福特PPAP供应商培训

生产件批准程序ProductionPartApprovalProcess(PPAP)Presentedby:MaxZhangFordCSOSTA9thAugust2007PPAPistodemonstratesupplier’sunderstandingof:PPAP是为表明供应商怎样理解以下内容的一个过程：-零件的用法Part’sUsage-相关的项目Associatedprograms-车辆Vehicle-型号年份ModelYear(MY)零件的功能Part’sfunctionality零件的特性Part’sCharacteristics特性的关键性Criticalityoffeatures怎样测量零件Howtogaugethepart生产要求Productionrequirements工程图纸要求Engineeringdrawingrequirements工程规范(ES)材料特性MaterialCharacteristics材料处理(热处理,外观)MaterialTreatment(HeatTreat,Appearance)安全特性OperatorSafetyfeatures,ifany关键特性CriticalCharacteristics重要特性SignificantCharacteristics高影响的特性HighImpactCharacteristics传递特性PassThroughCharacteristics使用哪些最为合适的量具Whatmostsuitablegaugestouse?-计量型量具Variablegauges-计数型量具Attributegauges基准Datum测量方法和装配工厂存在相关性MeasurementCorrelationwithusingplants何时需要？Whenneeded?哪里需要?Whereneeded?多少数量?Howmuch?-按节拍生产RunatRate-生产能力确认CapacityVerificationApplication什么时候用到PPAP?•PPAPisrequiredfor,butnotlimitedto:•PPAP对以下情况适用（但不局限于）：Allnewtooledparts（使用新模具生产零件）Allnewvehicleprogramsandrunningchangesforvehiclescurrentlyinproduction(新车型，或者是对现有车型的变更)Anychangeinsupplieroperatingpattern(i.e.newshift)(生产模式的变更)Anyadditional,modifiedorreconfiguredproductiontooling,equipmentorworkstreams（模具，设备或生产线的增加，改造或重新装配）RevisedcustomerDPV(DailyProductionVolume)exceedingverifiedsuppliercapacitylevel（客户需求量的增加）Content内容•PhasedPPAPintroduction•阶段性生产件批准程序的介绍•FordspecialrequirementstoPPAP18elements.•福特汽车对于生产件批准18个项目的要求。•VPPusage•VPP的使用方法阶段性生产件批准程序PHASEDPPAPPROCESSWhatisthePhasedPPAP?什么是PhasedPPAP？•PhasedPPAPisFord’sapproachtoPPAPprocessmanagementPhasedPPAP是福特特有的生产件批准管理程序。•Introducedtoimproveuponlaunchperformance用来提高项目开发和实施的表现。•Requiresasuppliersitetodemonstrate•Manufacturingcapability（制造能力）•Productquality（产品质量）•Andproductioncapacity（产能）•…priortojob#1（在J#1之前）PhasedPPAPvstheoldPPAPPhasedPPAP与PPAP的比较•PhasedPPAPorganizestheprocessintofourphases•Phase0:Run-at-Rate•Phase1:QualityVerification•Phase2:ProductionVerification•Phase3:CapacityVerificationPPAPX1PPFEUJob1PhasedPPAPPhase0Phase1Phase2Phase3SupplierPhasedPPAPProcessMap阶段性生产件批准程序示意图STATUS:Phase2CompletedPhase2Warrant[#18]YesStatusTrackingDatabase234ProceedtonextpageSubmittoCustomerImportantnote:Phase2andPhase3canhappenconcurrentlyifallInputsandOutputsaresatisfiedNoINPUTSReleaseddesign[#1,2,3&4]TrainedsupplierproductionoperatorsSub-supplier(s)materialstatusfromTier-xR@RJob1Location(finalsite&line)Quantityofpartsrequiredasdefinedbycustomer(default300consecutiveparts)Productionprocessincludingcontrolplan,flowdiagraminstructions&Processparameters[#5,6&7]ProductionTools,Facilities&Gauging[#8,16&17]EVENT:ConductRunatRatePlannedproductioncycletimesrequiredtosupportDailyProductionVolumeOutputsfromtheeventSTATUS:Phase0CompletedImplementCorrectiveActiononInputWasthePre-LaunchControlPlanfollowed?Weretheprescribednumberofacceptablepartsproduced?Werethepartsproducedinthedefinedperiod?Didalloperationsmeettheirplannedcycletime?YesYesYesYesNoNoNoNoAretheRun@Rateinputrequirementsinplacefortheproductionstream?YesSTARTNoCapacityAnalysisWorksheetStatusTrackingDatabase14ProceedtonextpageRequiredInputsSubmittoCustomerNote:[#x]referstotheElementNumberinPPAP4thEditionthatwillassistinconfirmingrequirementsSTATUS:Phase1CompletedContinueProductionPartApprovalProcess(PPAP)usingpartsfromPhase0-Dimensionalmeasurements[#9]-MaterialTests[#10]-Statisticalprocesspackage[#11]-PerformanceTests[#12]-Appearancecriteria[#13]-Sampleparts[#14]-Mastersamples[#15]-CustomerSpecificRequirements[#17]-asdefinedbyPPAPHavethePPAPelementsbeensatisfied?YesStatusTrackingDatabase1424Importantnote:ForsupplierswithonlyoneproductionstreamcompletionofPhase1&2occuratthesametimeProceedtonextpageReturntoPhase0forcorrectiveactionNoSubmittoCustomerPhase1Warrant[#18]Phase2WarrantScheduleddowntimedefined(TPM,changeover,Breaksetc.)SubsuppliermaterialstatusfromTier-xPhase3EVENT:ConductCapacityVerificationRunSTATUS:Phase3CompletedQuantityrequirediscustomerDPVforonefulldayAllpersonnelforallshifts,trainedAretheCVRinputrequirementsinplaceforallproductionstreams?YesENDStatusTrackingDatabaseReturntoaffectedphaseandstartcorrectiveactionPhase3Warrant[#18]&CapacityAnalysisReportDetermineRootCause&PlanCorrectiveActionWasthecontrolplanfollowed&acceptablepartsproduced?DidthevolumeofacceptablepartsproducedmeetorexceedtherequiredDPV?NoYesNo3RequiredInputsPhase0Phase1Phase2Phase0Run-at-RatePhase1QualityVerificationPhase2ProductionVerificationPhase3CapacityVerification1-DesignRecords2-EngineeringChangeDocuments3–CustomerEngineeringApproval4-DesignFMEA5-ProcessFlowDiagrams6-ProcessFMEA7-ControlPlans8-MeasurementSystemAnalysisStudies16-CheckingAids17-Customer-SpecificRequirements9-DimensionalResults10-RecordsofMaterial/PerformanceTestResults11-InitialProcessStudies12-QualifiedLaboratoryDocumentation13-AppearanceApprovalReport14-SampleProductionParts15-MasterSample18-PPAPWarrantPPAPWarrant(element18)Run-at-Rateforallproductionstreams(element1–8,16,17)QualityVerificationforallproductionstreams(element9–15)CapacityAnalysisReportCapacityAnalysisReportPPAPWarrant(element18)HaveRun-at-Rates(