第二部分：某汽车APQP状态报告程序

1、Module Introduction组成部分介绍Prototype Build样件制造1-38Process Flow过程流程程FeedbackAssessment &CorrectiveAction反馈、评评估和纠纠正措施施Product &ProcessValidation产品与过过程确认认Process Design& Devel opment过程设计计和开发发Product Design& Development产品设计计和开发发PrototypeBuild样件制造造Plan &Define计划与定定义1-39PrototypeBuildOverview样件制造造概述APQP Pro

2、totypeBuildelementssupportthesuccessfulplanningandconstruction of PrototypeBuildunits,whichprovideanunderstanding of thevehicles:APQP样件制造造要素支支持样件件制造单单位的成成功的策策划和构构造，提提供对于于车辆的的如下理理解：Design设计Functionality功能性Manufacturability可制造性性1-40PrototypeBuildElements样件制造造要素ThePBCPsupportstheplanningand constructio

3、nofprototypes by documenting theprocess steps of thePrototypeBuildphase.PBCP通过将样样件制造造阶段的的过程步步骤文件件化支持持样件的的策划和和构造。ThePrototype Build ensuresthatthecustomerreceivesCPs manufacturedandassembled prior to 1PP.样件制造造确保顾顾客在1PP前收到制制造和装装配好的的CP。1-41PBCP (PrototypeBuildControlPlan)DefinitionPBCP（样件制造造控制计计划）定定义Th

4、ePBCPdescriptionofthedimensionalmeasurements andmaterial/functional tests thatoccurduring theCPbuild.PBCP描述了发发生在CP制造中的的尺寸测测量和材材料/功功能试验验Itisthefirstsummarydocumentthat indicates:是说明如如下事项项的摘要要文件：ThestepsbetweenPrototypeBuildand Pre-LaunchleadingtotheProductionControl Plan产生生产产控制计计划的样样件制造造和试生生产之间间的步骤骤T

5、heprocessstepstoidentifyandalignboththeproducts characteristicsandits targets识别和调调整产品品特性及及其指标标的过程程步骤1-42PBCP GeneralExpectationsPBCP总的期望望Product characteristicsarereviewed评审产品品特性Thosecharacteristicsrequiredfor PBCPsareidentified.确定PBCP所要求的的特性。Allpotential significant andcriticalcharacteristicsfromth

6、eDFMEAsmust be included.必须包括括DFMEA输出的所所有潜在在重要和和关键特特性。Theprocessparameterconditionsmust be documented.过程参数数条件必必须被文文件化。This includes allspecial tooling, manufacturing, andassemblyconditions.包括所有有特殊工工具、制制造和装装配条件件。1-43PBCP ChecklistPBCP检查清单单1-44PrototypeBuild样件制造造Defines themanufactureandassemblyofcompo

7、nents,subsystems,systems,and vehicles supplied to thecustomerforbuilds occurringpriortothe1PP trial run定义在1PP试运行前前的样件件制造，以提供供给零部部件、子子系统、系统和和车辆的的制造和和装配。Includesnotonlytheactual build process, butthepreparationfor thebuildsothat CPsaresuppliedtothe customer prior to 1PP不仅包括括实际的的制造过过程，而而且包括括为了在在 1PP前将C

8、P提交给顾顾客而进进行的制制造准备备1-45PrototypeBuildExpectations样件制造造期望PBCPsarefollowed.按照PBCP进行Suppliersreceiveallnecessary information andparticipateaccordingtothe programsscheduleandtiming.供方收到到所有必必要的信信息并按按照项目目时间安安排定时时参与Thetiming forchanges willbeinlinewith thenext build phase.更改的时时间选择择应该符符合下一一个制造造阶段。Allprototyp

9、e materialsmust meet100 percentofthe dimensional specifications andfunctional requirementsatdeliverytomeet theCPIn-PlantDate.交付时所所有样件件材料必必须100% 满足足尺寸规规范和功功能要求求以满足足CP进厂日期期。1-46PrototypeBuildExpectations (Continued)样件制造造期望（续）Quality levelsarecheckedagainst thePBCP.按照PBCP检查质量量等级。Dimensionalandfunctiona

10、ldata is availableforreview by thecustomeroneach part.顾客可以以获得每每个零件件的尺寸寸和功能能数据以以进行评评审。Suppliersprovidecustomerswithanytestingandcheckingrequirements forprove-outoftheirpartdesign.供方向顾顾客提供供所有试试验和检检查要求求以证明明零件设设计是适适当的。AnAction Matrixisdeveloped to captureand resolveall concerns found duringbuildandany s

11、ubsequentlab,plant,and/or roadtesting,and allconcernsarereviewedwiththeprogramteam andappropriatemanagement.开发“措措施矩阵阵”以获获得和解解决在制制造和所所有试验验室、工工厂和/或道路路试验中中并发的的问题，和所有有项目小小组及适适当的管管理层评评审的问问题。1-47PrototypeBuildChecklist样件制造造检查清清单1-48ModuleIntroduction组成部分分介绍Process DesignandDevelopment过程设计计和开发发1-49Process

12、Flow过程流程程FeedbackAssessment &CorrectiveAction反馈、评评估和纠纠正措施施Product &ProcessValidation产品与过过程确认认Process Design& Development过程设计计和开发发Product Design& Development产品设计计和开发发PrototypeBuild样件制造造Plan &Define计划与定定义1-50Elements要素Facilities,Tools,and Gauges1.设设施施、工具具和量具具2.ManufacturingProcessFlow2.制制造造过程流流程3.Proc

13、ess FMEA3.过过程FMEA4.MeasurementSystemEvaluation4.测测量系统统评价5.Pre-Launch ControlPlan5.试试生产控控制计划划6.OperatorProcess Instructions6.操操作工过过程指导导书7.PackagingSpecifications7.包包装规范范1-51Facilities,Tools,and Gauges(8)设施、工工具和量量具(8)This elementidentifiesthenew,additional,refurbished,and relocatedfacilities andresour

14、cesnecessary to manufacture thecustomer-specifiedproductatdesignated quantity andquality levels.本要素确确定了以以规定的的数量和和质量等等级制造造顾客指指定的产产品所需需的新的的、额外外的、更更新的和和重新部部署的设设施和资资源。Theelementalso identifiesthe tools andgaugesusedinprocess machinerytotransformraw material intofinishedpartsorassemblies.本要素还还确定了了用于将将原材料

15、料转换为为完成的的零件或或组装件件的机械械加工过过程的工工具和量量具。1-52Expectations期望Theplanningand executionofthis elementmustalignwith: to milestonesPQOS Deliverables本要素的的计划和和执行必必须配合合里程碑到 PQOS需交付的的事务Facilitypermits,planningapproval,drawings, andutilitiesmustbeincludedontheManufacturingTimingPlan.Inaddition, fundingapprovals must

16、becompleted.制造时间间计划中中必须包包括设施施许可、计划批批准、图图样和效效用。另另外，必必须完成成资金批批准。Theprogramteam mustapprovestatisticalrequirementsand acceptancecriteriabefore sourcing of tools or gaugescanbemade.在可以进进行工具具和量具具的外包包之前，项目小小组必须须批准统统计要求求和接收收准则。1-53Expectations(Continued)期望（续续）Alltoolsand gaugesmust complywith Toolingand Eq

17、uipmentSupplement requirements.所有工具具和量具具必须符符合工装装和设备备补充要要求。Trialruns shouldoccuratthemachinebuilderslocationtoqualifyalltools.应该在机机械制造造者的现现场进行行试运行行，以验验证所有有工具合合格。Allcorrectiveactions forfacilities,tools,and gaugesnotmeetingcustomerrequirementsmustbecompletedbefore theProduction Trial Run.必须在产产品试生生产前完完

18、成针对对不满足足顾客要要求的设设施、工工具和量量具的所所有纠正正措施。Toolsandgauges mustbedelivered,setup, andapprovedintheirspecifiedfacilitiesbeforethe ProductionTrialRun.产品试生生产前工工具和量量具必须须以制定定的设施施交付、安装和和批准。1-54Facilities,Tools,and GaugingChecklist设施、工工具和量量具检查查清单1-55Manufacturing ProcessFlow(13)制造过程程流程（13）This elementisagraphic rep

19、resentation of thecurrent or proposed sequence of themanufacturing processtoensure thatthe processdefinition,PFMEA, andControl Plans canbecreated andanalyzedintheappropriatesequence.本要素制制造过程程的当前前的或建建议的次次序的图图解表示示，以确确保以适适当的次次序建立立和分析析过程定定义、PFMEA和控制计计划。1-56Manufacturing ProcessFlowExpectations制造过程程流程期期望

20、Manufacturing ProcessFlowgeneral expectationsarethat:制造过程程流程总总的期望望是：A cross-functionalteamledbyVOEngineeringdevelopsaManufacturing Processflowchart to serve as an input to PFMEAs.由VO工程领导导的横向向职能小小组开发发制造过过程流程程图作为为PFMEA的输入。Theprocessflowcharts aredevelopedusingPFMEAs andsurrogateprocesses to serve as i

21、nput fornewprocesses andtechnologies.使用PFMEA和替代的的过程开开发过程程流程图图，作为为新过程程和技术术的输入入。Thecurrentproduction flowchartsmay be modified to showrevisions to theprocess flow.可以修改改当前的的生产流流程图，以显示示对过程程流程的的修改。1-57Manufacturing ProcessFlowChecklist制造过程程流程检检查清单单1-58Process FMEA(14)过程FMEA (14)ThePFMEAisasystematic appr

22、oach usedbyamanufacturing-responsible teamtoensure thatpotential process-relatedfailure modes andtheirassociated causeshave beenconsideredandresolved.PFMEA是制造职职责小组组使用的的确保已已经考虑虑并解决决了潜在在的与过过程相关关的失效效模式及及其相关关原因的的系统化化的方法法。1-59Expectations期望AllProcessFMEAsarepreparedbyacross-functional teamled by Manufact

23、uringEngineeringfollowing thestepsdefined in theFMEA guideline.所有过程程FMEA以制造工工程为领领导的横横向职能能小组按按照FMEA指南中定定义的步步骤进行行准备。Process FMEAs mustbeestablishedany timethat:当存在如如下事项项时，必必须建立立过程FMEA：Newprocesses,technologies, products,orproduct features areintroduced.引入新的的过程、技术、产品或或产品特特征。Quality risks areidentified

24、thatcannot be resolved throughdesign changes.确定质量量风险不不能通过过设计变变更加以以解决。Majorquality concerns havenot beenresolvedduring thecurrent productionmodelyear.在当前的的生产模模型年中中，没有有解决重重大的涉涉及质量量的问题题。1-60Expectations(Continued)期望（续续）List of recommendedactionsandlessonslearned is incorporatedintheprocess(continuousim

25、provement).将列出的的“建议议措施”和学到到的经验验和并在在过程（持续改改进）中中。Poke-a-Yokehasbeenused in addressingcorrectiveactions.制定纠正正措施中中使用防防错方法法（Poke-a-Yoke）。1-61Process FMEAChecklist过程FMEA检查清单单Process FMEA1-62MeasurementSystemEvaluation(15)测量系统统评价（15）This elementassessesthe variationofthemeasurementsystem,anddetermineswheth

26、er it is acceptablefor monitoringthe productionprocess.本要素评评估测量量系统的的变差，确定是是否可以以接受测测量系统统监控生生产过程程。1-63Expectations期望Correlationstandardsare reachedand agreedtowith thecustomerforduplicate gaugesortest equipment.已达到相相同的测测量或试试验设备备的相关关标准和和顾客的的批准。Gaugeinstructionsand visualaids to ensureappropriateuseofga

27、ugeand testequipment in production.测量指导导书和目目视辅具具确保在在生产中中适当的的使用测测量和试试验设备备。Allmeasurementsystems(gauges andtest equipment)mustbemodifiedtoreflect thelatestengineeringpartlevelbeforethe ProductionTrialRun.在产品试试生产前前必须修修改所有有测量系系统（测测量和试试验设备备）以反反映最新新工程零零件等级级。1-64Expectations(Continued)期望（续续）Theuser/custome

28、rmust be given theopportunitytoreviewand concurwith thegaugesand testequipment study resultsbefore theProduction Trial Run.产品试生生产前使使用者/顾客,必须有有机会评评审和批批准测量量和试验验设备研研究结果果。TheMeasurementSystem Evaluationmustberepeatedandapprovedfollowing allgaugeandtestequipmentmodifications.所有测量量和试验验设备更更改后,必须重重新进行行测量系系统

29、评价价并获得得批准。TheProductionControl Planmustalignwith theMeasurementSystems Development plan.生产控制制计划必必须配合合测量系系统开发发计划。GaugeRepeatability andReproducibilitystudiesmust be conductedonallmeasurementsystems.所有测量量系统必必须进行行量具重重复性和和再现性性研究。1-65MeasurementSystemEvaluationChecklist测量系统统评价检检查清单单1-66Pre-Launch Control

30、Plan(16)试生产控控制计划划（16）This is adescriptionofthe dimensional measurementsandmaterial/functionalin-process tests or checksthat occur after prototypebuilds, butbeforefullproduction对发生在在样件制制造后，全面生生产前的的尺寸测测量、过过程中材材料/功功能试验验或检查查的描述述。1-67Expectations期望Legitimate/appropriate inspectionsample sizes,frequencies

31、,controlmethod, etc.inclusive topre-launch phase of productionare included.在生产的的试生产产阶段包包含合理理/适当当的检验验样本容容量、频频率、控控制方法法等。Allproduct& processcharacteristics forpre-launch controlplansare identifiedand reviewed.确定和评评审试生生产控制制计划的的所有产产品和过过程特性性。Results fromthe PBCPand DFMEA providethe outlinefor thePre-Launc

32、h ControlPlan.PBCP和DFMEA的结果提提供了试试生产控控制计划划的概要要。TheProductionControl Planfor thecurrent productionmodelisusedtoassistinthe development of thePre-Launch ControlPlanifAPQP Elements 8and 13 havenot beeninitiated.如果APQP要素8 和13还还未启启动，使使用当前前生产模模式的生生产控制制计划协协助开发发试生产产控制计计划。1-68Pre-Launch ControlPlanChecklist试生

33、产控控制计划划检查清清单1-69OperatorProcess Instructions(17)操作工过过程指导导书（17）This elementdescribes thedetails of thecontrolsandactionsthat operatingpersonnelmustperform to producequalityproducts.本要素描描述操作作人员为为生产质质量合格格的产品品所必须须执行的的控制和和措施的的详细情情况。Theseinstructionsare dividedintotwomajorcomponents:这些指导导书分为为两个主主要部分分：Desc

34、riptionoftheprocess过程描述述Operatorinstructions操作供指指导书1-70Expectations期望A completedOperatorProcess Instructionspackage.完成的整整套操作作工过程程指导书书。Instructionsdeveloped to be usedduring aproductiontrialruntoensure theprocess performs as intended.在产品试试生产中中使用开开发的指指导书以以确保过过程按预预期执行行。OperatorProcess Instructionsdescr

35、ibeallprocessstepsnecessarytoproducea qualityproduct.The training instructionsmust include:操作工过过程指导导书描述述了生产产质量合合格的产产品所需需的所有有过程步步骤。培培训指导导书必须须包括：Detailedinstructions详细的指指导书Visualaids目视辅具具Anyotherqualitymaterialsnecessary to supportthe productionoperator支持生产产操作工工所需的的任何质质量材料料1-71OperatorProcess Instruct

36、ionsChecklist操作工过过程指导导书检查查清单1-72PackagingSpecifications(18)包装规范范（18）This elementdescribes thedesignand development of theend-itemshipmentpackaging, includinginteriorpartitions.本要素描描述产品品最后出出货包装装的设计计与开发发，包括括包装内内部的分分隔配置置。1-73Expectations期望Past issuesonsimilar or surrogatepackagingare discussedandresolv

37、edbythe team.小组讨论论和解决决相似或或替代的的包装中中过去发发生的问问题。Corrective actionsexistfor anypackagingissues identifiedthataffectproductperformanceandcharacteristics.确定对于于任何影影响产品品性能和和特性的的包装问问题的现现存纠正正措施。Supplierandthe receivingplantagreeupon packagingrequirements.供方和接接收工厂厂就包装装要求达达成一致致。Packagingevaluationmust testthe pa

38、ckagingundertheexpectedconditionsoftransportand material handling.包装评价价必须在在运输和和材料处处理期望望的条件件下测试试包装Packagingdesign mustensure thatthe productperformanceand characteristicswill remainunchangedduring packing, shipping,andunpacking.包装设计计必须确确保在包包装、运运输和打打开包装装过程中中，产品品性能和和特性保保持不变变。1-74PackagingSpecifications

39、Checklist包装规范范检查清清单1-75ModuleIntroduction组成部分分介绍Product andProcess Validation产品和过过程确认认1-76Process Flow过程流程程FeedbackAssessment &CorrectiveAction反馈、评评估和纠纠正措施施Product &ProcessValidation产品与过过程确认认Process Design& Devel opment过程设计计和开发发Product Design& Development产品设计计和开发发PrototypeBuild样件制造造Plan &Define计划与定定

40、义1-77Elements要素Production Trial Run产品试生生产2.ProductionControlPlan生产控制制计划3.Preliminary ProcessCapability初始过程程能力4.ProductionValidationTesting生产确认认试验5.PartSubmissionWarrant零件提交交保证书书1-78Production Trial Run(19)产品试生生产（19）TheProductionTrialRunisavalidation of theeffectiveness of themanufacturing andassembl

41、yprocess,usingproduction tooling, equipment,environment(includingproduction operators), facilities, andcycletimes.产品试生生产是对对制造和和装配过过程、使使用的生生产工具具、设备备、环境境（包括括生产操操作工）、设施施和生产产周期时时间的有有效性的的确认。1-79Expectations期望Production facility,tooling,equipment, personnel,packaging,operators, PSW-1 parts,andPre-LaunchCo

42、ntrol Plans areused on trial run.在试生产产中使用用生产设设施、工工具、设设备、人人员、包包装、操操作工、PSW-1零件和试试生产控控制计划划。Concernsfrom thetrialrunthatcouldprevent Run-at-Rate andcapacitybydate required arelisted.列出在生生产试运运行中可可能影响响到“节节拍生产产”与“产能”的关注注点。Corrective designandprocessactions areestablished.建立设计计和过程程纠正措措施。ThePre-LaunchControl

43、 Planisfollowedduring the1PPProductionTrialRun.1PP产品试生生产中按按照试生生产控制制计划进进行。TheProductionTrialRunisusedtoconfirm or addalignmentbetweenproduct andprocess characteristics.产品试生生产用来来在产品品和过程程特性之之间进行行确认或或加强调调整。OperatorProcess Instructionsarefollowedduring theProduction Trial Run.在产品试试生产中中按照操操作工过过程指导导书执行行。1-

44、80Element Checklist要素检查查清单1-81Production ControlPlan(20)生产控制制计划（20）TheProductionControl Planisawritten planofthe systemsfor controlling parts andprocessesduring fullproduction.生产控制制计划是是在全面面生产中中控制零零件和过过程的系系统的书书面计划划。This document is based on thePre-Launch ControlPlanandisalivingdocumentthatmust be upd

45、atedtoreflecttheadditions anddeletionsofcontrols, based on experiencegained in theprocess of producingparts.本文件基基于试生生产控制制计划，是一份份动态文文件，必必须基于于从零件件生产过过程中获获得经验验，加以以更新以以反映对对控制的的增加和和删减。1-82Expectations期望ReactionPlansspecify correctiveand containment actionsnecessary to avoid operatingout-of-controlorprodu

46、cingnonconformingproducts.反应计划划明确规规定纠正正和限制制措施，以避免免操作失失去控制制或生产产不合格格产品。TheProductionControl Planisdeveloped by across-functionalteam ledbyManufacturing Engineering.由以制造造工程为为领导的的横向职职能小组组开发生生产控制制计划。TheProductionControl PlanfollowsthemethodologydocumentedintheAIAG/APQP andControlPlan Referencemanual.生产控制

47、制计划遵遵循AIAG/APQP和控制计计划参考考手册中中提供的的方法。Theoutcomesofthe final PBCPprovidethebasisfor thePre-Launch ControlPlanthat in turnbecomesthesource fortheProductionControl Plan.最终PBCP的输出给给试生产产控制计计划提供供了基础础，然后后顺次成成为生产产控制计计划的资资源。1-83Element Checklist要素检查查清单1-84PreliminaryProcess Capability(21)初始过程程能力(21)ThePrelimin

48、aryProcessCapability is astatisticalstudyand assessmentofthe abilitytoproduceproduct withinspecifications.初始过程程能力是是对按照照规范生生产产品品的能力力的统计计研究和和评估。1-85Expectations期望Results areanalyzedtoverifystatisticalstability as wellascapability.分析结果果以验证证统计稳稳定性和和能力。Thestatisticaland analyticaltechniquesused to determ

49、inecapability mustbeacceptabletothecustomer.顾客必须须接受用用来确定定能力的的统计和和分析工工具。PreliminaryProcess Capabilitystudiesmust be performedina waythat alignswith thedevelopmentofthePre-LaunchControl Plan.初始过程程能力研研究必须须以配合合试生产产控制计计划的开开发的方方式进行行。PreliminaryProcess Capabilitystudiesmust be completed:初始过程程能力研研究必须须完成：The

50、customermusthave theopportunitytoreviewthe studiesbefore ProductionPartApproval.在生产件件批准前前，顾客客必须有有机会对对研究进进行评审审。1-86Element Checklist要素检查查清单1-87Production ValidationTesting(22)生产确认认试验（22）Engineeringtestsvalidatethat theproductsmade fromthe productiontoolsand processesmeet engineering specifications工程试

51、验验确认生生产工具具和过程程制造的的产品满满足工程程规范。Internalandexternalsuppliers to FordMotorCompanymust complete ProductionValidationTesting as arequirementofaPSWfor 1PP作为1PP的PSW要求，福福特汽车车公司的的内、外外部供方方必须完完成生产产确认试试验。1-88Expectations期望A PV TestPlan,including progress achieved,isestablished.建立PV试验计划划，包括括取得的的改进。Concernsidentif

52、ied duringPVTesting areassigned,resolutionsare implemented,andsolutions aretracked throughclosureoftheconcern.指出在PV试验阶段段识别的的关注事事项，解解决方案案被实施施，而且且跟踪解解决方案案，彻底底解决了了关注事事项。Allparts, end-itemsorcomponents,subsystems,andsystemsforPVTestingmust be completedbeforethe FEUBuildaccordingtothe engineering specifi

53、cations in thePre-Launch ControlPlan.必须在根根据工程程规范建建立PEU前，在试试生产控控制计划划中完成成所有零零件，产产品最终终阶段基基组成部部分，子子系统和和系统的的PV试验。Allcustomer-specified dimensional,material,functional,and reliability tests mustbecompleted beforeProduction PartApproval.生产件批批准前必必须完成成所有顾顾客规定定的尺寸寸、材料料、功能能和可靠靠性试验验。1-89Element Checklist要素检查查清单1-90Part SubmissionWarrant(23)零件提交交保证书书（23）ThePSW ensuresthatengineeringdesignrequirements aremetbythe supplier,andthattheprocessused is capableofp