FORD福特汽車研發(fā)流程介紹

1、FORD流程簡(jiǎn)介1FORD福特汽車研發(fā)流程介紹早期參與團(tuán)隊(duì)標(biāo)準(zhǔn)化管理/匯報(bào) 采用唯一的，全球通用到，有紀(jì)律的流程盡量減少返工和重復(fù)。在產(chǎn)品開發(fā)過程早期，與供應(yīng)商更融洽地合作利用福特跨功能團(tuán)隊(duì)與供應(yīng)商一起在現(xiàn)場(chǎng)工作(4次拜訪)使用共同的，明確的交付報(bào)告和結(jié)構(gòu)化的管理評(píng)審模式GPDS（ Global Product Development System）是FORD公司全球產(chǎn)品開發(fā)體系，替代原FPDS福特產(chǎn)品開發(fā)體系 GPDS 全球產(chǎn)品開發(fā)體系FORD福特汽車研發(fā)流程介紹3GPDS 供應(yīng)商管理過程供應(yīng)商管理過程-總覽總覽 PTC/M1DJPTCC PA FDJ PEC LR/ FEC M1 VP T

2、T PP MP1 UnitPTC UnitPA33.5MBJ127MBJ125MBJ120.5MBJ127.5MBJ134MBJ117MBJ113MBJ18MBJ15.5MBJ15MBJ12.5MBJ10MBJ1供應(yīng)商選供應(yīng)商選點(diǎn)開始點(diǎn)開始高影響供高影響供應(yīng)商選擇應(yīng)商選擇跨功能小組形成跨功能小組形成啟動(dòng)會(huì)議啟動(dòng)會(huì)議開始開始第一次現(xiàn)場(chǎng)第一次現(xiàn)場(chǎng)評(píng)審評(píng)審第二次現(xiàn)場(chǎng)第二次現(xiàn)場(chǎng)評(píng)審評(píng)審第三次現(xiàn)場(chǎng)第三次現(xiàn)場(chǎng)評(píng)審評(píng)審第四次現(xiàn)場(chǎng)第四次現(xiàn)場(chǎng)評(píng)審評(píng)審解決問題解決問題決定：決定：是否進(jìn)是否進(jìn)行試生行試生產(chǎn)？產(chǎn)？更新供應(yīng)商更新供應(yīng)商 APQP/PPAP 準(zhǔn)備狀態(tài)評(píng)估報(bào)告準(zhǔn)備狀態(tài)評(píng)估報(bào)告 (A表表)(655/654)

3、FORD福特汽車研發(fā)流程介紹PTC-Program Target Compatibility 項(xiàng)目目標(biāo)整合PAPA- -Program Approval 項(xiàng)目批準(zhǔn) FDJ-FDJ-Final Data Judgement 工程數(shù)據(jù)發(fā)布VPVP- -Verification Prototype (OTS)樣件驗(yàn)證PEC-PEC-Preliminary Engineering Completion 工程數(shù)據(jù)凍結(jié)項(xiàng)目節(jié)點(diǎn)（里程碑）FORD福特汽車研發(fā)流程介紹LR- -Launch Readiness 生產(chǎn)準(zhǔn)備就緒（可生產(chǎn)）TTTT- -Tooling Trial 工裝樣件 （PSW1）PPPP- -

4、Pilot Production 試生產(chǎn)（可售）(PSW2)MP1MP1- -Mass Production 1 量產(chǎn) (PSW3)Job #1Job #1 整車投產(chǎn)項(xiàng)目節(jié)點(diǎn)（里程碑）FORD福特汽車研發(fā)流程介紹6 PTC/M1DJPTCC PA FDJ M1 UnitPTC UnitPA33.5MBJ127MBJ125MBJ120.5MBJ127.5MBJ134MBJ117MBJ113MBJ15MBJ12.5MBJ10MBJ1(655/654) PEC LR/ FEC VP TT PP8MBJ15.5MBJ1 MP1供應(yīng)商選供應(yīng)商選點(diǎn)開始點(diǎn)開始關(guān)鍵供關(guān)鍵供應(yīng)商選擇應(yīng)商選擇跨功能小組形成跨功能

5、小組形成啟動(dòng)會(huì)議啟動(dòng)會(huì)議開始開始第一次現(xiàn)場(chǎng)第一次現(xiàn)場(chǎng)評(píng)審評(píng)審第二次現(xiàn)場(chǎng)第二次現(xiàn)場(chǎng)評(píng)審評(píng)審第三次現(xiàn)第三次現(xiàn)場(chǎng)評(píng)審場(chǎng)評(píng)審第四次現(xiàn)場(chǎng)第四次現(xiàn)場(chǎng)評(píng)審評(píng)審解決問題解決問題決定：決定：是否進(jìn)是否進(jìn)行試生行試生產(chǎn)？產(chǎn)？更新供應(yīng)商更新供應(yīng)商 APQP/PPAP 準(zhǔn)備狀態(tài)評(píng)估報(bào)告準(zhǔn)備狀態(tài)評(píng)估報(bào)告 (A表表)OTSPPAPPhase0/1PPAPphase2PPAPphase3FORD項(xiàng)目跟蹤（裝車）節(jié)點(diǎn)項(xiàng)目批準(zhǔn)項(xiàng)目批準(zhǔn)工程數(shù)據(jù)發(fā)布手工樣件OTSFORD福特汽車研發(fā)流程介紹FORD項(xiàng)目開發(fā)節(jié)點(diǎn)FORD福特汽車研發(fā)流程介紹PPAP 的18項(xiàng)1.1. Design RecordsDesign Records設(shè)計(jì)記錄設(shè)

6、計(jì)記錄2.2. Engineering Change DocumentsEngineering Change Documents工工程變更文件程變更文件3.3. Engineering Approval Engineering Approval 工程批準(zhǔn)工程批準(zhǔn)4.4. Design FMEADesign FMEA設(shè)計(jì)設(shè)計(jì)FMEAFMEA5.5. Process Flow DiagramsProcess Flow Diagrams過程流程過程流程圖圖6.6. Process FMEAProcess FMEA過程過程FMEAFMEA7.7. Control PlansControl Plans控

7、制計(jì)劃控制計(jì)劃8.8. Measurement System Analysis Measurement System Analysis StudiesStudies測(cè)量系統(tǒng)分析研究測(cè)量系統(tǒng)分析研究9.9. Dimensional ResultsDimensional Results尺寸報(bào)告尺寸報(bào)告10.10. Records of Material / Performance Records of Material / Performance Test ResultsTest Results材料和性能測(cè)試結(jié)果及材料和性能測(cè)試結(jié)果及紀(jì)錄紀(jì)錄11.11. Initial Process Studi

8、esInitial Process Studies初始過程能初始過程能力研究力研究12.12. Qualified Laboratory Qualified Laboratory DocumentationDocumentation有資格的實(shí)驗(yàn)室文件有資格的實(shí)驗(yàn)室文件13.13. Appearance Approval ReportAppearance Approval Report外觀批外觀批準(zhǔn)報(bào)告準(zhǔn)報(bào)告14.14. Sample Production PartsSample Production Parts生產(chǎn)樣件生產(chǎn)樣件15.15. Master SampleMaster Sample標(biāo)

9、準(zhǔn)樣件標(biāo)準(zhǔn)樣件16.16. Checking AidsChecking Aids檢查輔具檢查輔具17.17. Customer-Specific RequirementsCustomer-Specific Requirements顧顧客特殊要求客特殊要求18.18. Production Part Approval Process Production Part Approval Process Submission Warrant (PSW)Submission Warrant (PSW)零件提交零件提交保證書保證書FORD福特汽車研發(fā)流程介紹Phased PPAP 要求Phased PPA

10、PPhased PPAP是是FORDFORD對(duì)對(duì)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產(chǎn)是的質(zhì)量表現(xiàn)主要目的是提高正式生產(chǎn)是的質(zhì)量表現(xiàn)需要供應(yīng)商證明以下要點(diǎn)：需要供應(yīng)商證明以下要點(diǎn)： 制造能力制造能力 產(chǎn)品質(zhì)量產(chǎn)品質(zhì)量 產(chǎn)能能力產(chǎn)能能力FORD福特汽車研發(fā)流程介紹全球階段性PPAP:是在怎樣的基礎(chǔ)上建立起來的Phase 3 Capacity Verification產(chǎn)能驗(yàn)證產(chǎn)能驗(yàn)證Phase 2Production Verification生產(chǎn)驗(yàn)證生產(chǎn)驗(yàn)證Phase 1Quality Verification質(zhì)量驗(yàn)證質(zhì)量驗(yàn)證Phase 0Run-at-Rate

11、節(jié)拍生產(chǎn)節(jié)拍生產(chǎn)加強(qiáng)溝通1. 一至性的溝通2. 關(guān)注少數(shù)重要的優(yōu)先點(diǎn)。3. 言簡(jiǎn)意賅4. 幫助使用者區(qū)分優(yōu)先級(jí)5. 去除障礙改善工作流程1. 簡(jiǎn)化2. 穩(wěn)定化3. 標(biāo)準(zhǔn)化4. 節(jié)奏化5. 持續(xù)性FORD福特汽車研發(fā)流程介紹供應(yīng)商階段性PPAP過程圖STATUS:Phase 2Completed Phase 2 Warrant#18YesStatus Tracking Database234Proceed to next pageSubmit to CustomerImportant note:Phase 2 and Phase 3 can happen concurrently if all

12、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 process including

13、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 Corrective A

14、ction 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 production stream?Yes

15、STARTNo 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) using part

16、s 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 Tracking Databa

17、se1424Important 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 etc.) Sub supp

18、lier 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 DatabaseReturn to

19、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?NoYesNo3Required Inpu

20、tsPhase 0Phase 1Phase 2Phase 0Run-at-RatePhase 1Quality VerificationPhase 2Production VerificationPhase 3Capacity Verification1 - 設(shè)計(jì)記錄2 - 工程變更文件3 顧客工程批準(zhǔn)4 - 設(shè)計(jì)FMEA5 - 過程流程圖6 - 過程FMEA7 - 控制計(jì)劃8 - 測(cè)量系統(tǒng)分析16 檢查輔具17 顧客特殊要求9 - 尺寸報(bào)告10 材料和性能檢測(cè)報(bào)告11 - 初始過程能力研究12 - 有資格的實(shí)驗(yàn)室文件13 外觀批準(zhǔn)報(bào)告14 生產(chǎn)樣件15 標(biāo)準(zhǔn)樣件18 零件提交保證書phase

21、1 PSW零件提交保證書 phase2 PSW(要素18)所有的生產(chǎn)線進(jìn)行節(jié)拍生產(chǎn) (要素1 8, 16, 17)對(duì)所有的生產(chǎn)線進(jìn)行質(zhì)量驗(yàn)證(要素9 15) 產(chǎn)能分析報(bào)告零件提交保證書phase3 PSW (要素 18)產(chǎn)能分析報(bào)告Have Run-at-Rates (Phase 0) been conducted and Quality Verifications (Phase 1) been satisfied for ALL production streams?FORD福特汽車研發(fā)流程介紹Phased PPAP與PPAP的比較 Phased PPAP organizes the pro

22、cess into four phasesPhased PPAP organizes the process into four phases Phase 0: Run-at-Rate 按節(jié)拍生產(chǎn)按節(jié)拍生產(chǎn) Phase 1: Quality Verification 質(zhì)量確認(rèn)（一條生產(chǎn)線）質(zhì)量確認(rèn)（一條生產(chǎn)線） Phase 2: Production Verification 產(chǎn)品驗(yàn)證產(chǎn)品驗(yàn)證 （多條生產(chǎn)線）（多條生產(chǎn)線） Phase 3: Capacity Verification 產(chǎn)能驗(yàn)證產(chǎn)能驗(yàn)證PPAPX1 PPFEUJob 1Phased PPAPPhase 0Phase 1Phase

23、 2Phase 3FORD福特汽車研發(fā)流程介紹階段PPAP的要求1. Phase 0：Run-at-Rate初始按節(jié)拍生產(chǎn)正式的生產(chǎn)場(chǎng)地、生產(chǎn)人員正式的設(shè)備、工裝 夾具、模具、量檢具文件齊全：EWO/DFMEA/ FC/ PFMEA/CP/培訓(xùn)記錄/顧客特殊要求至少300件連續(xù)生產(chǎn)產(chǎn)能分析、MSAFORD福特汽車研發(fā)流程介紹Building on the Basics: Phase 0STATUS:Phase 2Completed Phase 2 Warrant#18YesStatus Tracking Database234Proceed to next pageSubmit to Cust

24、omerImportant note:Phase 2 and 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 T

25、ests #12- Appearance criteria #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

26、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 etc.) Sub supplier material status from Tier-x Phase 3EVENT: Conduct Capacity Verification RunSTATUS:Phase 3 Completed Quanti

27、ty 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 DatabaseReturn to affected phase and start corrective action Phase 3 Warrant #18& Capacity Analysis Report Determine Root Cau

28、se & Plan Corrective Action 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 -

29、 Dimensional Results10 - Records 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 (ele

30、ment 1 8, 16, 17)Quality Verification 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 suppli

31、er 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 process including control plan, flow diagram instructions & Process parameters #5,6 & 7Produc

32、tion 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 Corrective Action on InputWas the Pre-Launch Control Plan followed?Were the prescribed number o

33、f 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 production stream?YesSTARTNo Capacity Analysis WorksheetStatus Tracking Database14Proceed to next pageRe

34、quired InputsSubmit to CustomerNote: #x refers to the Element Number in PPAP 4th Edition that will assist in confirming requirementsPhase 0Run-at-Rate1 - 設(shè)計(jì)記錄2 - 工程變更文件3 顧客工程批準(zhǔn)4 - 設(shè)計(jì)FMEA5 - 過程流程圖6 - 過程FMEA7 - 控制計(jì)劃8 - 測(cè)量系統(tǒng)分析16 檢查輔具17 顧客特殊要求產(chǎn)能分析報(bào)告FORD福特汽車研發(fā)流程介紹Phase 0: 節(jié)拍生產(chǎn)輸入設(shè)計(jì)發(fā)布(PPAP #1, 2, 3, 4)供應(yīng)商應(yīng)

35、該有可銷售產(chǎn)品的設(shè)計(jì)記錄，包括下層件的詳細(xì)信息。所有的電子檔數(shù)據(jù)，都需要有硬拷貝的文件來進(jìn)行追蹤，以及評(píng)審。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)Produc

36、tion 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 requirements in place for the production stream?Was the

37、 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-RateSTATUS: Phase 0 CompleteCapacity AnalysisReportStatus

38、 Tracking Database41YESNONONONONOYESYESYESSubmitto customerOutputs from the eventYESFORD福特汽車研發(fā)流程介紹Phase 0: 節(jié)拍生產(chǎn)輸入經(jīng)過培訓(xùn)的操作員供應(yīng)商必須出示證據(jù)，以證明所有涉及到的現(xiàn)場(chǎng)操作員，已經(jīng)得到了針對(duì)新模具、設(shè)備、流程等方面的培訓(xùn)。StartReleased Design#1, 2, 3, 4Trained supplier production operatorsSub-supplier(s) material status from Tier-X Run-at-RateQuantity

39、 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, 16, 17Planned production cycle times required

40、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?Did all operations meet their planned cycle time?

41、Implement corrective action on inputEVENT: Conduct Run-at-RateSTATUS: Phase 0 CompleteCapacity AnalysisReportStatus Tracking Database41YESNONONONONOYESYESYESSubmitto customerOutputs from the eventYESFORD福特汽車研發(fā)流程介紹Phase 0: 節(jié)拍生產(chǎn)輸入顧客定義的生產(chǎn)量一般默認(rèn)為300件連續(xù)性的產(chǎn)品供應(yīng)商必須使用計(jì)劃的量產(chǎn)狀態(tài)下的節(jié)拍，設(shè)備，人員和至少一套模具來進(jìn)行此次生產(chǎn)。StartRelea

42、sed 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 diagram instructions,

43、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 prescribed number of

44、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 Database41YESNONONONONOYESYESYESSubmitto customerOutpu

45、ts from the eventYESFORD福特汽車研發(fā)流程介紹底盤件：最少300件鈑金件：最少30-100件內(nèi)外飾件：最少30-100件電器件：最少300件 動(dòng)力系統(tǒng)動(dòng)力系統(tǒng)件：最少件：最少300件件排氣系統(tǒng)：最少300件燃油系統(tǒng)：最少300件節(jié)拍生產(chǎn)數(shù)量FORD福特汽車研發(fā)流程介紹19Phase 0: 節(jié)拍生產(chǎn)輸入供應(yīng)商量產(chǎn)零件所使用的生產(chǎn)場(chǎng)地所有的量產(chǎn)件需要在計(jì)劃的量產(chǎn)場(chǎng)地使用為量產(chǎn)開發(fā)的模具，檢具，過程，材料，人員，環(huán)境和過程設(shè)置進(jìn)行生產(chǎn)。所有的過程參數(shù)，必須在節(jié)拍生產(chǎn)前完成驗(yàn)證并確認(rèn)。StartReleased Design#1, 2, 3, 4Trained supplier

46、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 Process Parameters#5, 6, 7Producti

47、on 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 acceptable parts produced?Were the par

48、ts 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 the eventYESFORD福特汽車研發(fā)流程介紹20Ph

49、ase 0: 節(jié)拍生產(chǎn)輸入生產(chǎn)過程包括控制計(jì)劃，過程流程圖和過程參數(shù)PPAP #5,6,7供應(yīng)商必須有一個(gè)能夠清晰描述生產(chǎn)步驟和順序的過程流程圖供應(yīng)商必須要有過程FMEA供應(yīng)商必須要有過程控制計(jì)劃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 part

50、s)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 requirement

51、s 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-RateSTATUS: P

52、hase 0 CompleteCapacity AnalysisReportStatus Tracking Database41YESNONONONONOYESYESYESSubmitto customerOutputs from the eventYESFORD福特汽車研發(fā)流程介紹21Phase 0: 節(jié)拍生產(chǎn)輸入量產(chǎn)模具，設(shè)備和檢具PPAP #8,16,17供應(yīng)商必須確認(rèn)使用的設(shè)備、模具、檢具狀態(tài)是否為新開的，整修的還是遷移的用于量產(chǎn)的資源是否符合顧客要求的數(shù)量和質(zhì)量標(biāo)準(zhǔn)StartReleased Design#1, 2, 3, 4Trained supplier production o

53、peratorsSub-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, fa

54、cilities, 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 acceptable parts produced?Were the parts produced

55、in the defined period?Did all operations meet their planned cycle time?Implement corrective action on inputEVENT: Conduct Run-at-RateSTATUS: Phase 0 CompleteCapacity Analysis ReportStatus Tracking Database41YESNONONONONOYESYESYESSubmitto customerOutputs from the eventYESFORD福特汽車研發(fā)流程介紹22Phase 0: 節(jié)拍生產(chǎn)

56、輸入供應(yīng)商計(jì)劃產(chǎn)能的生產(chǎn)節(jié)拍必須滿足顧客的需求供應(yīng)商必須提供證據(jù)證明在計(jì)劃的量產(chǎn)現(xiàn)場(chǎng)都能滿足要求的情況下，生產(chǎn)線能夠生產(chǎn)出滿足顧客日產(chǎn)量的產(chǎn)品。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 si

57、te 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 requirements in place for the product

58、ion 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-RateSTATUS: Phase 0 CompleteCapacity An

59、alysisReportStatus Tracking Database41YESNONONONONOYESYESYESSubmitto customerOutputs from the eventYESFORD福特汽車研發(fā)流程介紹2. Phase 1：質(zhì)量確認(rèn) 零件尺寸報(bào)告 材料、性能檢測(cè)報(bào)告 初始過程能力研究， Ppk=1.67 生產(chǎn)樣件 分供方的PSW已簽署 提交Phase1 PSW階段PPAP的要求FORD福特汽車研發(fā)流程介紹3. Phase 2：產(chǎn)品驗(yàn)證 所有生產(chǎn)線按節(jié)拍生產(chǎn)（Phase0要求） 所有生產(chǎn)線的質(zhì)量驗(yàn)證（Phase1要求） 分供方全部完成Phase2 提交Phase2

60、PSW注：針對(duì)多條生產(chǎn)線生產(chǎn)同一產(chǎn)品，若只有一條線可省略。階段PPAP的要求FORD福特汽車研發(fā)流程介紹4. Phase 3：產(chǎn)能驗(yàn)證 Phase2 認(rèn)可的 PSW 所有班次人員完成培訓(xùn) 分供方產(chǎn)能分析 產(chǎn)能分析報(bào)告，GP9 證明在5天/周和3班/天的情況下能滿足顧客LCR 提交Phase3 PSW階段PPAP的要求FORD福特汽車研發(fā)流程介紹每次提交PPAP時(shí)，需要向STA提交檢查清單只有該檢查清單的所有要素均備STA認(rèn)可，才能簽署PSW 所有班次人員具體要求請(qǐng)聯(lián)系STA階段PPAP檢查清單FORD福特汽車研發(fā)流程介紹所有CC/SC/HIC 需要使用計(jì)量型量具所有CC/SC/HIC盡可能采用放錯(cuò)，如不能則需要SPC控制過程能力 Cpk1.33， Ppk1.67所有過程控制需滿足FORD特殊要求，如CQI-9過程能力要求FORD福特汽車研發(fā)流