APQP过程介绍(PPT-98页)课件

1、Module Introduction组成部分介绍Introduction to the APQP ProcessAPQP过程介绍1-12Feedback Assessment & Corrective Action反馈、评估和纠正措施Product & Process Validation产品与过程确认Process Design & Development过程设计和开发Product Design & Development产品设计和开发Prototype Build样件制造Plan & Define计划与定义1-2APQP Systemic FlowAPQP 系统流程1-3-EAPQP

2、Systemic FlowAPQP 系统流程APQP过程流程精致工艺资源决定顾客输入要求小组可行性承诺图纸/规范P-图失效模式和后果分析规范和目标（VDS/SDS/CDS）车辆/系统/子系统/部件的设计设计失效模式后果分析（DFMEA）图纸/规范（文件/电子档）设计验证计划（DVP）样件制造控制计划样件制造测量系统评价（尺寸控制）设施/工具/量具制造过程流程操作工过程指导书（过程定义）试生产控制计划过程失效模式后果分析（PFMEA）操作工过程指导书（验证和培训）生产控制计划产品试生产初始过程能力生产确认试验零件提交保证书（PSW）向前的信息流向后的信息流设计/制造评审（在所有APQP要素后）1

3、-3-CAccessing the APQP Guidelines访问 APQP 指南Both the Guideline and the forms are available.指南和表格均可由此获得。/apqp1-4APQP Generic Program Gantt Chart1-5Matrix for Quality Planning质量策划矩阵1-6Module Introduction组成部分介绍Plan and Define计划与定义1-7Process Flow过程流程Feedback Assessment & Corrective Action反馈、评估和纠正措施Produc

4、t & Process Validation产品与过程确认Process Design & Devel opment过程设计和开发Product Design & Development产品设计和开发Prototype Build样件制造Plan & Define计划与定义1-8Sourcing Decision资源决定It is a document that advises internal and external suppliers of key contact personnel within Ford (STA, purchasing, engineers, etc.).是内、外部

5、供方与 Ford （STA、采购、工程等）协商关键联络人的文件。 It serves as a formal customer commitment to work with all internal and external part suppliers, tooling suppliers, and facility suppliers on a program. 作为与项目中的内、外部零件供方、工装供方和设施供方共同工作的正式对顾客的承诺。1-9Sourcing Decision Expectations资源决定的期望All internal and external suppliers

6、 for a program are identified 项目所有的内、外部供方已经确定Early sourcing target agreements are established and signed by appropriate areas由适当的区域建立并签署早期资源指标协议All non-Q1 suppliers are identified所有非 Q1 供方已经确定Special arrangements for non-Q1 suppliers are identified非 Q1 供方的特殊安排已经确定A program timeline, aligned to FPDS,

7、 is established from to 已经建立了从 到 的、与 FPDS 一致的项目时间安排1-10Sourcing Decision Checklist资源决定检查清单1-11Customer Input Requirements顾客输入要求The Customer Input Requirements element ensures that the program team appropriately assesses the potential manufacturing, process, and design issues early in the product dev

8、elopment phase.顾客输入要求要素为了要让项目小组，在产品开发阶段适当的评估潜在的制造、过程和设计问题。 Customer Input Requirements are the design criteria and the program requirements necessary to initiate the APQP process. 顾客输入要求是启动 APQP 过程的必要的设计准则和项目要求。1-12Customer Input Requirements Expectations顾客输入要求期望Issues from surrogate components or p

9、lants are identified and addressed with product and manufacturing.已经识别了暂时代替的零部件或工厂的问题，并解决了生产和制造问题Component targets and product assumptions are defined.已经定义了零部件指标和产品假设Targets for TGW, TGR, Warranty, Useful Life Reliability, and Incoming Quality are established.已经建立 TGW、TGR、保证、使用寿命可靠性和进货质量指标Capacity p

10、lanning volumes are defined.生产量策划值已定义1-13Customer Input Expectations (Continued)顾客输入要求期望（续）System component designs and specifications should include:系统部件设计和规范应该包括： Product assumptions 产品假设Functional performance性能表现Dimensions几何尺寸 Weight重量 Material材料 Reliability and quality goals可靠性和质量目标1-14Customer

11、Input Checklist顾客输入检查清单1-15Craftsmanship is an assessment of what the customer sees, touches, uses, hears, and smells. It affects design and manufacturing, and it improves the overall perception of value.精致工艺是对顾客看到的、感觉到的、使用的、听到的和闻到的评估。影响设计和生产，并改进全面感官的价值。 Craftsmanship精致工艺1-16Craftsmanship Expectatio

12、ns精致工艺期望Obtain Craftsmanship targets and objectives to develop Craftsmanship plans获得精致工艺 指标和目标以开发精致工艺计划Develop the Craftsmanship strategy开发精致工艺战略Implement a plan to achieve Craftsmanship targets实施计划以达到精致工艺指标 Integrate plans to support the final Craftsmanship theme 整合各项计划以支持最终精致工艺计划Ensure that the de

13、sign and manufacturing processes comply with Craftsmanship strategy and plans 确保设计和制造过程符合精致工艺战略和计划Identify and resolve Craftsmanship issues that arise识别并解决发生的精致工艺问题1-17Craftsmanship Checklist精致工艺检查清单1-18Team Feasibility Commitment小组可行性承诺The Team Feasibility Commitment element determines whether the

14、proposed design can be manufactured within the programs guidelines and specifications.小组可行性承诺要素确定了建议的设计是否能根据项目指南和规范进行制造 The goals of this element are to verify that all of the:本要素的目的是验证所有：Activities agree that they can produce the product within specifications.活动可以生产符合规范的产品Feasibility concerns are r

15、esolved and necessary product and process changes are completed before first production prove-outs (1PP).在第一预生产单元建立（1PP）前解决可行性问题和必要的产品和过程更改.1-19Team Feasibility Commitment Expectations小组可行性承诺期望 The program team must establish a formal feasibility process and document.项目小组必须建立正式的可行性过程和文件。Feasibilitie

16、s are tracked and major feasibility concerns can be resolved before Production Trial Run.在产品试生产前追踪可行性，并解决可行性涉及的重要问题。WERS and AIMS concerns are resolved, and the product can be manufactured to meet Cp/Cpk and tolerance requirements.解决了WERS 和 AIMS 设计的问题，可以在满足Cp/Cpk 和公差要求的情况下制造产品。Suppliers and subsuppl

17、iers were part of the feasibility process.供方和分承包方式可行性过程的一部分。1-20Team Feasibility Commitment Checklist小组可行性承诺检查清单1-21Module Introduction组成部分介绍Product Design and Development产品设计和开发1-22Product Design and Development产品设计和开发Feedback Assessment & Corrective Action反馈、评估和纠正措施Product & Process Validation产品与过

18、程确认Process Design & Devel opment过程设计和开发Product Design & Development产品设计和开发Prototype Build样件制造Plan & Define计划与定义1-23Elements要素Design FMEA设计 FMEADVP&R设计验证计划和报告 Subcontractor/Subsupplier APQP Status分承包方/分供方 APQP 状态Drawings and Specifications图样和规范1-24Design FMEA设计 FMEAA group of activities intended to:一

19、组活动，用于:Identify potential: 识别潜在的:Product failure modes early in the product development phase产品开发阶段的早期产品失效模式 Product design safety concerns产品设计安全涉及的问题 Significant/critical/special characteristics重要/关键/特殊特性Establish a priority for design improvement actions 为设计改进活动建立优先顺序Document the rationale behind

20、product design changes to the development of future product designs将产品设计变更中的思路文件化，作为未来产品设计的开发的输入1-25DFMEA ExpectationsDFMEA 期望Completing DFMEAs that focus on what has changed in the design and its effect on the entire system完成关注设计中进行的更改及其对整个系统的影响的 DFMEACreating a list of potential Special Characteri

21、stics (YC, YS) resulting from DFMEAs or equivalent analysis建立 DFMEA 或类似的分析输出的潜在特殊特性 (YC, YS) 清单Addressing lessons learned and quality issues found in element 2, Customer Input Requirement解决在要素 2，顾客输入要求中发现的质量问题和学到的经验Ensuring that the DFMEA info is sent to PFMEA teams, including the special characteri

22、stics list确保将 DFMEA 信息，包括特殊特性清单传递给 PFMEA 小组1-26Design FMEA Checklist设计 FMEA 检查清单1-27DVP&R设计验证计划和报告 Lists the engineering evaluations and tests required to establish that a design is fit for use in the intended environment列出建立适于在预期的环境中使用的设计所要求的工程评价和试验Assists Product Development (PD) in verifying and

23、documenting the functionality, reliability, and durability of the vehicles design through planned tests and evaluations协助产品开发（PD）按计划的试验和评价，验证和文件化车辆设计的功能性、可靠性和耐久性Documents the plans and reports for Design Verification of a given design将对给定设计进行设计验证的策划和报告文件化Identifies tests, acceptance criteria, sample

24、 sizes, and completion dates in a standard format以标准的形式确定试验、接受准则、样本容量和完成日期1-28DVP&R Expectations设计验证计划和报告期望Corrective action plans must be completed for any test result that does not meet design spec and reliability goals必须针对任何没有满足设计期望和可靠性目标的试验结果完成纠正措施计划The DVP&R must:DVP&R 必须： Align with PQOS deliv

25、erables配合 PQOS 可交付性 Provide inputs to complete reports and proformas向完成报告和形式提供输入Identify any specific tests, methods, equipment, acceptance criteria, sample sizes, design level, and timing确定任何特殊的试验、方法、设备、接收准则、样本容量、设计等级和时间安排1-29DVP&R Checklist设计验证计划和报告检查清单1-30Subcontractor APQP Status分承包方 APQP 状态The

26、Subcontractor APQP Status element identifies and reports on the condition of external contractors (i.e., suppliers) and subcontractors APQP process. 分承包方 APQP 状态要素确定和报告外部承包方（例如供方）和分承包方 APQP 过程的状况Internal and external suppliers identify APQP requirements by cascading program targets APQP requirements

27、 to their subcontractors, and by conducting APQP reviews, as appropriate.内部和外部供方通过向分承包方逐级传递项目指标 APQP 要求和适当时进行 APQP 评审确定 APQP 要求1-31Subcontractor Expectations分承包方期望Subcontractor APQP Status general expectations are that all internal and external suppliers must: 分承包方 APQP 状态的总的期望是所有内部和外部供方必须：Assess th

28、e risk and specify the level of their subcontractors APQP participation评估风险和确定它们的分承包方参与 APQP 的等级 Cascade APQP requirements to their subcontractors向它们的分承包方逐级传递 APQP 要求 Hold regularly scheduled APQP review meetings with their subcontractors有规律的与分承包方会议，进行安排好的 APQP 评审 1-32Subcontractor APQP Checklist分承包

29、方 APQP 检查清单1-33Drawing and Specifications图样和规范This element provides an evaluation of the development of targets and specifications to be input to the design process and drawings.本要素提供对输入到设计过程和图样的指标和规范的开发的评价。These drawings include all engineering drawings, CAD data, material specifications, and engin

30、eering specifications.这些图样包括所有工程图样、CAD 数据、材料规范和工程规范。1-34Drawing and Specifications Expectations图样和规范期望Program Need Dates are communicated and agreed to by effected areas.项目所需数据由受到影响的区域进行沟通和批准。SCs and CCs are identified on the drawings or attached documents.在图样和附带文件中确定 SC 和 CC。Tolerances and part spe

31、cs are compatible with accepted manufacturing standards for gauges and equipment.公差和零件规格与量具和设备的可接受的制造标准一致。Drawings and specifications must include:图样和规范必须包括： Engineering specification tests工程规范试验 Product validation test requirements产品确认试验要求 Documentation to support prototype build and pre-launch con

32、trol plan development文件化以支持样件制造和试生产控制计划的开发 1-35Drawing and Specifications Expectations (Continued)图样和规范期望（续）The drawing information and engineering specifications will be used as a prerequisite to the PBCP. 图样信息和工程规范将作为样件制造控制计划（ PBCP） 的先决条件。Material used by the suppliers or the subcontractors must b

33、e approved and included in the Ford Approved Source list.供方或分承包方使用的材料，必须被批准并包含在福特批准资源清单内。PD and ME personnel will assess drawings and specifications to ensure they meet the programs ABS and quality requirements.PD 和 ME 人员将评估图样和规范，以确保满足项目 ABS 和质量要求。1-36Drawings and Specifications Checklist图样和规范检查清单1-

34、37Module Introduction组成部分介绍Prototype Build样件制造1-38Process Flow过程流程Feedback Assessment & Corrective Action反馈、评估和纠正措施Product & Process Validation产品与过程确认Process Design & Devel opment过程设计和开发Product Design & Development产品设计和开发Prototype Build样件制造Plan & Define计划与定义1-39Prototype Build Overview样件制造概述APQP Pro

35、totype 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造，提供对于车辆的如下理解：Design设计Functionality功能性Manufacturability可制造性1-40Prototype Build Elements样件制造要素The PBCP supports the planning and c

36、onstruction 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件化支持样件的策划和构造。The Prototype Build ensures that the customer receives CPs manufactured and assembled prior to 1PP.样件制造确保顾客在 1PP 前收到制造和装配好的 CP。1-41PBCP (Prototype Build Control Plan) DefinitionPB

37、CP（样件制造控制计划）定义The PBCP description of the dimensional measurements and material/functional tests that occur during the CP build.PBCP 描述了发生在 CP 制造中的尺寸测量和材料/功能试验It is the first summary document that indicates:是说明如下事项的摘要文件：The steps between Prototype Build and Pre-Launch leading to the Production Contr

38、ol Plan产生生产控制计划的样件制造和试生产之间的步骤The process 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1-42PBCP General ExpectationsPBCP 总的期望Product characteristics are reviewed评审产品特性Those characteristics required for PBCPs are identified.确定 PBCP 所要求的特性。All potential

39、 significant and critical characteristics from the DFMEAs must be included.必须包括 DFMEA 输出的所有潜在重要和关键特性。The process parameter conditions must be documented.过程参数条件必须被文件化。This includes all special tooling, manufacturing, and assembly conditions.包括所有特殊工具、制造和装配条件。1-43PBCP ChecklistPBCP 检查清单1-44Prototype Bu

40、ild样件制造Defines 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 1PP 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。Includes not only the actual build process, but the preparation for the build so that CPs ar

41、e 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 1PP 前将 CP 提交给顾客而进行的制造准备1-45Prototype Build Expectations样件制造期望PBCPs are followed.按照 PBCP 进行Suppliers 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The timing for change

42、s 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。All 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 100% 满足尺寸规范和功能要求以满足 CP 进厂日期。1-46Prototype Build Expectations (Continued)样件制造

43、期望（续）Quality levels are checked against the PBCP.按照 PBCP 检查质量等级。Dimensional 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。Suppliers 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

44、设计是适当的。An 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“措施矩阵”以获得和解决在制造和所有试验室、工厂和/或道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。1-47Prototype Bui

45、ld Checklist样件制造检查清单1-48Module Introduction组成部分介绍Process Design and Development过程设计和开发1-49Process Flow过程流程Feedback Assessment & Corrective Action反馈、评估和纠正措施Product & Process Validation产品与过程确认Process Design & Devel opment过程设计和开发Product Design & Development产品设计和开发Prototype Build样件制造Plan & Define计划与定义1-

46、50Elements要素Facilities, Tools, and Gauges1. 设施、工具和量具2. Manufacturing Process Flow2. 制造过程流程3. Process FMEA3. 过程 FMEA4. Measurement System Evaluation4. 测量系统评价5. Pre-Launch Control Plan5. 试生产控制计划6. Operator Process Instructions6. 操作工过程指导书7. Packaging Specifications7. 包装规范1-51Facilities, Tools, and Gaug

47、es (8)设施、工具和量具(8)This element identifies the new, additional, refurbished, and relocated facilities and resources necessary 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。The element also identifies the tool

48、s and gauges used in process machinery to transform raw material into 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组装件的机械加工过程的工具和量具。1-52Expectations期望The planning and execution of this element must align with: to milestones PQOS Deliverables 本要素的计划和执行必须配合 里程碑 到 PQOS 需交付的事务Facility permits, pl

49、anning 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。另外，必须完成资金批准。The program team must approve statistical requirements and acceptance criteria before sourcing of tools or gauges can be

50、 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和接收准则。1-53Expectations (Continued)期望（续）All 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。Trial runs should occur at the machine builders location to qualify all tools.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。All corrective a

51、ctions 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、工具和量具的所有纠正措施。Tools and gauges must be delivered, set up, 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

52、施交付、安装和批准。1-54Facilities, Tools, and Gauging Checklist设施、工具和量具检查清单1-55Manufacturing Process Flow (13)制造过程流程（13）This element is a graphic representation of the current or proposed sequence of the manufacturing process to ensure that the process definition, PFMEA, and Control Plans can be created and

53、analyzed in the appropriate sequence.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程定义、PFMEA 和控制计划。1-56Manufacturing Process Flow Expectations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：A cross-functional team led by VO Engineering develops a Manufacturing Process flowchart

54、to serve as an input to PFMEAs.由 VO 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。The process flowcharts are developed using PFMEAs and surrogate processes to serve as input for new processes and technologies.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输入。The current production flowcharts may be modified to show revisions t

55、o 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。1-57Manufacturing Process Flow Checklist制造过程流程检查清单1-58Process FMEA (14) 过程 FMEA (14)The PFMEA is a systematic approach used by a manufacturing-responsible team to ensure that potential process-related failure modes and their associated causes have been con

56、sidered and resolved.PFMEA 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其相关原因的系统化的方法。1-59Expectations期望All 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 FMEA 以制造工程为领导的横向职能小组按照 FMEA 指南中定义的步骤进行准备。Process FMEAs must be

57、 established any time that: 当存在如下事项时，必须建立过程 FMEA： New processes, technologies, products, or product features are introduced. 引入新的过程、技术、产品或产品特征。Quality 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。Major quality concerns have not been resolved during the curr

58、ent 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。1-60Expectations (Continued)期望（续）List of recommended actions and lessons learned is incorporated in the process (continuous improvement).将列出的“建议措施”和学到的经验和并在过程（持续改进）中。Poke-a-Yoke has been used in addressing corrective actions.制定纠正措施中使用防错方法（Poke-a-Yo

59、ke）。1-61Process FMEA Checklist过程 FMEA 检查清单Process FMEA 1-62Measurement System Evaluation (15)测量系统评价（15）This element assesses the 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，确定是否可以接受测量系统监控生产过程。1-63Expectations期望Correl

60、ation 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。Gauge 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验设备。All measurement systems (gauges and test equ