第二部分：福特APQP状态报告程序(共61页).ppt

1、A AP P Q QP P S S t ta a t tu u s s R Re e p p o o r r t ti in n g g P P r r o o c c e e s s s sModule IntroductionModule Introduction组成部分介绍组成部分介绍Prototype Build样件制造样件制造1-38A AP P Q QP P S S t ta a t tu u s s R Re e p p o o r r t ti in n g g P P r r o o c c e e s s s sProcess FlowProcess Flow过程流程过程流

2、程Feedback Assessment & Corrective Action反馈、评估和纠正措施反馈、评估和纠正措施Product & Process Validation产品与过程确认产品与过程确认Process Design & Devel opment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1-39A AP P Q QP P S S t ta a t tu u s s R Re e

3、p p o o r r t ti in n g g P P r r o o c c e e s s s sPrototype Build OverviewPrototype Build Overview样件制造概述样件制造概述APQP Prototype Build elements support the successful planning and construction of Prototype Build units, which provide an understanding of the vehicles:APQP 样件制造要素支持样件制造单位的成功的策划和构样件制造要素支持

4、样件制造单位的成功的策划和构造，提供对于车辆的如下理解：造，提供对于车辆的如下理解：lDesign设计设计lFunctionality功能性功能性lManufacturability可制造性可制造性1-40A AP P Q QP P S S t ta a t tu u s s R Re e p p o o r r t ti in n g g P P r r o o c c e e s s s sPrototype Build ElementsPrototype Build Elements样件制造要素样件制造要素lThe PBCP supports the planning and const

5、ruction of prototypes by documenting the process steps of the Prototype Build phase.PBCP 通过将样件制造阶段的过程步骤文通过将样件制造阶段的过程步骤文件化支持样件的策划和构造。件化支持样件的策划和构造。lThe Prototype Build ensures that the customer receives CPs manufactured and assembled prior to 1PP.样件制造确保顾客在样件制造确保顾客在 1PP 前收到制造和装前收到制造和装配好的配好的 CP。1-41A AP

6、 P Q QP P S S t ta a t tu u s s R Re e p p o o r r t ti in n g g P P r r o o c c e e s s s sPBCP (Prototype Build Control Plan) DefinitionPBCP (Prototype Build Control Plan) DefinitionPBCPPBCP（样件制造控制计划）定义样件制造控制计划）定义lThe PBCP description of the dimensional measurements and material/functional tests t

7、hat occur during the CP build.PBCP 描述了发生在描述了发生在 CP 制造中的尺寸测量和材料制造中的尺寸测量和材料/功能试验功能试验lIt is the first summary document that indicates:是说明如下事项的摘要文件：是说明如下事项的摘要文件：qThe steps between Prototype Build and Pre-Launch leading to the Production Control Plan产生生产控制计划的样件制造和试生产之间的步骤产生生产控制计划的样件制造和试生产之间的步骤qThe proces

8、s steps to identify and align both the products characteristics and its targets识别和调整产品特性及其指标的过程步骤识别和调整产品特性及其指标的过程步骤1-42A AP P Q QP P S S t ta a t tu u s s R Re e p p o o r r t ti in n g g P P r r o o c c e e s s s sPBCP General ExpectationsPBCP General ExpectationsPBCP PBCP 总的期望总的期望lProduct characte

9、ristics are reviewed评审产品特性评审产品特性qThose characteristics required for PBCPs are identified.确定确定 PBCP 所要求的特性。所要求的特性。qAll potential significant and critical characteristics from the DFMEAs must be included.必须包括必须包括 DFMEA 输出的所有潜在重要和关键特性。输出的所有潜在重要和关键特性。lThe process parameter conditions must be documented.

10、过程参数条件必须被文件化。过程参数条件必须被文件化。qThis includes all special tooling, manufacturing, and assembly conditions.包括所有特殊工具、制造和装配条件。包括所有特殊工具、制造和装配条件。1-43A AP P Q QP P S S t ta a t tu u s s R Re e p p o o r r t ti in n g g P P r r o o c c e e s s s sPBCP ChecklistPBCP ChecklistPBCP PBCP 检查清单检查清单1-44A AP P Q QP P S

11、 S t ta a t tu u s s R Re e p p o o r r t ti in n g g P P r r o o c c e e s s s sPrototype BuildPrototype Build样件制造样件制造lDefines the manufacture and assembly of components, subsystems, systems, and vehicles supplied to the customer for builds occurring prior to the 1PP trial run 定义在定义在 1PP 试运行前的样件制造，

12、以提供给零部件、试运行前的样件制造，以提供给零部件、子系统、系统和车辆的制造和装配。子系统、系统和车辆的制造和装配。lIncludes not only the actual build process, but the preparation for the build so that CPs are supplied to the customer prior to 1PP不仅包括实际的制造过程，而且包括为了在不仅包括实际的制造过程，而且包括为了在 1PP 前将前将 CP 提交给顾客而进行的制造准备提交给顾客而进行的制造准备1-45A AP P Q QP P S S t ta a t tu

13、 u s s R Re e p p o o r r t ti in n g g P P r r o o c c e e s s s sPrototype Build ExpectationsPrototype Build Expectations样件制造期望样件制造期望lPBCPs are followed.按照按照 PBCP 进行进行lSuppliers receive all necessary information and participate according to the programs schedule and timing.供方收到所有必要的信息并按照项目时间安排定时参与

14、供方收到所有必要的信息并按照项目时间安排定时参与lThe timing for changes will be in line with the next build phase.更改的时间选择应该符合下一个制造阶段。更改的时间选择应该符合下一个制造阶段。lAll prototype materials must meet 100 percent of the dimensional specifications and functional requirements at delivery to meet the CP In-Plant Date.交付时所有样件材料必须交付时所有样件材料必须

15、 100% 满足尺寸规范和功能要求以满满足尺寸规范和功能要求以满足足 CP 进厂日期。进厂日期。1-46A AP P Q QP P S S t ta a t tu u s s R Re e p p o o r r t ti in n g g P P r r o o c c e e s s s sPrototype Build Expectations (Continued)Prototype Build Expectations (Continued)样件制造期望（续）样件制造期望（续）lQuality levels are checked against the PBCP.按照按照 PBCP

16、 检查质量等级。检查质量等级。lDimensional and functional data is available for review by the customer on each part.顾客可以获得每个零件的尺寸和功能数据以进行评审。顾客可以获得每个零件的尺寸和功能数据以进行评审。lSuppliers provide customers with any testing and checking requirements for prove-out of their part design.供方向顾客提供所有试验和检查要求以证明零件设计是适当的。供方向顾客提供所有试验和检查要求

17、以证明零件设计是适当的。lAn Action Matrix is developed to capture and resolve all concerns found during build and any subsequent lab, plant, and/or road testing, and all concerns are reviewed with the program team and appropriate management.开发开发“措施矩阵措施矩阵”以获得和解决在制造和所有试验室、工厂和以获得和解决在制造和所有试验室、工厂和/或道或道路试验中并发的问题，和所有项

18、目小组及适当的管理层评审的问题。路试验中并发的问题，和所有项目小组及适当的管理层评审的问题。1-47A AP P Q QP P S S t ta a t tu u s s R Re e p p o o r r t ti in n g g P P r r o o c c e e s s s sPrototype Build ChecklistPrototype Build Checklist样件制造检查清单样件制造检查清单1-48A AP P Q QP P S S t ta a t tu u s s R Re e p p o o r r t ti in n g g P P r r o o c c

19、 e e s s s sModule IntroductionModule Introduction组成部分介绍组成部分介绍Process Design and Development过程设计和开发过程设计和开发1-49A AP P Q QP P S S t ta a t tu u s s R Re e p p o o r r t ti in n g g P P r r o o c c e e s s s sProcess FlowProcess Flow过程流程过程流程Feedback Assessment & Corrective Action反馈、评估和纠正措施反馈、评估和纠正措

20、施Product & Process Validation产品与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1-50A AP P Q QP P S S t ta a t tu u s s R Re e p p o o r r t ti in n g g P P r r o o c c e e s s s sElementsEle

21、ments要素要素lFacilities, Tools, and Gauges1. 设施、工具和量具设施、工具和量具2. Manufacturing Process Flow2. 制造过程流程制造过程流程3. Process FMEA3. 过程过程 FMEA4. Measurement System Evaluation4. 测量系统评价测量系统评价5. Pre-Launch Control Plan5. 试生产控制计划试生产控制计划6. Operator Process Instructions6. 操作工过程指导书操作工过程指导书7. Packaging Specifications7.

22、包装规范包装规范1-51A AP P Q QP P S S t ta a t tu u s s R Re e p p o o r r t ti in n g g P P r r o o c c e e s s s sFacilities, Tools, and Gauges (8)Facilities, Tools, and Gauges (8)设施、工具和量具设施、工具和量具(8)(8)lThis element identifies the new, additional, refurbished, and relocated facilities and resources necess

23、ary to manufacture the customer-specified product at designated quantity and quality levels. 本要素确定了以规定的数量和质量等级制造顾客指本要素确定了以规定的数量和质量等级制造顾客指定的产品所需的新的、额外的、更新的和重新部署定的产品所需的新的、额外的、更新的和重新部署的设施和资源。的设施和资源。lThe element also identifies the tools and gauges used in process machinery to transform raw material int

24、o finished parts or assemblies. 本要素还确定了用于将原材料转换为完成的零件或本要素还确定了用于将原材料转换为完成的零件或组装件的机械加工过程的工具和量具。组装件的机械加工过程的工具和量具。1-52A AP P Q QP P S S t ta a t tu u s s R Re e p p o o r r t ti in n g g P P r r o o c c e e s s s sExpectationsExpectations期望期望lThe planning and execution of this element must align with: l

25、 to milestones lPQOS Deliverables 本要素的计划和执行必须配合本要素的计划和执行必须配合 里程碑里程碑 到到 PQOS 需交付的事务需交付的事务lFacility permits, planning approval, drawings, and utilities must be included on the Manufacturing Timing Plan. In addition, funding approvals must be completed.制造时间计划中必须包括设施许可、计划批准、图样和效用。另制造时间计划中必须包括设施许可、计划批准、图

26、样和效用。另外，必须完成资金批准。外，必须完成资金批准。lThe program team must approve statistical requirements and acceptance criteria before sourcing of tools or gauges can be made. 在可以进行工具和量具的外包之前，项目小组必须批准统计要求在可以进行工具和量具的外包之前，项目小组必须批准统计要求和接收准则。和接收准则。1-53A AP P Q QP P S S t ta a t tu u s s R Re e p p o o r r t ti in n g g P P

27、 r r o o c c e e s s s sExpectations (Continued)Expectations (Continued)期望（续）期望（续）lAll tools and gauges must comply with Tooling and Equipment Supplement requirements.所有工具和量具必须符合工装和设备补充要求。所有工具和量具必须符合工装和设备补充要求。lTrial runs should occur at the machine builders location to qualify all tools.应该在机械制造者的现场进

28、行试运行，以验证所有工具合格。应该在机械制造者的现场进行试运行，以验证所有工具合格。lAll corrective actions for facilities, tools, and gauges not meeting customer requirements must be completed before the Production Trial Run.必须在产品试生产前完成针对不满足顾客要求的设施、工具和量必须在产品试生产前完成针对不满足顾客要求的设施、工具和量具的所有纠正措施。具的所有纠正措施。lTools and gauges must be delivered, set u

29、p, and approved in their specified facilities before the Production Trial Run. 产品试生产前工具和量具必须以制定的设施交付、安装和批准。产品试生产前工具和量具必须以制定的设施交付、安装和批准。1-54A AP P Q QP P S S t ta a t tu u s s R Re e p p o o r r t ti in n g g P P r r o o c c e e s s s sFacilities, Tools, and Gauging ChecklistFacilities, Tools, and Ga

30、uging Checklist设施、工具和量具检查清单设施、工具和量具检查清单1-55A AP P Q QP P S S t ta a t tu u s s R Re e p p o o r r t ti in n g g P P r r o o c c e e s s s sManufacturing Process Flow (13)Manufacturing Process Flow (13)制造过程流程（制造过程流程（1313）This element is a graphic representation of the current or proposed sequence of

31、the manufacturing process to ensure that the process definition, PFMEA, and Control Plans can be created and analyzed in the appropriate sequence.本要素制造过程的当前的或建议的次序的图本要素制造过程的当前的或建议的次序的图解表示，以确保以适当的次序建立和分析过解表示，以确保以适当的次序建立和分析过程定义、程定义、PFMEA 和控制计划。和控制计划。1-56A AP P Q QP P S S t ta a t tu u s s R Re e p p o

32、 o r r t ti in n g g P P r r o o c c e e s s s sManufacturing Process Flow ExpectationsManufacturing Process Flow Expectations制造过程流程期望制造过程流程期望Manufacturing Process Flow general expectations are that:制造过程流程总的期望是：制造过程流程总的期望是：lA cross-functional team led by VO Engineering develops a Manufacturing Proce

33、ss flowchart to serve as an input to PFMEAs.由由 VO 工程领导的横向职能小组开发制造过程流程图作为工程领导的横向职能小组开发制造过程流程图作为 PFMEA 的输入。的输入。lThe process flowcharts are developed using PFMEAs and surrogate processes to serve as input for new processes and technologies.使用使用 PFMEA 和替代的过程开发过程流程图，作为新过程和技术的和替代的过程开发过程流程图，作为新过程和技术的输入。输入。

34、lThe current production flowcharts may be modified to show revisions to the process flow.可以修改当前的生产流程图，以显示对过程流程的修改。可以修改当前的生产流程图，以显示对过程流程的修改。1-57A AP P Q QP P S S t ta a t tu u s s R Re e p p o o r r t ti in n g g P P r r o o c c e e s s s sManufacturing Process Flow ChecklistManufacturing Process Flo

35、w Checklist制造过程流程检查清单制造过程流程检查清单1-58A AP P Q QP P S S t ta a t tu u s s R Re e p p o o r r t ti in n g g P P r r o o c c e e s s s sProcess FMEA (14) Process FMEA (14) 过程过程 FMEA (14)FMEA (14)The PFMEA is a systematic approach used by a manufacturing-responsible team to ensure that potential process-r

36、elated failure modes and their associated causes have been considered and resolved.PFMEA 是制造职责小组使用的确保已经考是制造职责小组使用的确保已经考虑并解决了潜在的与过程相关的失效模式及虑并解决了潜在的与过程相关的失效模式及其相关原因的系统化的方法。其相关原因的系统化的方法。1-59A AP P Q QP P S S t ta a t tu u s s R Re e p p o o r r t ti in n g g P P r r o o c c e e s s s sExpectationsExpec

37、tations期望期望lAll Process FMEAs are prepared by a cross-functional team led by Manufacturing Engineering following the steps defined in the FMEA guideline.所有过程所有过程 FMEA 以制造工程为领导的横向职能小组按照以制造工程为领导的横向职能小组按照 FMEA 指南指南中定义的步骤进行准备。中定义的步骤进行准备。lProcess FMEAs must be established any time that: 当存在如下事项时，必须建立过程当存

38、在如下事项时，必须建立过程 FMEA： qNew processes, technologies, products, or product features are introduced. 引入新的过程、技术、产品或产品特征。引入新的过程、技术、产品或产品特征。qQuality risks are identified that cannot be resolved through design changes. 确定质量风险不能通过设计变更加以解决。确定质量风险不能通过设计变更加以解决。qMajor quality concerns have not been resolved durin

39、g the current production model year.在当前的生产模型年中，没有解决重大的涉及质量的问题。在当前的生产模型年中，没有解决重大的涉及质量的问题。1-60A AP P Q QP P S S t ta a t tu u s s R Re e p p o o r r t ti in n g g P P r r o o c c e e s s s sExpectations (Continued)Expectations (Continued)期望（续）期望（续）lList of recommended actions and lessons learned is in

40、corporated in the process (continuous improvement).将列出的将列出的“建议措施建议措施”和学到的经验和并在过程和学到的经验和并在过程（持续改进）中。（持续改进）中。lPoke-a-Yoke has been used in addressing corrective actions.制定纠正措施中使用防错方法（制定纠正措施中使用防错方法（Poke-a-Yoke）。）。1-61A AP P Q QP P S S t ta a t tu u s s R Re e p p o o r r t ti in n g g P P r r o o c c e

41、 e s s s sProcess FMEA ChecklistProcess FMEA Checklist过程过程 FMEA FMEA 检查清单检查清单Process FMEA 1-62A AP P Q QP P S S t ta a t tu u s s R Re e p p o o r r t ti in n g g P P r r o o c c e e s s s sMeasurement System Evaluation (15)Measurement System Evaluation (15)测量系统评价（测量系统评价（1515）This element assesses t

42、he variation of the measurement system, and determines whether it is acceptable for monitoring the production process.本要素评估测量系统的变差，确定是本要素评估测量系统的变差，确定是否可以接受测量系统监控生产过程。否可以接受测量系统监控生产过程。1-63A AP P Q QP P S S t ta a t tu u s s R Re e p p o o r r t ti in n g g P P r r o o c c e e s s s sExpectationsExpect

43、ations期望期望lCorrelation standards are reached and agreed to with the customer for duplicate gauges or test equipment.已达到相同的测量或试验设备的相关标准和顾客的批准。已达到相同的测量或试验设备的相关标准和顾客的批准。lGauge instructions and visual aids to ensure appropriate use of gauge and test equipment in production.测量指导书和目视辅具确保在生产中适当的使用测量和试测量指导书

44、和目视辅具确保在生产中适当的使用测量和试验设备。验设备。lAll measurement systems (gauges and test equipment) must be modified to reflect the latest engineering part level before the Production Trial Run. 在产品试生产前必须修改所有测量系统（测量和试验设在产品试生产前必须修改所有测量系统（测量和试验设备）以反映最新工程零件等级。备）以反映最新工程零件等级。 1-64A AP P Q QP P S S t ta a t tu u s s R Re e

45、p p o o r r t ti in n g g P P r r o o c c e e s s s sExpectations (Continued)Expectations (Continued)期望（续）期望（续）lThe user/customer must be given the opportunity to review and concur with the gauges and test equipment study results before the Production Trial Run. 产品试生产前使用者产品试生产前使用者/顾客顾客,必须有机会评审和批准测量和

46、试验设备研究必须有机会评审和批准测量和试验设备研究结果。结果。lThe Measurement System Evaluation must be repeated and approved following all gauge and test equipment modifications.所有测量和试验设备更改后所有测量和试验设备更改后,必须重新进行测量系统评价并获得批准。必须重新进行测量系统评价并获得批准。 lThe Production Control Plan must align with the Measurement Systems Development plan.生产控

47、制计划必须配合测量系统开发计划。生产控制计划必须配合测量系统开发计划。 lGauge Repeatability and Reproducibility studies must be conducted on all measurement systems.所有测量系统必须进行量具重复性和再现性研究。所有测量系统必须进行量具重复性和再现性研究。1-65A AP P Q QP P S S t ta a t tu u s s R Re e p p o o r r t ti in n g g P P r r o o c c e e s s s sMeasurement System Evaluat

48、ion ChecklistMeasurement System Evaluation Checklist测量系统评价检查清单测量系统评价检查清单1-66A AP P Q QP P S S t ta a t tu u s s R Re e p p o o r r t ti in n g g P P r r o o c c e e s s s sPre-Launch Control Plan (16)Pre-Launch Control Plan (16)试生产控制计划（试生产控制计划（1616）This is a description of the dimensional measuremen

49、ts and material/functional in-process tests or checks that occur after prototype builds, but before full production 对发生在样件制造后，全面生产前的尺寸测对发生在样件制造后，全面生产前的尺寸测量、过程中材料量、过程中材料/功能试验或检查的描述。功能试验或检查的描述。1-67A AP P Q QP P S S t ta a t tu u s s R Re e p p o o r r t ti in n g g P P r r o o c c e e s s s sExpectati

50、onsExpectations期望期望lLegitimate/appropriate inspection sample sizes, frequencies, control method, etc. inclusive to pre-launch phase of production are included.在生产的试生产阶段包含合理在生产的试生产阶段包含合理/适当的检验样本容量、频率、控制方法等。适当的检验样本容量、频率、控制方法等。lAll product & process characteristics for pre-launch control plans are

51、identified and reviewed.确定和评审试生产控制计划的所有产品和过程特性。确定和评审试生产控制计划的所有产品和过程特性。lResults from the PBCP and DFMEA provide the outline for the Pre-Launch Control Plan.PBCP 和和 DFMEA 的结果提供了试生产控制计划的概要。的结果提供了试生产控制计划的概要。lThe Production Control Plan for the current production model is used to assist in the developmen

52、t of the Pre-Launch Control Plan if APQP Elements 8 and 13 have not been initiated.如果如果 APQP 要素要素 8 和和 13 还未启动，使用当前生产模式的生产控制计划协助开发还未启动，使用当前生产模式的生产控制计划协助开发试生产控制计划。试生产控制计划。1-68A AP P Q QP P S S t ta a t tu u s s R Re e p p o o r r t ti in n g g P P r r o o c c e e s s s sPre-Launch Control Plan Checkl

53、istPre-Launch Control Plan Checklist试生产控制计划检查清单试生产控制计划检查清单1-69A AP P Q QP P S S t ta a t tu u s s R Re e p p o o r r t ti in n g g P P r r o o c c e e s s s sOperator Process Instructions (17)Operator Process Instructions (17)操作工过程指导书（操作工过程指导书（1717） lThis element describes the details of the control

54、s and actions that operating personnel must perform to produce quality products.本要素描述操作人员为生产质量合格的产品所必须本要素描述操作人员为生产质量合格的产品所必须执行的控制和措施的详细情况。执行的控制和措施的详细情况。lThese instructions are divided into two major components:这些指导书分为两个主要部分：这些指导书分为两个主要部分：qDescription of the process过程描述过程描述 qOperator instructions操作供指

55、导书操作供指导书1-70A AP P Q QP P S S t ta a t tu u s s R Re e p p o o r r t ti in n g g P P r r o o c c e e s s s sExpectationsExpectations期望期望lA completed Operator Process Instructions package.完成的整套操作工过程指导书。完成的整套操作工过程指导书。lInstructions developed to be used during a production trial run to ensure the proces

56、s performs as intended. 在产品试生产中使用开发的指导书以确保过程按预期执行。在产品试生产中使用开发的指导书以确保过程按预期执行。lOperator Process Instructions describe all process steps necessary to produce a quality product. The training instructions must include:操作工过程指导书描述了生产质量合格的产品所需的所有过程步骤。操作工过程指导书描述了生产质量合格的产品所需的所有过程步骤。培训指导书必须包括：培训指导书必须包括：qDetail

57、ed instructions详细的指导书详细的指导书qVisual aids目视辅具目视辅具qAny other quality materials necessary to support the production operator支持生产操作工所需的任何质量材料支持生产操作工所需的任何质量材料1-71A AP P Q QP P S S t ta a t tu u s s R Re e p p o o r r t ti in n g g P P r r o o c c e e s s s sOperator Process Instructions Checklist Operator

58、 Process Instructions Checklist 操作工过程指导书检查清单操作工过程指导书检查清单1-72A AP P Q QP P S S t ta a t tu u s s R Re e p p o o r r t ti in n g g P P r r o o c c e e s s s sPackaging Specifications (18)Packaging Specifications (18)包装规范（包装规范（1818） This element describes the design and development of the end-item ship

59、ment packaging, including interior partitions.本要素描述产品最后出货包装的设计本要素描述产品最后出货包装的设计与开发，包括包装内部的分隔配置。与开发，包括包装内部的分隔配置。 1-73A AP P Q QP P S S t ta a t tu u s s R Re e p p o o r r t ti in n g g P P r r o o c c e e s s s sExpectationsExpectations期望期望lPast issues on similar or surrogate packaging are discussed

60、and resolved by the team.小组讨论和解决相似或替代的包装中过去发生的问题。小组讨论和解决相似或替代的包装中过去发生的问题。lCorrective actions exist for any packaging issues identified that affect product performance and characteristics.确定对于任何影响产品性能和特性的包装问题的现存纠正措施。确定对于任何影响产品性能和特性的包装问题的现存纠正措施。lSupplier and the receiving plant agree upon packaging requirements.供方和接收工厂就包装要求达成一致。供方和接收工厂就包装要求达成一致。lPackaging ev