福特APQP状态报告程序-APQP(Ford)-第二部分.ppt

ModuleIntroduction组成部分介绍,PrototypeBuild样件制造,1-38,ProcessFlow过程流程,FeedbackAssessment&CorrectiveAction反馈、评估和纠正措施,Product&ProcessValidation产品与过程确认,ProcessDesign&Development过程设计和开发,ProductDesign&Development产品设计和开发,PrototypeBuild样件制造,Plan&Define计划与定义,1-39,PrototypeBuildOverview样件制造概述,APQPPrototypeBuildelementssupportthesuccessfulplanningandconstructionofPrototypeBuildunits,whichprovideanunderstandingofthevehicles:APQP样件制造要素支持样件制造单位的成功的策划和构造，提供对于车辆的如下理解：Design设计Functionality功能性Manufacturability可制造性,1-40,PrototypeBuildElements样件制造要素,ThePBCPsupportstheplanningandconstructionofprototypesbydocumentingtheprocessstepsofthePrototypeBuildphase.PBCP通过将样件制造阶段的过程步骤文件化支持样件的策划和构造。ThePrototypeBuildensuresthatthecustomerreceivesCPsmanufacturedandassembledpriorto1PP.样件制造确保顾客在1PP前收到制造和装配好的CP。,1-41,PBCP(PrototypeBuildControlPlan)DefinitionPBCP（样件制造控制计划）定义,ThePBCPdescriptionofthedimensionalmeasurementsandmaterial/functionalteststhatoccurduringtheCPbuild.PBCP描述了发生在CP制造中的尺寸测量和材料/功能试验Itisthefirstsummarydocumentthatindicates:是说明如下事项的摘要文件：ThestepsbetweenPrototypeBuildandPre-LaunchleadingtotheProductionControlPlan产生生产控制计划的样件制造和试生产之间的步骤Theprocessstepstoidentifyandalignboththeproductscharacteristicsanditstargets识别和调整产品特性及其指标的过程步骤,1-42,PBCPGeneralExpectationsPBCP总的期望,Productcharacteristicsarereviewed评审产品特性ThosecharacteristicsrequiredforPBCPsareidentified.确定PBCP所要求的特性。AllpotentialsignificantandcriticalcharacteristicsfromtheDFMEAsmustbeincluded.必须包括DFMEA输出的所有潜在重要和关键特性。Theprocessparameterconditionsmustbedocumented.过程参数条件必须被文件化。Thisincludesallspecialtooling,manufacturing,andassemblyconditions.包括所有特殊工具、制造和装配条件。,1-43,PBCPChecklistPBCP检查清单,1-44,PrototypeBuild样件制造,Definesthemanufactureandassemblyofcomponents,subsystems,systems,andvehiclessuppliedtothecustomerforbuildsoccurringpriortothe1PPtrialrun定义在1PP试运行前的样件制造，以提供给零部件、子系统、系统和车辆的制造和装配。Includesnotonlytheactualbuildprocess,butthepreparationforthebuildsothatCPsaresuppliedtothecustomerpriorto1PP不仅包括实际的制造过程，而且包括为了在1PP前将CP提交给顾客而进行的制造准备,1-45,PrototypeBuildExpectations样件制造期望,PBCPsarefollowed.按照PBCP进行Suppliersreceiveallnecessaryinformationandparticipateaccordingtotheprogramsscheduleandtiming.供方收到所有必要的信息并按照项目时间安排定时参与Thetimingforchangeswillbeinlinewiththenextbuildphase.更改的时间选择应该符合下一个制造阶段。Allprototypematerialsmustmeet100percentofthedimensionalspecificationsandfunctionalrequirementsatdeliverytomeettheCPIn-PlantDate.交付时所有样件材料必须100%满足尺寸规范和功能要求以满足CP进厂日期。,1-46,PrototypeBuildExpectations(Continued)样件制造期望（续）,QualitylevelsarecheckedagainstthePBCP.按照PBCP检查质量等级。Dimensionalandfunctionaldataisavailableforreviewbythecustomeroneachpart.顾客可以获得每个零件的尺寸和功能数据以进行评审。Suppliersprovidecustomerswithanytestingandcheckingrequirementsforprove-outoftheirpartdesign.供方向顾客提供所有试验和检查要求以证明零件设计是适当的。AnActionMatrixisdevelopedtocaptureandresolveallconcernsfoundduringbuildandanysubsequentlab,plant,and/orroadtesting,andallconcernsarereviewedwiththeprogramteamandappropriatemanagement.开发“措施矩阵”以获得和解决在制造和所有试验室、工厂和/或道路试验中并发的问题，和所有项目小组及适当的管理层评审的问题。,1-47,PrototypeBuildChecklist样件制造检查清单,1-48,ModuleIntroduction组成部分介绍,ProcessDesignandDevelopment过程设计和开发,1-49,ProcessFlow过程流程,FeedbackAssessment&CorrectiveAction反馈、评估和纠正措施,Product&ProcessValidation产品与过程确认,ProcessDesign&Development过程设计和开发,ProductDesign&Development产品设计和开发,PrototypeBuild样件制造,Plan&Define计划与定义,1-50,Elements要素,Facilities,Tools,andGauges1.设施、工具和量具2.ManufacturingProcessFlow2.制造过程流程3.ProcessFMEA3.过程FMEA4.MeasurementSystemEvaluation4.测量系统评价5.Pre-LaunchControlPlan5.试生产控制计划6.OperatorProcessInstructions6.操作工过程指导书7.PackagingSpecifications7.包装规范,1-51,Facilities,Tools,andGauges(8)设施、工具和量具(8),Thiselementidentifiesthenew,additional,refurbished,andrelocatedfacilitiesandresourcesnecessarytomanufacturethecustomer-specifiedproductatdesignatedquantityandqualitylevels.本要素确定了以规定的数量和质量等级制造顾客指定的产品所需的新的、额外的、更新的和重新部署的设施和资源。Theelementalsoidentifiesthetoolsandgaugesusedinprocessmachinerytotransformrawmaterialintofinishedpartsorassemblies.本要素还确定了用于将原材料转换为完成的零件或组装件的机械加工过程的工具和量具。,1-52,Expectations期望,Theplanningandexecutionofthiselementmustalignwith:tomilestonesPQOSDeliverables本要素的计划和执行必须配合里程碑到PQOS需交付的事务Facilitypermits,planningapproval,drawings,andutilitiesmustbeincludedontheManufacturingTimingPlan.Inaddition,fundingapprovalsmustbecompleted.制造时间计划中必须包括设施许可、计划批准、图样和效用。另外，必须完成资金批准。Theprogramteammustapprovestatisticalrequirementsandacceptancecriteriabeforesourcingoftoolsorgaugescanbemade.在可以进行工具和量具的外包之前，项目小组必须批准统计要求和接收准则。,1-53,Expectations(Continued)期望（续）,AlltoolsandgaugesmustcomplywithToolingandEquipmentSupplementrequirements.所有工具和量具必须符合工装和设备补充要求。Trialrunsshouldoccuratthemachinebuilderslocationtoqualifyalltools.应该在机械制造者的现场进行试运行，以验证所有工具合格。Allcorrectiveactionsforfacilities,tools,andgaugesnotmeetingcustomerrequirementsmustbecompletedbeforetheProductionTrialRun.必须在产品试生产前完成针对不满足顾客要求的设施、工具和量具的所有纠正措施。Toolsandgaugesmustbedelivered,setup,andapprovedintheirspecifiedfacilitiesbeforetheProductionTrialRun.产品试生产前工具和量具必须以制定的设施交付、安装和批准。,1-54,Facilities,Tools,andGaugingChecklist设施、工具和量具检查清单,1-55,ManufacturingProcessFlow(13)制造过程流程（13）,Thiselementisagraphicrepresentationofthecurrentorproposedsequenceofthemanufacturingprocesstoensurethattheprocessdefinition,PFMEA,andControlPlanscanbecreatedandanalyzedintheappropriatesequence.本要素制造过程的当前的或建议的次序的图解表示，以确保以适当的次序建立和分析过程定义、PFMEA和控制计划。,1-56,ManufacturingProcessFlowExpectations制造过程流程期望,ManufacturingProcessFlowgeneralexpectationsarethat:制造过程流程总的期望是：Across-functionalteamledbyVOEngineeringdevelopsaManufacturingProcessflowcharttoserveasaninputtoPFMEAs.由VO工程领导的横向职能小组开发制造过程流程图作为PFMEA的输入。TheprocessflowchartsaredevelopedusingPFMEAsandsurrogateprocessestoserveasinputfornewprocessesandtechnologies.使用PFMEA和替代的过程开发过程流程图，作为新过程和技术的输入。Thecurrentproductionflowchartsmaybemodifiedtoshowrevisionstotheprocessflow.可以修改当前的生产流程图，以显示对过程流程的修改。,1-57,ManufacturingProcessFlowChecklist制造过程流程检查清单,1-58,ProcessFMEA(14)过程FMEA(14),ThePFMEAisasystematicapproachusedbyamanufacturing-responsibleteamtoensurethatpotentialprocess-relatedfailuremodesandtheirassociatedcauseshavebeenconsideredandresolved.PFMEA是制造职责小组使用的确保已经考虑并解决了潜在的与过程相关的失效模式及其相关原因的系统化的方法。,1-59,Expectations期望,AllProcessFMEAsarepreparedbyacross-functionalteamledbyManufacturingEngineeringfollowingthestepsdefinedintheFMEAguideline.所有过程FMEA以制造工程为领导的横向职能小组按照FMEA指南中定义的步骤进行准备。ProcessFMEAsmustbeestablishedanytimethat:当存在如下事项时，必须建立过程FMEA：Newprocesses,technologies,products,orproductfeaturesareintroduced.引入新的过程、技术、产品或产品特征。Qualityrisksareidentifiedthatcannotberesolvedthroughdesignchanges.确定质量风险不能通过设计变更加以解决。Majorqualityconcernshavenotbeenresolvedduringthecurrentproductionmodelyear.在当前的生产模型年中，没有解决重大的涉及质量的问题。,1-60,Expectations(Continued)期望（续）,Listofrecommendedactionsandlessonslearnedisincorporatedintheprocess(continuousimprovement).将列出的“建议措施”和学到的经验和并在过程（持续改进）中。Poke-a-Yokehasbeenusedinaddressingcorrectiveactions.制定纠正措施中使用防错方法（Poke-a-Yoke）。,1-61,ProcessFMEAChecklist过程FMEA检查清单,ProcessFMEA,1-62,MeasurementSystemEvaluation(15)测量系统评价（15）,Thiselementassessesthevariationofthemeasurementsystem,anddetermineswhetheritisacceptableformonitoringtheproductionprocess.本要素评估测量系统的变差，确定是否可以接受测量系统监控生产过程。,1-63,Expectations期望,Correlationstandardsarereachedandagreedtowiththecustomerforduplicategaugesortestequipment.已达到相同的测量或试验设备的相关标准和顾客的批准。Gaugeinstructionsandvisualaidstoensureappropriateuseofgaugeandtestequipmentinproduction.测量指导书和目视辅具确保在生产中适当的使用测量和试验设备。Allmeasurementsystems(gaugesandtestequipment)mustbemodifiedtoreflectthelatestengineeringpartlevelbeforetheProductionTrialRun.在产品试生产前必须修改所有测量系统（测量和试验设备）以反映最新工程零件等级。,1-64,Expectations(Continued)期望（续）,Theuser/customermustbegiventheopportunitytoreviewandconcurwiththegaugesandtestequipmentstudyresultsbeforetheProductionTrialRun.产品试生产前使用者/顾客,必须有机会评审和批准测量和试验设备研究结果。TheMeasurementSystemEvaluationmustberepeatedandapprovedfollowingallgaugeandtestequipmentmodifications.所有测量和试验设备更改后,必须重新进行测量系统评价并获得批准。TheProductionControlPlanmustalignwiththeMeasurementSystemsDevelopmentplan.生产控制计划必须配合测量系统开发计划。GaugeRepeatabilityandReproducibilitystudiesmustbeconductedonallmeasurementsystems.所有测量系统必须进行量具重复性和再现性研究。,1-65,MeasurementSystemEvaluationChecklist测量系统评价检查清单,1-66,Pre-LaunchControlPlan(16)试生产控制计划（16）,Thisisadescriptionofthedimensionalmeasurementsandmaterial/functionalin-processtestsorchecksthatoccurafterprototypebuilds,butbeforefullproduction对发生在样件制造后，全面生产前的尺寸测量、过程中材料/功能试验或检查的描述。,1-67,Expectations期望,Legitimate/appropriateinspectionsamplesizes,frequencies,controlmethod,etc.inclusivetopre-launchphaseofproductionareincluded.在生产的试生产阶段包含合理/适当的检验样本容量、频率、控制方法等。Allproduct&processcharacteristicsforpre-launchcontrolplansareidentifiedandreviewed.确定和评审试生产控制计划的所有产品和过程特性。ResultsfromthePBCPandDFMEAprovidetheoutlineforthePre-LaunchControlPlan.PBCP和DFMEA的结果提供了试生产控制计划的概要。TheProductionControlPlanforthecurrentproductionmodelisusedtoassistinthedevelopmentofthePre-LaunchControlPlanifAPQPElements8and13havenotbeeninitiated.如果APQP要素8和13还未启动，使用当前生产模式的生产控制计划协助开发试生产控制计划。,1-68,Pre-LaunchControlPlanChecklist试生产控制计划检查清单,1-69,OperatorProcessInstructions(17)操作工过程指导书（17）,Thiselementdescribesthedetailsofthecontrolsandactionsthatoperatingpersonnelmustperformtoproducequalityproducts.本要素描述操作人员为生产质量合格的产品所必须执行的控制和措施的详细情况。Theseinstructionsaredividedintotwomajorcomponents:这些指导书分为两个主要部分：Descriptionoftheprocess过程描述Operatorinstructions操作供指导书,1-70,Expectations期望,AcompletedOperatorProcessInstructionspackage.完成的整套操作工过程指导书。Instructionsdevelopedtobeusedduringaproductiontrialruntoensuretheprocessperformsasintended.在产品试生产中使用开发的指导书以确保过程按预期执行。OperatorProcessInstructionsdescribeallprocessstepsnecessarytoproduceaqualityproduct.Thetraininginstructionsmustinclude:操作工过程指导书描述了生产质量合格的产品所需的所有过程步骤。培训指导书必须包括：Detailedinstructions详细的指导书Visualaids目视辅具Anyotherqualitymaterialsnecessarytosupporttheproductionoperator支持生产操作工所需的任何质量材料,1-71,OperatorProcessInstructionsChecklist操作工过程指导书检查清单,1-72,PackagingSpecifications(18)包装规范（18）,Thiselementdescribesthedesignanddevelopmentoftheend-itemshipmentpackaging,includinginteriorpartitions.本要素描述产品最后出货包装的设计与开发，包括包装内部的分隔配置。,1-73,Expectations期望,Pastissuesonsimilarorsurrogatepackagingarediscussedandresolvedbytheteam.小组讨论和解决相似或替代的包装中过去发生的问题。Correctiveactionsexistforanypackagingissuesidentifiedthataffectproductperformanceandcharacteristics.确定对于任何影响产品性能和特性的包装问题的现存纠正措施。Supplierandthereceivingplantagreeuponpackagingrequirements.供方和接收工厂就包装要求达成一致。Packagingevaluationmusttestthepackagingundertheexpectedconditionsoftransportandmaterialhandling.包装评价必须在运输和材料处理期望的条件下测试包装Packagingdesignmustensurethattheproductperformanceandcharacteristicswillremainunchangedduringpacking,shipping,andunpacking.包装设计必须确保在包装、运输和打开包装过程中，产品性能和特性保持不变。,1-74,PackagingSpecificationsChecklist包装规范检查清单,1-75,ModuleIntroduction组成部分介绍,ProductandProcessValidation产品和过程确认,1-76,ProcessFlow过程流程,FeedbackAssessment&CorrectiveAction反馈、评估和纠正措施,Product&ProcessValidation产品与过程确认,ProcessDesign&Development过程设计和开发,ProductDesign&Development产品设计和开发,PrototypeBuild样件制造,Plan&Define计划与定义,1-77,Elements要素,ProductionTrialRun产品试生产2.ProductionControlPlan生产控制计划3.PreliminaryProcessCapability初始过程能力4.ProductionValidationTesting生产确认试验5.PartSubmissionWarrant零件提交保证书,1-78,ProductionTrialRun(19)产品试生产（19）,TheProductionTrialRunisavalidationoftheeffectivenessofthemanufacturingandassemblyprocess,usingproductiontooling,equipment,environment(includingproductionoperators),facilities,andcycletimes.产品试生产是对制造和装配过程、使用的生产工具、设备、环境（包括生产操作工）、设施和生产周期时间的有效性的确认。,1-79,Expectations期望,Productionfacility,tooling,equipment,personnel,packaging,operators,PSW-1parts,andPre-LaunchControlPlansareusedontrialrun.在试生产中使用生产设施、工具、设备、人员、包装、操作工、PSW-1零件和试生产控制计划。ConcernsfromthetrialrunthatcouldpreventRun-at-Rateandcapacitybydaterequiredarelisted.列出在生产试运行中可能影响到“节拍生产”与“产能”的关注点。Correctivedesignandprocessactionsareestablished.建立设计和过程纠正措施。ThePre-LaunchControlPlanisfollowedduringthe1PPProductionTrialRun.1PP产品试生产中按照试生产控制计划进行。TheProductionTrialRunisusedtoconfirmoraddalignmentbetweenproductandprocesscharacteristics.产品试生产用来在产品和过程特性之间进行确认或加强调整。OperatorProcessInstructionsarefollowedduringtheProductionTrialRun.在产品试生产中按照操作工过程指导书执行。,1-80,ElementChecklist要素检查清单,1-81,ProductionControlPlan(20)生产控制计划（20）,TheProductionControlPlanisawrittenplanofthesystemsforcontrollingpartsandprocessesduringfullproduction.生产控制计划是在全面生产中控制零件和过程的系统的书面计划。ThisdocumentisbasedonthePre-LaunchControlPlanandisalivingdocumentthatmustbeupdatedtoreflecttheadditionsanddeletionsofcontrols,basedonexperiencegainedintheprocessofproducingparts.本文件基于试生产控制计划，是一份动态文件，必须基于从零件生产过程中获得经验，加以更新以反映对控制的增加和删减。,1-82,Expectations期望,ReactionPlansspecifycorrectiveandcontainmentactionsnecessarytoavoidoperatingout-of-controlorproducingnonconformingproducts.反应计划明确规定纠正和限制措施，以避免操作失去控制或生产不合格产品。TheProductionControlPlanisdevelopedbyacross-functionalteamledbyManufacturingEngineering.由以制造工程为领导的横向职能小组开发生产控制计划。TheProductionControlPlanfollowsthemethodologydocumentedintheAIAG/APQPandControlPlanReferencemanual.生产控制计划遵循AIAG/APQP和控制计划参考手册中提供的方法。TheoutcomesofthefinalPBCPprovidethebasisforthePre-LaunchControlPlanthatinturnbecomesthesourcefortheProductionControlPlan.最终PBCP的输出给试生产控制计划提供了基础，然后顺次成为生产控制计划的资源。,1-83,ElementChecklist要素检查清单,1-84,PreliminaryProcessCapability(21)初始过程能力(21),ThePreliminaryProcessCapabilityisastatisticalstudyandassessmentoftheabilitytoproduceproductwithinspecifications.初始过程能力是对按照规范生产产品的能力的统计研究和评估。,1-85,Expectations期望,Resultsareanalyzedtoverifystatisticalstabilityaswellascapability.分析结果以验证统计稳定性和能力。Thestatisticalandanalyticaltechniquesusedtodeterminecapabilitymustbeacceptabletothecustomer.顾客必须接受用来确定能力的统计和分析工具。PreliminaryProcessCapabilitystudiesmustbeperformedinawaythatalignswiththedevelopmentofthePre-LaunchControlPlan.初始过程能力研究必须以配合试生产控制计划的开发的方式进行。PreliminaryProcessCapabilitystudiesmustbecompleted:初始过程能力研究必须完成：ThecustomermusthavetheopportunitytoreviewthestudiesbeforeProductionPartApproval.在生产件批准前，顾客必须有机会对研究进行评审。,1-86,ElementChecklist要素检查清单,1-87,ProductionValidationTesting(22)生产确认试验（22）,Engineeringtestsvalidatethattheproductsmadefromtheproductiontoolsandprocessesmeetengineeringspecifications工程试验确认生产工具和过程制造的产品满足工程规范。InternalandexternalsupplierstoFordMotorCompanymustcompleteProductionValidationTestingasarequirementofaPSWfor1PP作为1PP的PSW要求，福特汽车公司的内、外部供方必须完成生产确认试验。,1-88,Expectations期望,APVTestPlan,includingprogressachieved,isestablished.建立PV试验计划，包括取得的改进。ConcernsidentifiedduringPVTestingareassigned,resolutionsareimplemented,andsolutionsaretrackedthroughclosureoftheconcern.指出在PV试验阶段识别的关注事项，解决方案被实施，而且跟踪解决方案，彻底解决了关注事项。Allparts,end-itemsorcomponents,subsystems,andsystemsforPVTestingmustbecompletedbeforetheFEUBuildaccordingtotheengineeringspecificationsinthePre-LaunchControlPlan.必须在根据工程规范建立PEU前，在试生产控制计划中完成所有零件，产品最终阶段基组成部分，子系统和系统的PV试验。Allcustomer-specifieddimensional,material,functional,andreliabilitytestsmustbecompletedbeforeProductionPartApproval.生产件批准前必须完成所有顾客规定的尺寸、材料、功能和可靠性试验。,1-89,ElementChecklist要素检查清单,1-90,PartSubmissionWarrant(23)零件提交保证书（23）,ThePSWensuresthatengineeringdesignrequirementsaremetbythesupplier,andthattheprocessusediscapableofp