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1、GLOBAL PURCHASINGSupplier Technical AssistanceEdition 1, October 2002Phased PPAP Phased Production Part Approval ProcessPhased PPAP Ford Motor CompanySupplier Technical AssistanceOctober, 2002Table of ContentsAcknowledgements Foreword CONTENTSPhased PPAP Introduction3PPAP Milestones4Phased PPAP Over
2、view5Phased PPAP Process Flow6Run-at-Rate7Phase 1 PPAP Quality Verification8Phase 2 PPAP Production Verification9Phase 3 PPAP Capacity Verification10Customer Disposition of the PSW13Expectations14Appendix A15Appendix B21Appendix C22Appendix D24AcknowledgementsThe development of Phased PPAP and the s
3、upporting systems has represented a substantial undertaking. We would like to thank the members of the Ford development team as well as acknowledge key suppliers for their time and effort in this project, including: Dana Lear Magna Meridian Automotive SY Systems Technologies TRW VisteonForeword Phas
4、ed PPAPVision Partner with suppliers to drive flawless execution in vehicle launch and deliver products that surpass customer expectations.TeamworkFord Motor Company and its suppliers must work together to deliver a quality part, produced on-time, that meets all Ford engineering requirements. To acc
5、omplish this goal, Ford and its suppliers must place trust, integrity and accuracy above all else in the Production Part Approval Process.Supplier Responsibility in Flawless LaunchSupplier delivers a successful launch with no quality or capacity issues that affect the Ford production process. What P
6、hased PPAP Means to Ford Motor CompanyPhased Production Part Approval Process (PPAP) is the process in which the supplier demonstrates they can produce quality parts and provide these parts to Ford at the required volume. Successful completion of Phased PPAP demonstrates supplier readiness using the
7、 production machinery, tooling, and facilities with the intended personnel at the intended production rate that is capable of meeting the Ford required volumes (as specified on the Request for Quotation).Phased PPAP IntroductionAs a result of reviewing industry best practices, Ford has modified PPAP
8、 into a three phased approach that will independently verify product quality, production readiness and capacity prior to Job #1. Phased PPAP will provide the launch team with an improved method of risk management and provide a consistent method for a supplier to determine if they meet Ford projected
9、 program volumes (See Appendix A). Phased PPAP ensures that the supplier process has the potential to produce a quality product that consistently meets Ford requirements during an actual production run at the quoted production rate.Phased PPAP separates the PPAP process into three phases: q Phase 1
10、is called Quality Verificationq Phase 2 is called Production Verificationq Phase 3 is called Capacity Verification.This Phased approach requires the supplier to provide promise dates to Ford for each of the three events, and additionally includes the requirement for the supplier to indicate that Run
11、 at Rate has been successfully completed. (Appendix B, Table 1 summarizes these requirements)Note: For less complex components/commodities/production streams, it is possible to complete multiple phases as a single event.Phased PPAP OverviewScopePhased PPAP redefines both the interpretation and execu
12、tion of the Production Part Approval Process (PPAP) (including the Part Submission Warrant (PSW) and is required for the following:1. A new part or product (i.e., a specific part, material or color not previously supplied to the specific customer).2. Correction of a discrepancy on a previously submi
13、tted part.3. Product modified by an engineering change to design records, specifications, or materials.4. Any situations required by Section I.3.1 from the AIAG PPAP Manual, 3rd Ed. (See Appendix C).These requirements are a minimum; local operations may require additional approvals.Phased PPAP will
14、eventually be applied globally in the Production Part Approval Process. Suppliers are required to apply the Phased PPAP process, including promise dates, confirmation and event completion for all new tooled parts.Phased PPAP applies to both new vehicle programs and for vehicles currently in producti
15、on, i.e. running changes. Benefits of Phased PPAPSuppliers and Ford will benefit from the use of Phased PPAP. Phased PPAP: Requires planning for launch Divides PPAP activities into more manageable segments Ensures assessment of supplier ability to handle production volume Provides a consistent mecha
16、nism to determine capacity verification Provides the program team with additional measures to forecast program readiness Provides clarity to the existing PPAP process Phased PPAP MilestonesPhase 2Phase 3Phase 1Quality VerificationCapacity VerificationProduction VerificationThe complete actual produc
17、tion stream (tool, line, facilities, personnel, etc.) intended for this specific program / launch is in place and operationalDimensional, Lab and ES testing complete from all tools, cavities, molds, production streams (including all appearance approvals)Supplier submits Part Submission Warrant (PSW)
18、.Parts are produced from the complete actual production stream (tooling, equipment, facilities, personnel)Capacity Verification is demonstrated by yielding quality parts to meet a minimum of one day of Ford production ( Daily Planning Volume DPV)Parts are produced from a minimum of one production st
19、ream (tool, line, facilities, etc.)Dimensional, Lab and Engineering Specification (ES) testing complete for this production stream (less appearance approvals)Initial Run at RateParts produced from a production stream (from a minimum of one production tool / line / process stream) at production feeds
20、 and speeds.Provides an early indicator if supplier can make future timingParts from the initial Run at Rate may be used for Phase 1 and Phase 2.Reference: Ford Product Development System (FPDS)J1LR*CCCPPAPHSCSI1/2PS KO*Note: 1PP Build occurs during Launch Readiness phase of FPDS, which is 4.5 month
21、s prior to J1 for an S3 and above program. Supplier completes Capacity Verification (Phase 3 PPAP) target completion is 4 weeks prior to Job 1 - demonstrating ability to meet Ford required volumes under intended operating pattern supplier dispositions completion and provides Demonstrated Weekly Capa
22、city numbers in systemSupplier completes Production Verification (Phase 2 PPAP) for specific program / plant by In Plant Date for 1PP build phase (all 19 elements of PPAP on parts from actual production streams (tools/cavities/molds/lines/etc.) supplier dispositions in system and forwards PSW docume
23、ntation.Supplier completes Quality Verification (Phase 1 PPAP) (16 of 19 elements of PPAP - excludes PSW, Appearance Approval and Master Sample) supplier dispositions in systemSupplier completes a minimum of one production stream and performs initial Run-at-Rate supplier indicates successful Run-at-
24、Rate in systemSupplier receives notification in work queue supplier is required to provide promise dates for Quality Verification, Production Verification, and Capacity VerificationParts are released -supplier is sourcedPhased PPAP Process FlowPhased PPAP: Detailed Process FlowINITIAL RUN-AT-RATEIni
25、tial Run-at-RateDEFINITION: Once tooling and equipment are in place at the intended supplier production facility for a minimum of one line/tool/cavity/production stream, supplier performs an initial run of the production stream. This run is typically a minimum of one to eight hours and a minimum of
26、300 pieces. The process must be run at production feeds and speeds based on the yield requirement for that product stream, supporting the latest authorized program volumes (based on the RFQ (Request for Quote). The initial run may be more or less than 300 pieces, as appropriate for the commodity or
27、part complexity - requires approval from authorized customer quality representative. For external suppliers, this would be Supplier Technical Assistance (STA). TIMING: This must completed in time to support the subsequent completion of Quality Verification (Phase 1). SYSTEM: Upon successful completi
28、on, the supplier inputs a Y indicator into the CMMS3 Vehicle Parts Progress screen this event is date-stamped. System will reflect RACFID as identification of system user.DOCUMENTATION: No additional documentation required (documented by supplier in system)STA ROLE: Business practices may vary by re
29、gion.Phase One: Quality VerificationDEFINITION: The supplier must achieve Quality Verification (Phase 1) by completing dimensional verification and ES (engineering specification) testing. Completion of Quality Verification requires 16 of the 19 elements of PPAP as stated in the AIAG PPAP manual, 3rd
30、 Edition (See Appendix D) (all items except item (13) PSW, (14) Appearance Approval, and (17) Master Sample). Upon successful completion of the 16 of 19 elements, the supplier has met the Phase 1 requirement. TIMING: This must completed in time to permit completion of Production Verification (Phase
31、2) prior to the In-Plant Date (IPD) for the 1PP vehicle build. SYSTEM: Upon successful completion of Phase 1, the supplier inputs Ready for Inspection (Y code) into CMMS3 Vehicle Parts Progress Detail Screen. The system then date stamps the completion of the event, and automatically accepts the part
32、 as approved (disposition code Q) regardless of PPAP level. STA can override with Approve (A) or Reject (R). System will reflect RACF ID as identification of system user.DOCUMENTATION: Supplier shall retain supporting documentation of all 16 elements per QS-9000, ISO/TS-16949 - and make them readily
33、 available to customer if requested.STA ROLE: STA may verify as necessary, and has the ability to override supplier declaration to disposition the Phase 1 completion using codes for Approval (A) or Reject (R). Phased PPAP: Detailed Process FlowQUALITY VERIFICATIONUpon completing initial run-at-rate
34、at production feeds and speeds, supplier completes the necessary dimensional verification and Engineering Specs (ES) testing on parts - this completes Quality Verification (Phase 1). Suppliers shall use parts from the Initial Run-at-Rate for Quality Verification.Dimensional, Lab and ES Testing and a
35、ll Appearance Approvals for all parts from all production streamsPhase 2 Production Verification is completeOnce the supplier has all production streams/tools/cavities in place on the plant floor, the supplier proceeds to achieve all required levels of testing and dimensional verification for all pr
36、oduction streams intended for a specific program (lead program or lead plant), including all appearance approvals and completed PSW documentation.Phased PPAP: Detailed Process FlowPRODUCTION VERIFICATIONPhase Two: Production VerificationDEFINITION: Once the supplier has completed Phase 1, the suppli
37、er should follow the necessary steps to achieve all part testing, verifications and runs-at-rate from all actual production streams (all tools /lines /molds /cavities /facilities etc.) required for a specific program launch. All appearance approvals must be completed (color, graining, surface appear
38、ance). All 19 elements of PPAP must be completed per AIAG Guidelines (PPAP, 3rd edition). Deficiency in meeting Phase 2 requirements by 1PP IPD and subsequent builds will require an WERS alert and build support plan. TIMING: This must completed by the 1PP IPD date (prior to 1PP) to support program b
39、uild event as required for this launch (lead program or lead plant). SYSTEM: Upon successful completion of Phase 2, the supplier inputs Ready for Inspection (Y code) into CMMS3, and system date stamps the completion of the event. System will reflect RACF ID of system user.DOCUMENTATION: Supplier mus
40、t complete all 19 elements of PPAP including PSW submission and maintain supporting documentation. See AIAG PPAP Manual Table I.4.1 for submission requirements.STA ROLE: STA will disposition Production Verification (Phase 2) completion for PPAP level 2-5 suppliers, and has ability to override PPAP l
41、evel 1 supplier declaration, with Approve (A) or Reject (R). STA tracks supplier performance in Supplier Improvement Metrics (SIM).CBACapacity Verification: Phase 3 PPAP Requirements - DetailCapacity Verification forms and requirements may vary by region and program. The following describes how to c
42、omplete Phase 3 documentation (Capacity Verification) for North America. The supplier will input Weekly Demonstrated Capacity into CMMS3.Prepare for Capacity Verification -Form PP-S-F041 (Attachment A)Suppliers must verify Production Readiness by completing Form PP-S-F041, Capacity Verification. Thi
43、s worksheet will assess if a supplier has a true production environment in place and has adequately prepared their organization and sub-suppliers for the start of production and ramp-up. 1. The supplier is to input production plan variables on Form PP-S-F041 and determine if the Potential Capacity F
44、orecast meets Ford Motor Companys Capacity Planning Volume (CPV). 2. The supplier must complete the Shared Capacity Analysis section on Form PP-S-F041 and determine if capacity or production hours are oversold.3. The supplier must complete the Production Readiness Questionnaire.4. The supplier then
45、summarizes their results and determines if they can proceed to Perform Capacity Verification (Form PP-S-F042).Perform Capacity Verification -Form PP-S-F042 (Attachment B)Suppliers must Perform Capacity Verification by completing Form PP-S-F042. This worksheet will determine if a supplier can produce
46、 quality parts at production feeds and speeds in the necessary production environment.1. The supplier must determine the number of parts to be produced for Capacity Verification. The quantity must be sufficient to validate that the process performs in a manner sufficient to support the required Ford Capacity Planning Volume. The supplier is required to support the Ford Motor Company standard operating pattern and schedule: based on 5 days, 100 hours, 2 shifts (North America) or 3 shifts (Europe). The minimum required length of the Capacity Verification
