of the Ford development team as well as acknowledge key suppliers for their time and effort in this project, including:· Dana· Lear· Magna· Meridian Automotive· SY Systems T

4、echnologies· TRW· VisteonForeword Phased PPAPVision Partner with suppliers to drive flawless execution in vehicle launch and deliver products that surpass customer expectations.TeamworkFord Motor Company and its suppliers must work together to deliver a quality part, produced on-time, that

5、 meets all Ford engineering requirements. To accomplish this goal, Ford and its suppliers must place trust, integrity and accuracy above all else in the Production Part Approval Process.Supplier Responsibility in Flawless LaunchSupplier delivers a successful launch with no quality or capacity issues

6、 that affect the Ford production process. What Phased PPAP Means to Ford Motor CompanyPhased Production Part Approval Process (PPAP) is the process in which the supplier demonstrates they can produce quality parts and provide these parts to Ford at the required volume. Successful completion of Phase

7、d PPAP demonstrates supplier readiness using the production machinery, tooling, and facilities with the intended personnel at the intended production rate that is capable of meeting the Ford required volumes (as specified on the Request for Quotation).Phased PPAP IntroductionAs a result of reviewing

8、 industry best practices, Ford has modified PPAP into a three phased approach that will independently verify product quality, production readiness and capacity prior to Job #1. Phased PPAP will provide the launch team with an improved method of risk management and provide a consistent method for a s

9、upplier to determine if they meet Ford projected program volumes (See Appendix A). Phased PPAP ensures that the supplier process has the potential to produce a quality product that consistently meets Ford requirements during an actual production run at the quoted production rate.Phased PPAP separate

10、s the PPAP process into three phases: q Phase 1 is called 'Quality Verification'q Phase 2 is called Production Verificationq Phase 3 is called Capacity Verification.This Phased approach requires the supplier to provide promise dates to Ford for each of the three events, and additionally incl

11、udes the requirement for the supplier to indicate that Run at Rate has been successfully completed. (Appendix B, Table 1 summarizes these requirements)Note: For less complex components/commodities/production streams, it is possible to complete multiple phases as a single event.Phased PPAP OverviewSc

12、opePhased PPAP redefines both the interpretation and execution of the Production Part Approval Process (PPAP) (including the Part Submission Warrant (PSW) and is required for the following:1. A new part or product (i.e., a specific part, material or color not previously supplied to the specific cust

13、omer).2. Correction of a discrepancy on a previously submitted part.3. Product modified by an engineering change to design records, specifications, or materials.4. Any situations required by Section I.3.1 from the AIAG PPAP Manual, 3rd Ed. (See Appendix C).These requirements are a minimum; local ope

14、rations may require additional approvals.Phased PPAP will eventually be applied globally in the Production Part Approval Process. Suppliers are required to apply the Phased PPAP process, including promise dates, confirmation and event completion for all new tooled parts.Phased PPAP applies to both n

15、ew vehicle programs and for vehicles currently in production, i.e. "running changes". Benefits of Phased PPAPSuppliers and Ford will benefit from the use of Phased PPAP. Phased PPAP:· Requires planning for launch· Divides PPAP activities into more manageable segments· Ensure

16、s assessment of supplier ability to handle production volume· Provides a consistent mechanism to determine capacity verification· Provides the program team with additional measures to forecast program readiness· Provides clarity to the existing PPAP process Phased PPAP MilestonesPhase

17、 2Phase 3Phase 1Quality VerificationCapacity VerificationProduction VerificationThe complete actual production stream (tool, line, facilities, personnel, etc.) intended for this specific program / launch is in place and operationalDimensional, Lab and ES testing complete from all tools, cavities, mo

18、lds, production streams (including all appearance approvals)Supplier submits Part Submission Warrant (PSW).Parts are produced from the complete actual production stream (tooling, equipment, facilities, personnel)Capacity Verification is demonstrated by yielding quality parts to meet a minimum of one

19、 day of Ford production ( Daily Planning Volume DPV)Parts are produced from a minimum of one production stream (tool, line, facilities, etc.)Dimensional, Lab and Engineering Specification (ES) testing complete for this production stream (less appearance approvals)Initial Run at RateParts produced fr

20、om a production stream (from a minimum of one production tool / line / process stream) at production feeds and speeds.Provides an early indicator if supplier can make future timingParts from the initial Run at Rate may be used for Phase 1 and Phase 2.Reference: Ford Product Development System (FPDS)

21、J1LR*CCCPPAPHSCSI1/2PS KO*Note: 1PP Build occurs during <LR> Launch Readiness phase of FPDS, which is 4.5 months prior to J1 for an S3 and above program. Supplier completes Capacity Verification (Phase 3 PPAP) target completion is 4 weeks prior to Job 1 - demonstrating ability to meet Ford req

22、uired volumes under intended operating pattern supplier dispositions completion and provides Demonstrated Weekly Capacity numbers in systemSupplier completes Production Verification (Phase 2 PPAP) for specific program / plant by In Plant Date for 1PP build phase (all 19 elements of PPAP on parts fro

23、m actual production streams (tools/cavities/molds/lines/etc.) supplier dispositions in system and forwards PSW documentation.Supplier completes Quality Verification (Phase 1 PPAP) (16 of 19 elements of PPAP - excludes PSW, Appearance Approval and Master Sample) supplier dispositions in systemSupplie

24、r completes a minimum of one production stream and performs initial Run-at-Rate supplier indicates successful Run-at-Rate in systemSupplier receives notification in work queue supplier is required to provide promise dates for Quality Verification, Production Verification, and Capacity VerificationPa

25、rts are released -supplier is sourcedPhased PPAP Process FlowSupplier has equipment and tooling for a minimum of one production stream on the plant floor. Supplier does an initial run-at-rate at production feeds and speeds.Production linePartsPhased PPAP: Detailed Process FlowINITIAL RUN-AT-RATEInit

26、ial Run-at-RateDEFINITION: Once tooling and equipment are in place at the intended supplier production facility for a minimum of one line/tool/cavity/production stream, supplier performs an initial run of the production stream. This run is typically a minimum of one to eight hours and a minimum of 3

27、00 pieces. The process must be run at production feeds and speeds based on the yield requirement for that product stream, supporting the latest authorized program volumes (based on the RFQ (Request for Quote). The initial run may be more or less than 300 pieces, as appropriate for the commodity or p

28、art complexity - requires approval from authorized customer quality representative. For external suppliers, this would be Supplier Technical Assistance (STA). TIMING: This must completed in time to support the subsequent completion of Quality Verification (Phase 1). SYSTEM: Upon successful completio

29、n, the supplier inputs a Y indicator into the CMMS3 Vehicle Parts Progress screen this event is date-stamped. System will reflect RACFID as identification of system user.DOCUMENTATION: No additional documentation required (documented by supplier in system)STA ROLE: Business practices may vary by reg

30、ion.Production linePartsQuality-Verified PartsDimensional Verification, Lab and ES Testing CompletedPhase 1 is CompletePhase One: Quality VerificationDEFINITION: The supplier must achieve Quality Verification (Phase 1) by completing dimensional verification and ES (engineering specification) testing

31、. Completion of Quality Verification requires 16 of the 19 elements of PPAP as stated in the AIAG PPAP manual, 3rd Edition (See Appendix D) (all items except item (13) PSW, (14) Appearance Approval, and (17) Master Sample). Upon successful completion of the 16 of 19 elements, the supplier has met th

32、e Phase 1 requirement. TIMING: This must completed in time to permit completion of Production Verification (Phase 2) prior to the In-Plant Date (IPD) for the 1PP vehicle build. SYSTEM: Upon successful completion of Phase 1, the supplier inputs Ready for Inspection (Y code) into CMMS3 Vehicle Parts P

33、rogress Detail Screen. The system then date stamps the completion of the event, and automatically accepts the part as approved (disposition code Q) regardless of PPAP level. STA can override with Approve (A) or Reject (R). System will reflect RACF ID as identification of system user.DOCUMENTATION: S

34、upplier shall retain supporting documentation of all 16 elements per QS-9000, ISO/TS-16949 - and make them readily available to customer if requested.STA ROLE: STA may verify as necessary, and has the ability to override supplier declaration to disposition the Phase 1 completion using codes for Appr

35、oval (A) or Reject (R). Phased PPAP: Detailed Process FlowQUALITY VERIFICATIONUpon completing initial run-at-rate at production feeds and speeds, supplier completes the necessary dimensional verification and Engineering Specs (ES) testing on parts - this completes Quality Verification (Phase 1). Sup

36、pliers shall use parts from the Initial Run-at-Rate for Quality Verification.Dimensional, Lab and ES Testing and all Appearance Approvals for all parts from all production streamsPhase 2 Production Verification is completeProduction Stream APartsPartsPartsProduction Stream BProduction Stream COnce t

37、he supplier has all production streams/tools/cavities in place on the plant floor, the supplier proceeds to achieve all required levels of testing and dimensional verification for all production streams intended for a specific program (lead program or lead plant), including all appearance approvals

38、and completed PSW documentation.Phased PPAP: Detailed Process FlowPRODUCTION VERIFICATIONPhase Two: Production VerificationDEFINITION: Once the supplier has completed Phase 1, the supplier should follow the necessary steps to achieve all part testing, verifications and runs-at-rate from all actual p

39、roduction streams (all tools /lines /molds /cavities /facilities etc.) required for a specific program launch. All appearance approvals must be completed (color, graining, surface appearance). All 19 elements of PPAP must be completed per AIAG Guidelines (PPAP, 3rd edition). Deficiency in meeting Ph

40、ase 2 requirements by 1PP IPD and subsequent builds will require an WERS alert and build support plan. TIMING: This must completed by the 1PP IPD date (prior to 1PP) to support program build event as required for this launch (lead program or lead plant). SYSTEM: Upon successful completion of Phase 2

41、, the supplier inputs Ready for Inspection (Y code) into CMMS3, and system date stamps the completion of the event. System will reflect RACF ID of system user.DOCUMENTATION: Supplier must complete all 19 elements of PPAP including PSW submission and maintain supporting documentation. See AIAG PPAP M

42、anual Table I.4.1 for submission requirements.STA ROLE: STA will disposition Production Verification (Phase 2) completion for PPAP level 2-5 suppliers, and has ability to override PPAP level 1 supplier declaration, with Approve (A) or Reject (R). STA tracks supplier performance in Supplier Improveme

43、nt Metrics (SIM).CBACapacity Verification: Phase 3 PPAP Requirements - DetailCapacity Verification forms and requirements may vary by region and program. The following describes how to complete Phase 3 documentation (Capacity Verification) for North America. The supplier will input Weekly Demonstrat

44、ed Capacity into CMMS3.Prepare for Capacity Verification -Form PP-S-F041 (Attachment A)Suppliers must verify Production Readiness by completing Form PP-S-F041, Capacity Verification. This worksheet will assess if a supplier has a true production environment in place and has adequately prepared their

45、 organization and sub-suppliers for the start of production and ramp-up. 1. The supplier is to input production plan variables on Form PP-S-F041 and determine if the Potential Capacity Forecast meets Ford Motor Companys Capacity Planning Volume (CPV). 2. The supplier must complete the Shared Capacit

46、y Analysis section on Form PP-S-F041 and determine if capacity or production hours are oversold.3. The supplier must complete the Production Readiness Questionnaire.4. The supplier then summarizes their results and determines if they can proceed to Perform Capacity Verification (Form PP-S-F042).Perf

47、orm Capacity Verification -Form PP-S-F042 (Attachment B)Suppliers must Perform Capacity Verification by completing Form PP-S-F042. This worksheet will determine if a supplier can produce quality parts at production feeds and speeds in the necessary production environment.1. The supplier must determi

48、ne the number of parts to be produced for Capacity Verification. The quantity must be sufficient to validate that the process performs in a manner sufficient to support the required Ford Capacity Planning Volume. The supplier is required to support the Ford Motor Company standard operating pattern a

49、nd schedule: based on 5 days, 100 hours, 2 shifts (North America) or 3 shifts (Europe). The minimum required length of the Capacity Verification is one day of the Fords daily production requirement at production feeds and speeds. To demonstrate process robustness, the production run shall be perform

50、ed over all applicable shifts, unless otherwise approved by the STA Engineer. 2. The supplier must enter planned values into Form PP-S-F042 and run the process at production feeds and speeds. Record values for Total Good Parts, Scrap/Off-Line Rework Parts, Downtime, Breaks, and Changeover Time.3. In

51、dicate the percent (above or below) the daily planned volume produced.4. Determine Overall Equipment Effectiveness (OEE). This is calculated from the actual production data.5. Determine Weekly Production Volume from your process run. 6. Summarize the results and determine if you meet Ford Motor Comp

52、any requirements.7. Input Demonstrated Capacity Number into CMMS3 system (Weekly Production Volume).8. Upon completion of the above, external suppliers shall maintain records of the Capacity Verification worksheets per QS-9000 / TS-16949 requirements, and provide a copy of the completed Capacity Ver

53、ification worksheets to STA Engineers as requested. Customer Disposition of Phased PPAPApproval · Successful completion of Phase 2 with no Worldwide Engineering Release Alert (WERS) alert.· Meets all 19 elements of PPAP (See Appendix D). The part meets all customer specifications and requi

54、rements for all molds, tools, cavities, lines etc. and the part has been manufactured under production conditions. Rejected · Does not meet one or more of the 19 elements of PPAP must have an approved WERS engineering alert to authorize shipment. What PPAP is NotAn approved PPAP part is not:

55、83; A part produced somewhere other than the actual production source (e.g. parts manufactured from tools located at a tool shop)· A part manufactured off prototype tools· A part with an alert· Parts produced from process other than the intended production processExpectations Sub-Supp

56、lierPer Q1 2002, sub-suppliers are required to meet all PPAP requirements. Tier 1 Suppliers shipping to Ford must use a PPAP process for their sub-suppliers. Additionally, it is recommended that suppliers require their sub-suppliers to verify they can meet required volumes at the required time - suppliers and/or sub-suppliers may use the Ford Capacity Verification documentation.Phased PPAP Application.· Suppliers are able to view / update data related to their own u