FORD流程简介

1、1FORD流程简介早期参与团队标准化管理/汇报 采用唯一的，全球通用到，有纪律的流程尽量减少返工和重复。在产品开发过程早期，与供应商更融洽地合作利用福特跨功能团队与供应商一起在现场工作(4次拜访)使用共同的，明确的交付报告和结构化的管理评审模式GPDS（ Global Product Development System）是FORD公司全球产品开发体系，替代原FPDS福特产品开发体系 GPDS 全球产品开发体系3GPDS 供应商管理过程供应商管理过程-总览总览 PTC/M1DJPTCC PA FDJ PEC LR/ FEC M1 VP TT PP MP1 UnitPTC UnitPA33.5M

2、BJ127MBJ125MBJ120.5MBJ127.5MBJ134MBJ117MBJ113MBJ18MBJ15.5MBJ15MBJ12.5MBJ10MBJ1供应商选供应商选点开始点开始高影响供高影响供应商选择应商选择跨功能小组形成跨功能小组形成启动会议启动会议开始开始第一次现场第一次现场评审评审第二次现场第二次现场评审评审第三次现场第三次现场评审评审第四次现场第四次现场评审评审解决问题解决问题决定：决定：是否进是否进行试生行试生产？产？更新供应商更新供应商 APQP/PPAP 准备状态评估报告准备状态评估报告 (A表表)(655/654) PTC-Program Target Compatib

3、ility 项目目标整合PAPA- -Program Approval 项目批准 FDJ-FDJ-Final Data Judgement 工程数据发布VPVP- -Verification Prototype (OTS)样件验证PEC-PEC-Preliminary Engineering Completion 工程数据冻结项目节点（里程碑） LR- -Launch Readiness 生产准备就绪（可生产）TTTT- -Tooling Trial 工装样件 （PSW1）PPPP- -Pilot Production 试生产（可售）(PSW2)MP1MP1- -Mass Production

4、 1 量产 (PSW3)Job #1Job #1 整车投产项目节点（里程碑）6 PTC/M1DJPTCC PA FDJ M1 UnitPTC UnitPA33.5MBJ127MBJ125MBJ120.5MBJ127.5MBJ134MBJ117MBJ113MBJ15MBJ12.5MBJ10MBJ1(655/654) PEC LR/ FEC VP TT PP8MBJ15.5MBJ1 MP1供应商选供应商选点开始点开始关键供关键供应商选择应商选择跨功能小组形成跨功能小组形成启动会议启动会议开始开始第一次现场第一次现场评审评审第二次现场第二次现场评审评审第三次现第三次现场评审场评审第四次现场第四次现场

5、评审评审解决问题解决问题决定：决定：是否进是否进行试生行试生产？产？更新供应商更新供应商 APQP/PPAP 准备状态评估报告准备状态评估报告 (A表表)FORD项目跟踪（装车）节点项目批准工程数据发布手工样件OTSFORD项目开发节点PPAP 的18项Design RecordsDesign Records设计记录设计记录Engineering Change DocumentsEngineering Change Documents工工程变更文件程变更文件Engineering Approval Engineering Approval 工程批准工程批准Design FMEADesign F

6、MEA设计设计FMEAFMEAProcess Flow DiagramsProcess Flow Diagrams过程流程过程流程图图Process FMEAProcess FMEA过程过程FMEAFMEAControl PlansControl Plans控制计划控制计划Measurement System Analysis Measurement System Analysis StudiesStudies测量系统分析研究测量系统分析研究Dimensional ResultsDimensional Results尺寸报告尺寸报告Records of Material / Performan

7、ce Records of Material / Performance Test ResultsTest Results材料和性能测试结果及材料和性能测试结果及纪录纪录Initial Process StudiesInitial Process Studies初始过程能初始过程能力研究力研究Qualified Laboratory Qualified Laboratory DocumentationDocumentation有资格的实验室文件有资格的实验室文件Appearance Approval ReportAppearance Approval Report外观批外观批准报告准报告Sam

8、ple Production PartsSample Production Parts生产样件生产样件Master SampleMaster Sample标准样件标准样件Checking AidsChecking Aids检查辅具检查辅具Customer-Specific RequirementsCustomer-Specific Requirements顾顾客特殊要求客特殊要求Production Part Approval Process Production Part Approval Process Submission Warrant (PSW)Submission Warrant

9、(PSW)零件提交零件提交保证书保证书Phased PPAP 要求 Phased PPAPPhased PPAP是是FORDFORD对对PPAPPPAP流程管理的特殊流程管理的特殊要求要求 主要目的是提高正式生产是的质量表现主要目的是提高正式生产是的质量表现 需要供应商证明以下要点：需要供应商证明以下要点： 制造能力制造能力 产品质量产品质量 产能能力产能能力全球阶段性PPAP:是在怎样的基础上建立起来的Phase 3 Capacity Verification产能验证产能验证Phase 2Production Verification生产验证生产验证Phase 1Quality Verifi

10、cation质量验证质量验证Phase 0Run-at-Rate节拍生产节拍生产加强沟通 一至性的沟通 关注少数重要的优先点。 言简意赅 帮助使用者区分优先级1. 去除障碍改善工作流程 简化 稳定化 标准化 节奏化1. 持续性PhasedPPAP供应商阶段性PPAP过程图STATUS:Phase 2Completed Phase 2 Warrant#18YesStatus Tracking Database234Proceed to next pageSubmit to CustomerImportant note:Phase 2 and Phase 3 can happen concurre

11、ntly if all Inputs and Outputs are satisfiedNoINPUTSReleased design#1,2,3 & 4Trained supplier production operatorsSub-supplier(s) material status from Tier-x RRJob 1 Location (final site & line)Quantity of parts required as defined by customer (default 300 consecutive parts)Production proces

12、s including control plan, flow diagram instructions & Process parameters #5,6 & 7Production Tools, Facilities & Gauging#8,16 & 17EVENT:Conduct Run at RatePlanned production cycle times required to support Daily Production VolumeOutputs from the eventSTATUS:Phase 0 CompletedImplement

13、Corrective Action on InputWas the Pre-Launch Control Plan followed?Were the prescribed number of acceptable parts produced? Were the parts produced in the defined period?Did all operations meet their planned cycle time?YesYesYesYesNoNoNoNoAre the RunRate input requirements in place for the productio

14、n stream?YesSTARTNo Capacity Analysis WorksheetStatus Tracking Database14Proceed to next pageRequired InputsSubmit to CustomerNote: #x refers to the Element Number in PPAP 4th Edition that will assist in confirming requirementsSTATUS: Phase 1 Completed Continue Production Part Approval Process (PPAP

15、) using parts from Phase 0- Dimensional measurements #9- Material Tests #10- Statistical process package #11- Performance Tests #12- Appearance criteria #13- Sample parts #14- Master samples #15- Customer Specific Requirements#17- as defined by PPAPHave the PPAP elements been satisfied?YesStatus Tra

16、cking Database1424Important note: For suppliers with only one production stream completion of Phase 1 & 2 occur at the same timeProceed to next pageReturn to Phase 0 for corrective actionNoSubmit to CustomerPhase 1 Warrant#18Phase 2 WarrantScheduled down time defined (TPM, change over, Breaks et

17、c.) Sub supplier material status from Tier-x Phase 3EVENT: Conduct Capacity Verification RunSTATUS:Phase 3 Completed Quantity required is customer DPV for one full dayAll personnel for all shifts, trained Are the CVR input requirements in place for all production streams?YesENDStatus Tracking Databa

18、seReturn to affected phase and start corrective action Phase 3 Warrant #18& Capacity Analysis Report Determine Root Cause & Plan Corrective Action Was the control plan followed& acceptable parts produced?Did the volume of acceptable parts produced meet or exceed the requiredDPV?NoYesNo3R

19、equired InputsPhase 0Phase 1Phase 2Phase 0Run-at-RatePhase 1Quality VerificationPhase 2Production VerificationPhase 3Capacity Verification1 - 设计记录2 - 工程变更文件3 顾客工程批准4 - 设计FMEA5 - 过程流程图6 - 过程FMEA7 - 控制计划8 - 测量系统分析16 检查辅具17 顾客特殊要求9 - 尺寸报告10 材料和性能检测报告11 - 初始过程能力研究12 - 有资格的实验室文件13 外观批准报告14 生产样件15 标准样件18

20、零件提交保证书phase1 PSW零件提交保证书 phase2 PSW(要素18)所有的生产线进行节拍生产 (要素1 8, 16, 17)对所有的生产线进行质量验证(要素9 15) 产能分析报告零件提交保证书phase3 PSW (要素 18)产能分析报告Have Run-at-Rates (Phase 0) been conducted and Quality Verifications (Phase 1) been satisfied for ALL production streams?Phased PPAP与PPAP的比较Phased PPAP organizes the proces

21、s into four phasesPhased PPAP organizes the process into four phases Phase 0: Run-at-Rate 按节拍生产按节拍生产 Phase 1: Quality Verification 质量确认（一条生产线）质量确认（一条生产线） Phase 2: Production Verification 产品验证产品验证 （多条生产线）（多条生产线） Phase 3: Capacity Verification 产能验证产能验证PPAPX1 PPFEUJob 1Phased PPAPPhase 0Phase 1Phase 2P

22、hase 3阶段PPAP的要求1. Phase 0：Run-at-Rate初始按节拍生产正式的生产场地、生产人员正式的设备、工装 夹具、模具、量检具文件齐全：EWO/DFMEA/ FC/ PFMEA/CP/培训记录/顾客特殊要求至少300件连续生产产能分析、MSABuilding on the Basics: Phase 0STATUS:Phase 2Completed Phase 2 Warrant#18YesStatus Tracking Database234Proceed to next pageSubmit to CustomerImportant note:Phase 2 and

23、Phase 3 can happen concurrently if all Inputs and Outputs are satisfiedNoSTATUS: Phase 1 Completed Continue Production Part Approval Process (PPAP) using parts from Phase 0- Dimensional measurements #9- Material Tests #10- Statistical process package #11- Performance Tests #12- Appearance criteria #

24、13- Sample parts #14- Master samples #15- Customer Specific Requirements#17- as defined by PPAPHave the PPAP elements been satisfied?YesStatus Tracking Database1424Important note: For suppliers with only one production stream completion of Phase 1 & 2 occur at the same timeProceed to next pageRe

25、turn to Phase 0 for corrective actionNoSubmit to CustomerPhase 1 Warrant#18Phase 2 WarrantScheduled down time defined (TPM, change over, Breaks etc.) Sub supplier material status from Tier-x Phase 3EVENT: Conduct Capacity Verification RunSTATUS:Phase 3 Completed Quantity required is customer DPV for

26、 one full dayAll personnel for all shifts, trained Are the CVR input requirements in place for all production streams?YesENDStatus Tracking DatabaseReturn to affected phase and start corrective action Phase 3 Warrant #18& Capacity Analysis Report Determine Root Cause & Plan Corrective Action

27、 Was the control plan followed& acceptable parts produced?Did the volume of acceptable parts produced meet or exceed the requiredDPV?NoYesNo3Required InputsPhase 0Phase 1Phase 2Phase 1Quality VerificationPhase 2Production VerificationPhase 3Capacity Verification9 - Dimensional Results10 - Record

28、s of Material / Performance Test Results11 - Initial Process Studies12 - Qualified Laboratory Documentation13 - Appearance Approval Report14 - Sample Production Parts15 - Master Sample18 - PPAP WarrantPPAP Warrant (element 18)Run-at-Rate for all production streams (element 1 8, 16, 17)Quality Verifi

29、cation for all production streams (element 9 15) Capacity Analysis Report PPAP Warrant (element 18)Have Run-at-Rates (Phase 0) been conducted and Quality Verifications (Phase 1) been satisfied for ALL production streams?INPUTSReleased design#1,2,3 & 4Trained supplier production operatorsSub-supp

30、lier(s) material status from Tier-x RRJob 1 Location (final site & line)Quantity of parts required as defined by customer (default 300 consecutive parts)Production process including control plan, flow diagram instructions & Process parameters #5,6 & 7Production Tools, Facilities & Ga

31、uging#8,16 & 17EVENT:Conduct Run at RatePlanned production cycle times required to support Daily Production VolumeOutputs from the eventSTATUS:Phase 0 CompletedImplement Corrective Action on InputWas the Pre-Launch Control Plan followed?Were the prescribed number of acceptable parts produced? We

32、re the parts produced in the defined period?Did all operations meet their planned cycle time?YesYesYesYesNoNoNoNoAre the RunRate input requirements in place for the production stream?YesSTARTNo Capacity Analysis WorksheetStatus Tracking Database14Proceed to next pageRequired InputsSubmit to Customer

33、Note: #x refers to the Element Number in PPAP 4th Edition that will assist in confirming requirementsPhase 0Run-at-Rate1 - 设计记录2 - 工程变更文件3 顾客工程批准4 - 设计FMEA5 - 过程流程图6 - 过程FMEA7 - 控制计划8 - 测量系统分析16 检查辅具17 顾客特殊要求产能分析报告Phase 0: 节拍生产输入设计发布(PPAP #1, 2, 3, 4)供应商应该有可销售产品的设计记录，包括下层件的详细信息。所有的电子档数据，都需要有硬拷贝的文件来进

34、行追踪，以及评审。StartReleased Design#1, 2, 3, 4Trained supplier production operatorsSub-supplier(s) material status from Tier-X Run-at-RateQuantity of parts required as defined by customer (default 300 consecutive parts)Job 1 location (final site and line)Production process including control plan, flow dia

35、gram instructions, and Process Parameters#5, 6, 7Production tools, facilities, and gauging#8, 16, 17Planned production cycle times required to support daily production volumeAre the Run-at-Rate input requirements in place for the production stream?Was the pre-launch Control Plan followed?Were the pr

36、escribed number of acceptable parts produced?Were the parts produced in the defined period?Did all operations meet their planned cycle time?Implement corrective action on inputEVENT: Conduct Run-at-RateSTATUS: Phase 0 CompleteCapacity AnalysisReportStatus Tracking Database41YESNONONONONOYESYESYESSub

37、mitto customerOutputs from the eventYESPhase 0: 节拍生产输入经过培训的操作员供应商必须出示证据，以证明所有涉及到的现场操作员，已经得到了针对新模具、设备、流程等方面的培训。StartReleased Design#1, 2, 3, 4Trained supplier production operatorsSub-supplier(s) material status from Tier-X Run-at-RateQuantity of parts required as defined by customer (default 300 cons

38、ecutive parts)Job 1 location (final site and line)Production process including control plan, flow diagram instructions, and Process Parameters#5, 6, 7Production tools, facilities, and gauging#8, 16, 17Planned production cycle times required to support daily production volumeAre the Run-at-Rate input

39、 requirements in place for the production stream?Was the pre-launch Control Plan followed?Were the prescribed number of acceptable parts produced?Were the parts produced in the defined period?Did all operations meet their planned cycle time?Implement corrective action on inputEVENT: Conduct Run-at-R

40、ateSTATUS: Phase 0 CompleteCapacity AnalysisReportStatus Tracking Database41YESNONONONONOYESYESYESSubmitto customerOutputs from the eventYESPhase 0: 节拍生产输入顾客定义的生产量一般默认为300件连续性的产品供应商必须使用计划的量产状态下的节拍，设备，人员和至少一套模具来进行此次生产。StartReleased Design#1, 2, 3, 4Trained supplier production operatorsSub-supplier(s)

41、 material status from Tier-X Run-at-RateQuantity of parts required as defined by customer (default 300 consecutive parts)Job 1 location (final site and line)Production process including control plan, flow diagram instructions, and Process Parameters#5, 6, 7Production tools, facilities, and gauging#8

42、, 16, 17Planned production cycle times required to support daily production volumeAre the Run-at-Rate input requirements in place for the production stream?Was the pre-launch Control Plan followed?Were the prescribed number of acceptable parts produced?Were the parts produced in the defined period?D

43、id all operations meet their planned cycle time?Implement corrective action on inputEVENT: Conduct Run-at-RateSTATUS: Phase 0 CompleteCapacity AnalysisReportStatus Tracking Database41YESNONONONONOYESYESYESSubmitto customerOutputs from the eventYES底盘件：最少300件钣金件：最少30-100件内外饰件：最少30-100件电器件：最少300件 动力系统件

44、：最少动力系统件：最少300件件排气系统：最少300件燃油系统：最少300件节拍生产数量19Phase 0: 节拍生产输入供应商量产零件所使用的生产场地所有的量产件需要在计划的量产场地使用为量产开发的模具，检具，过程，材料，人员，环境和过程设置进行生产。所有的过程参数，必须在节拍生产前完成验证并确认。StartReleased Design#1, 2, 3, 4Trained supplier production operatorsSub-supplier(s) material status from Tier-X Run-at-RateQuantity of parts required

45、 as defined by customer (default 300 consecutive parts)Job 1 location (final site and line)Production process including control plan, flow diagram instructions, and Process Parameters#5, 6, 7Production tools, facilities, and gauging#8, 16, 17Planned production cycle times required to support daily p

46、roduction volumeAre the Run-at-Rate input requirements in place for the production stream?Was the pre-launch Control Plan followed?Were the prescribed number of acceptable parts produced?Were the parts produced in the defined period?Did all operations meet their planned cycle time?Implement correcti

47、ve action on inputEVENT: Conduct Run-at-RateSTATUS: Phase 0 CompleteCapacity AnalysisReportStatus Tracking Database41YESNONONONONOYESYESYESSubmitto customerOutputs from the eventYES20Phase 0: 节拍生产输入生产过程包括控制计划，过程流程图和过程参数PPAP #5,6,7供应商必须有一个能够清晰描述生产步骤和顺序的过程流程图供应商必须要有过程FMEA供应商必须要有过程控制计划StartReleased Des

48、ign#1, 2, 3, 4Trained supplier production operatorsSub-supplier(s) material status from Tier-X Run-at-RateQuantity of parts required as defined by customer (default 300 consecutive parts)Job 1 location (final site and line)Production process including control plan, flow diagram instructions, and Pro

49、cess Parameters#5, 6, 7Production tools, facilities, and gauging#8, 16, 17Planned production cycle times required to support daily production volumeAre the Run-at-Rate input requirements in place for the production stream?Was the pre-launch Control Plan followed?Were the prescribed number of accepta

50、ble parts produced?Were the parts produced in the defined period?Did all operations meet their planned cycle time?Implement corrective action on inputEVENT: Conduct Run-at-RateSTATUS: Phase 0 CompleteCapacity AnalysisReportStatus Tracking Database41YESNONONONONOYESYESYESSubmitto customerOutputs from

51、 the eventYES21Phase 0: 节拍生产输入量产模具，设备和检具PPAP #8,16,17供应商必须确认使用的设备、模具、检具状态是否为新开的，整修的还是迁移的用于量产的资源是否符合顾客要求的数量和质量标准StartReleased Design#1, 2, 3, 4Trained supplier production operatorsSub-supplier(s) material status from Tier-X Run-at-RateQuantity of parts required as defined by customer (default 300 con

52、secutive parts)Job 1 location (final site and line)Production process including control plan, flow diagram instructions, and Process Parameters#5, 6, 7Production tools, facilities, and gauging#8, 16, 17Planned production cycle times required to support daily production volumeAre the Run-at-Rate inpu

53、t requirements in place for the production stream?Was the pre-launch Control Plan followed?Were the prescribed number of acceptable parts produced?Were the parts produced in the defined period?Did all operations meet their planned cycle time?Implement corrective action on inputEVENT: Conduct Run-at-

54、RateSTATUS: Phase 0 CompleteCapacity Analysis ReportStatus Tracking Database41YESNONONONONOYESYESYESSubmitto customerOutputs from the eventYES22Phase 0: 节拍生产输入供应商计划产能的生产节拍必须满足顾客的需求供应商必须提供证据证明在计划的量产现场都能满足要求的情况下，生产线能够生产出满足顾客日产量的产品。StartReleased Design#1, 2, 3, 4Trained supplier production operatorsSub

55、-supplier(s) material status from Tier-X Run-at-RateQuantity of parts required as defined by customer (default 300 consecutive parts)Job 1 location (final site and line)Production process including control plan, flow diagram instructions, and Process Parameters#5, 6, 7Production tools, facilities, a

56、nd gauging#8, 16, 17Planned production cycle times required to support daily production volumeAre the Run-at-Rate input requirements in place for the production stream?Was the pre-launch Control Plan followed?Were the prescribed number of acceptable parts produced?Were the parts produced in the defi

57、ned period?Did all operations meet their planned cycle time?Implement corrective action on inputEVENT: Conduct Run-at-RateSTATUS: Phase 0 CompleteCapacity AnalysisReportStatus Tracking Database41YESNONONONONOYESYESYESSubmitto customerOutputs from the eventYES2. Phase 1：质量确认 零件尺寸报告 材料、性能检测报告 初始过程能力研究

58、， Ppk=1.67 生产样件 分供方的PSW已签署 提交Phase1 PSW阶段PPAP的要求3. Phase 2：产品验证 所有生产线按节拍生产（Phase0要求） 所有生产线的质量验证（Phase1要求） 分供方全部完成Phase2 提交Phase2 PSW注：针对多条生产线生产同一产品，若只有一条线可省略。阶段PPAP的要求4. Phase 3：产能验证 Phase2 认可的 PSW 所有班次人员完成培训 分供方产能分析 产能分析报告，GP9 证明在5天/周和3班/天的情况下能满足顾客LCR 提交Phase3 PSW阶段PPAP的要求每次提交PPAP时，需要向STA提交检查清单只有该检

59、查清单的所有要素均备STA认可，才能签署PSW 所有班次人员具体要求请联系STA阶段PPAP检查清单所有CC/SC/HIC 需要使用计量型量具所有CC/SC/HIC尽可能采用放错，如不能则需要SPC控制过程能力 Cpk1.33， Ppk1.67所有过程控制需满足FORD特殊要求，如CQI-9过程能力要求Thank You!项目管理项目管理三大要素项目管理三大要素质量、进度、资源质量、进度、资源产品项目特点产品项目特点: : 项目时间性较强项目时间性较强 具备一定的要求或标准具备一定的要求或标准顾客输入顾客输入 产品项目的开展遵循产品项目的开展遵循规定规定的路径的路径顾客要求顾客要求 成本限定性较强成本限定性较强目标成本分解目标成本分解阶段评审（质量阀）项目进度问题清单经验教训商务问题人力资源变更管理发货跟踪项目管理样件确认是一个宝贵的机会，关键的闸口样件确认是一个宝贵的机会，关键的闸口是否只有个别样本？是否只有个别样本？ ( (质量阀质量阀) )小批运行能力小批运行能力是否来自于确定制程？是否来自于确定制程？外观要求确立外观要