某汽車階段性PPAP(英文)

1、Global PurchasingEdition 1, October 2002Edition 1, October 2002Acknowledgements Foreword ContentsPhased PPAP Introduction3PPAP Milestones4Phased PPAP Overview5Phased PPAP Process Flow6Run-at-Rate7Phase 1 PPAP Quality Verification8Phase 2 PPAP Production Verification9Phase 3 PPAP Capacity Verificatio

2、n10Customer Disposition of the PSW13Expectations14Appendix A15Appendix B21Appendix C22Appendix D24The development of Phased PPAP and 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

3、for their time and effort in this project, including:DanaLearMagnaMeridian AutomotiveSY Systems TechnologiesTRWVisteonPhased 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 p

4、roduction rate.Phased PPAP separates the PPAP process into three phases: Phase 1 is called Quality VerificationPhase 2 is called Production VerificationPhase 3 is called Capacity Verification.This Phased approach requires the supplier to provide promise dates to Ford for each of the three events, an

5、d additionally includes the requirement for the supplier to indicate thatRun 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.Bene

6、fits of Phased PPAPSuppliers and Ford will benefit from the use of Phased PPAP. Phased PPAP:Requires planning for launchDivides PPAP activities into more manageable segmentsEnsures assessment of supplier ability to handle production volumeProvides a consistent mechanism to determine capacity verific

7、ationProvides the program team with additional measures to forecast program readinessProvides clarity to the existing PPAP processPhase 2Phase 3Phase 1Phase 2Phase 3Phase 1Quality VerificationCapacity VerificationProduction VerificationQuality VerificationCapacity VerificationProduction Verification

8、The 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, molds, production streams (including all The complete actual production stream (to

9、ol, line, facilities, personnel, etc.) intended for this specific program / launch is in place and operationalDimensional, Lab and ES testing complete from all tools, cavities, molds, production streams (including all appearance approvals)Supplier submits Part Submission Warrant (PSW).Parts are prod

10、uced from the complete actual production stream (tooling, equipment, facilities, personnel)Capacity Verification is demonstrated by yielding quality parts to meet a minimum of one day of Ford production ( Daily Planning Volume DPV)Parts are produced from a minimum of one production stream (tool, lin

11、e, facilities, etc.)Dimensional, Lab and Engineering Specification (ES) testing complete for this production stream (less appearance approvals)Initial Run at RateInitial Run at RateParts produced from a production stream (from a minimum of one production tool / line / process stream) at production f

12、eeds andParts produced from 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 Parts from the initial Run at Rate may be used for Ph

13、ase 1 and Phase 2.J1LR*CCCPPAPHSCSI1/2PS KOJ1LR*CCCPPAPHSCSI1/2PS KO*Note: 1PP Build occurs during 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 - demonst

14、rating ability to meet Ford required 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 1

15、9 elements of PPAP on parts from 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) supplie

16、r dispositions in systemSupplier 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 Verificati

17、on, and Capacity VerificationParts are released -supplier is sourcedPhased PPAP Process FlowSupplier completes Capacity Verification (Phase 3 PPAP) target completion is 4 weeks prior to Job 1 - demonstrating ability to meet Ford required volumes under intended operating pattern supplier dispositions

18、 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 from actual production streams (tools/cavities/molds/lines/etc.) suppli

19、er 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 systemSupplier completes a minimum of one production stream and performs initial

20、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 VerificationParts are released -supplier is sourcedPhased PPAP Process FlowSupplie

21、r 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 lineSupplier has equipment and tooling for a minimum of one production stream on the plant floor. Supplier does an initial run-at-rate

22、 at production feeds and speeds.Production linePartsPhased PPAP: Detailed Process FlowINITIAL RUN-AT-RATEInitial Run-at-RateInitial 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, sup

23、plier performs an initial run of the production stream. This run is typically a minimum of one to eight hours and a minimum of 300 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 (

24、based on the RFQ (Request for Quote). The initial run may be more or less than 300 pieces, as appropriate for the commodity or part complexity - requires approval from authorized customer quality representative. For external suppliers, this would be Supplier Technical Assistance (STA). TIMING: This

25、must completed in time to support the subsequent completion of Quality Verification (Phase 1). SYSTEM: Upon successful completion, 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.DO

26、CUMENTATION: No additional documentation required (documented by supplier in system)STA ROLE: Business practices may vary by region.Production lineProduction linePartsQuality-Verified PartsDimensional Verification, Lab and ES Testing CompletedPhase 1 is CompletePhase One: Quality VerificationPhase O

27、ne: Quality VerificationDEFINITION: The supplier must achieve Quality Verification (Phase 1) by completing dimensional verification and ES (engineering specification) testing. Completion of Quality Verification requires 16 of the 19 elements of PPAP as stated in the AIAG PPAP manual, 3rd Edition (Se

28、e 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 the Phase 1 requirement. TIMING: This must completed in time to permit completion of Production Verification (Phase 2) prior to

29、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 Progress Detail Screen. The system then date stamps the completion of the event, and automatically accepts the part as approved

30、 (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: Supplier shall retain supporting documentation of all 16 elements per QS-9000, ISO/TS-16949 - and make them readily available t

31、o 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 Approval (A) or Reject (R). Phased PPAP: Detailed Process FlowPhased PPAP: Detailed Process FlowQUALITY VERIFICATIONUpon completin

32、g 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). Suppliers shall use parts from the Initial Run-at-Rate for Quality Verification.Dimensional, La

33、b 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 the supplier has all production streams/tools/cavities in place on the plant floor, the suppl

34、ier 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 and completed PSW documentation.Phased PPAP: Detailed Process FlowPRODUCTION VERIFICATIONPha

35、se 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 production streams (all tools /lines /molds /cavities /facilities etc.) required for a specif

36、ic 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 Phase 2 requirements by 1PP IPD and subsequent builds will require an WERS alert and build sup

37、port plan. 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 the supplier has all production streams/tools/cavities in place on

38、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 and completed PSW documentation.Phased PPAP: Detailed Process Flow

39、PRODUCTION 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 production streams (all tools /lines /molds /cavities /facilities e

40、tc.) 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 Phase 2 requirements by 1PP IPD and subsequent builds will require a

41、n 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, the supplier inputs Ready for Inspection (Y code) into CMMS3, an

42、d 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 Manual Table I.4.1 for submission requirements.STA ROLE: STA will d

43、isposition 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 Improvement Metrics (SIM).CBAPercent (above/below) Daily Planned Volume (8 Hr Shift)Percent (above/below) Daily Planned Volume (8 Hr Shift)% Parts Required / 8 Hr Shift)-(Total Good Parts Produced / 8 Hr Shift (Parts Required / 8 Hr Shift)(x