福特公司-APQP教程

1、1Use of Ford APQP Status Report福特APQP使用的报告Tong LeiSupplier Technical AssistanceFord Motor Company2Use of Ford APQP Status Report福特APQP使用的报告n APQP OverviewnAPQP概述n Introduction to Ford APQP Status Reporting Systemn介绍福特APQP使用报告系统n How to use Ford APQP Status Reporting Systemn怎样使用福特APQP报告系统n Q&An问答

2、3APQP OverviewnAPQP is a structured method for guiding an organization to execute the necessary actions to ensure that the product satisfies the customers. nAPQP is a supplier-led program that is applicable for all systems, subsystems and components levels.4APQP Overview- The Goal of APQPnThe goal o

3、f APQP is to facilitate communication between all involved personnel and disciplines in a program by completing all required steps on time, at acceptable cost and quality levels. Flawless product launch will result.5Elements of APQP (AIAG)n19 are from the AIAG APQP and Control Plan manual.Facilities

4、 / Tools / GaugesPrototype BuildsDrawings and SpecificationsTeam Feasibility CommitmentMeasurement Systems EvaluationPackaging SpecificationsProduction Trial RunPreliminary Process Capability StudyProduction Validation TestingProduction Part Approval (PSW)Design FMEADesign Verification Plan & Re

5、portPrototype Build Control PlanManufacturing Process Flow ChartProcess FMEAPre-Launch Control PlanOperation Process InstructionsProduction Control PlanDesign & Mfg. Review(s)6AIAG APQP Timing ChartFeedback Assessment & Corrective Action反馈、评估和纠正措施反馈、评估和纠正措施Product & Process Validation产品与

6、过程确认产品与过程确认Process Design & Development过程设计和开发过程设计和开发Product Design & Development产品设计和开发产品设计和开发Prototype Build样件制造样件制造Plan & Define计划与定义计划与定义7Ford APQP Status Reporting SystemnAn improvement of the AIAG APQP system.nFour additional elementsnElements start and finish are tied to program m

7、ilestones.8Purpose of APQP Status ReportnCommon APQP expectations for internal and external suppliers to Ford Motor CompanynCommon APQP process metricsnA common program status reporting formatnRoles and responsibilities for those involved in APQP element implementation.Establishing: 9Ford APQP Statu

8、s Reporting Systemn23 elements.19 elements from AIAG APQP, plus4 Ford unique elements. They are:nSourcing DecisionnCustomer Input RequirementsnSubcontractor APQP StatusnCraftsmanship10Approach of Ford APQPnThis status reporting guideline describes 23 key APQP elements.nFord Motor Company expectation

9、s are defined for these key elements in definitions, and detailed checklists.nThe status for these elements is summarized using metrics described in the Reporting section.nThis status reporting guideline is written from a supplier standpoint.11The Applicability of Ford APQPnAPQP status reporting is

10、a requirement of all internal and external suppliers to FordnAPQP must be done for new programs/parts and major part changes as appropriate.12APQP Process Flow13The APQP Process includes 5 main functions:nPlanning of the APQP elementsnExecution of the APQP elementsnMonitoring the Quality-of-Event of

11、 the execution of the elements, as well as the timing, by the team in-between milestonesnIssues ResolutionnStatus Reporting (minimum at each milestones)14Use of Ford APQP Status Reportn How to use Ford APQP Status Report for Emerging Market Re-sourcing Programs.15Backgrounds of APQP for Emerging Mar

12、ket Re-sourcing Programs - Ford APQP v3.2nFord APQP Status Report v3.2 is one Excel 26 work sheets.n2 Summary sheetsAPQP Status Report (linked)APQP Status Report (manual)n1 Information sheetn23 worksheets for 23 Ford APQP elements. One sheet for each element.1)Ford APQP Status Report v3.2 uses miles

13、tones from Ford FPDS Ford Product Development System.16Backgrounds of APQP for Emerging Market Re-sourcing Programs - Ford APQP v3.217Backgrounds of APQP for Emerging Market Re-sourcing Programs - FPDSnFPDS Ford Product Development System Ford uses FPDS to Plan, Design, Develop and Launch new vehicl

14、es.Championed by Ford PD.Contains 15 milestones. 12 of them are used in Ford APQP Status Report v3.2.18FPDSOptimizeVehicleSystemSubsystemComponentProduct/ProcessDesignCascadeVerifyDesign/Mfg. ConfirmationLaunch/Mass Prod.ConfirmationUpdateCorporateMemoryMANAGEDefineArchitectureProgram InputDEFINEDES

15、IGNVERIFY AND LAUNCHPS1KOPS2SIPASCPHSTPRCPJ1FSLSLRCC14.5041301925.5-35019FPDS Definitions 15 Milestones Kick-Off (The beginning of program specific work)开球-项目具体工作的开展 Pre#1 (Mission/vision & target customers defined)任务/愿景&目标顾客的定义 Pre#2 (Target ranges assessed)评估指标范围 Strategic Intent (Initial

16、program direction established)最初的计划方向建立 Strategic Confirmation (Teams confirms strategy/viability)团队确认策略/可行性 Proportions & Handpoints (Vehicle proportion frozen)车辆比例的冻结 Program Approval (All targets become objectives)项目批准-所有目的成为目标(ST) Surface Transfer (Interior/exterior surface provided)外观面的转移（内

17、外饰外观） Product Readiness (Designs ready for CP builds)产品准备就绪（准备设计CP结构）(CP) Confirmation Prototype (First CP vehicle available)确认模型（第一次CP车辆可行性分析）20FPDS Definitions 15 Milestones (contd) Change Cut-Off (Commitment to Job #1 timing) Launch Readiness (Engineering Sign-off complete) Launch Sign-Off (Ready

18、 to Launch) Job #1 Achieved (Start Production) Final Status21Backgrounds of APQP for Emerging Market Re-sourcing Programs - EMLPnEMLP Emerging Market Launch PlanDeveloped to track status of Emerging Market re-sourcing programs within Ford.Championed by Ford EMS PD.22Backgrounds - EMLP (contd)nEMLP E

19、merging Market Launch Plan7 milestones, from program approval to part arrival at Ford receiving plant.nGSSM+2W GSSM+2 weeks. EMLP kick-off; issue sourcing agreement. nPR Product Readiness. 2D drwgs/3D model/DFMEA received by supplier.nCP Confirmation Prototype. Prototype parts built; “DV” test start

20、ed.nESO Engineering Sign Off. “DV” test completed; nPSW/LS PSW/Launch Sign. PSW and functional sign-off completed.nSJ1 Supplier Job 1. Supplier ships out first production shipment.nIPD In Plant Date. Parts received at Ford plant(s).23Two Systems, One Objective Flawless Launch!APQP feeds EMLPEMLP(Cha

21、mpioned by Ford PD)APQP(Championed by Supplier)24APQP for Emerging Market Re-sourcingvs. Ford APQP v3.2nAPQP for EM Re-sourcing uses 7 EMLP milestones (for re-sourcing programs); nAPQP v3.2 uses 12 FPDS milestones (for new programs). 25APQP for Emerging Market Re-sourcingvs. Ford APQP v3.2FPDS Miles

22、tones Remain for ReferenceEMLP Milestones Added26APQP for Emerging Market Re-sourcingvs. Ford APQP v3.2nAPQP for EM Re-sourcing uses 7 EMLP milestones (for re-sourcing programs); APQP v3.2 uses 12 FPDS milestones (for new programs). nAPQP for EM eliminates New Program specific requirements, which ar

23、e not required for Re-sourcing Programs, from APQP v3.2. Maintains original APQP requirements as guideline.27APQP for Emerging Market Re-sourcingvs. Ford APQP v3.2Eliminates New Program specific requirementsMaintains original APQP requirements as guideline28APQP for Emerging Market Re-sourcingvs. Fo

24、rd APQP v3.2nAPQP for EM Re-sourcing uses 7 EMLP milestones (for re-sourcing programs); APQP v3.2 uses 12 FPDS milestones (for new programs). nAPQP for EM eliminates New Program specific requirements, which are not required for Re-sourcing Programs, from APQP v3.2. Maintains original APQP requiremen

25、ts as guideline.nChecklist includes additional EMLP unique Supplier responsible requirements for the 23 elements. (At bottom of the checklist for each element.)29APQP for Emerging Market Re-sourcingvs. Ford APQP v3.2Additional EMLP unique Supplier responsible requirements30APQP for Emerging Market R

26、e-sourcingvs. Ford APQP v3.2nAPQP for EM Re-sourcing uses 7 EMLP milestones (for re-sourcing programs); APQP v3.2 uses 12 FPDS milestones (for new programs). nAPQP for EM eliminates New Program specific requirements, which are not required for Re-sourcing Programs, from APQP v3.2. Maintains original

27、 APQP requirements as guideline.nChecklist includes additional EMLP unique Supplier responsible requirements for the 23 elements. (At bottom of the checklist for each element.)nWorksheet of “Action Plan” has been added to APQP for EM, to reduce “copies and pastes” of action plans from 23 elements to

28、 the summary sheet.31APQP for Emerging Market Re-sourcingvs. Ford APQP v3.2Sheet of “Action Plan” has been added.32APQP for Emerging Market Re-sourcingvs. Ford APQP v3.2nAPQP for EM Re-sourcing uses 7 EMLP milestones (for re-sourcing programs); APQP v3.2 uses 12 FPDS milestones (for new programs). n

29、APQP for EM eliminates New Program specific requirements, which are not required for Re-sourcing Programs, from APQP v3.2. Maintains original APQP requirements as guideline.nChecklist includes additional EMLP unique Supplier responsible requirements for the 23 elements. (At bottom of the checklist f

30、or each element.)nWorksheet of “Action Plan” has been added to APQP for EM, to reduce “copies and pastes” of action plans from 23 elements to the summary sheet.nFor forward model (new) programs, Ford APQP v3.2 should be used.33Complete APQP Status Report For EM Re-sourcing programsComplete Informati

31、on SheetInput milestone dates. Should be same as timing plan.Input Part Number and PPAP information.Input team information, for both supplier and Ford.Input program change history, if any.34Complete APQP Status Report For EM Re-sourcing programs - continuenComplete Program Information on sheet of “A

32、PQP Status Report (linked)”.35Complete APQP Status Report For EM Re-sourcing programs - continueReview status of 23 elements.Next slide uses status review of element 11, drawing and specs, at PR as an example.36Sample Check sheet at PRLight Gray shaded cells: Review expectation at these milestones.

33、If R or Y, this issue requires corrective actionIf R or Y, review at next milestone (until its G), even if “Finish Target” date is passed.Overall status is worst rating of all expectations. Manual input is NOT required.Record identified issue and corrective action here.Status Can be updated continuo

34、usly until Milestone Date is metPrior Milestone Status is FrozenInput actual start and finish dates for each expectation. 37Rating and Assessment G/Y/R StatusRiskColorDefinitionHighRed Target dates and/or deliverables are at risk. A recovery work plan is not available and/or implemented, or the work

35、 plan does not achieve program targets.ModerateYellow Target dates and/or deliverables are at risk, but a resourced recovery work plan has been developed to achieve program targets, and has been approved by the appropriate Management Team.LowGreen Target dates and deliverables are on track and meeti

36、ng objectives.38Complete APQP Status Report For EM Re-sourcing programs - continuenComplete the summary sheet on “APQP Status Report (linked)”.Auto-linked to the overall status of the checksheet for this element. Overall status is worst rating of all elements. Manual input is NOT required.39Complete APQP Status Report For EM Re-sourcing programs - continuenComplete action pl