XXXX某汽车AQ状态报告程序AQFord第二部分

ModuleIntroduction

组成部分介绍PrototypeBuild样件制造1-38ProcessFlow

过程流程FeedbackAssessment&CorrectiveAction反馈、评估和纠正措施Product&ProcessValidation产品与过程确认ProcessDesign&Development过程设计和开发ProductDesign&Development产品设计和开发PrototypeBuild样件制造Plan&Define计划与定义1-39PrototypeBuildOverview

样件制造概述APQPPrototypeBuildelementssupportthesuccessfulplanningandconstructionofPrototypeBuildunits,whichprovideanunderstandingofthevehicle's: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1-40PrototypeBuildElements

样件制造要素ThePBCPsupportstheplanningandconstructionofprototypesbydocumentingtheprocessstepsofthePrototypeBuildphase. 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。ThePrototypeBuildensuresthatthecustomerreceivesCPsmanufacturedandassembledpriorto1PP.

样件制造确保顾客在1PP前收到制造和装配好的CP。1-41PBCP(PrototypeBuildControlPlan)Definition

PBCP（样件制造控制计划）定义ThePBCPdescriptionofthedimensionalmeasurementsandmaterial/functionalteststhatoccurduringtheCPbuild. PBCP描述了发生在CP制造中的尺寸测量和材料/功能试验Itisthefirstsummarydocumentthatindicates:

是说明如下事项的摘要文件：ThestepsbetweenPrototypeBuildandPre-LaunchleadingtotheProductionControlPlan

产生生产控制计划的样件制造和试生产之间的步骤Theprocessstepstoidentifyandalignboththeproduct'scharacteristicsanditstargets

识别和调整产品特性及其指标的过程步骤1-42PBCPGeneralExpectations

PBCP总的期望Productcharacteristicsarereviewed

评审产品特性ThosecharacteristicsrequiredforPBCPs

areidentified.

确定PBCP所要求的特性。AllpotentialsignificantandcriticalcharacteristicsfromtheDFMEA'smustbeincluded.

必须包括DFMEA输出的所有潜在重要和关键特性。Theprocessparameterconditionsmustbedocumented.

过程参数条件必须被文件化。Thisincludesallspecialtooling,manufacturing,andassemblyconditions.

包括所有特殊工具、制造和装配条件。1-43PBCPChecklist

PBCP检查清单1-44PrototypeBuild

样件制造Definesthemanufactureandassemblyofcomponents,subsystems,systems,andvehiclessuppliedtothecustomerforbuildsoccurringpriortothe1PPtrialrun

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。Includesnotonlytheactualbuildprocess,butthepreparationforthebuildsothatCPsaresuppliedtothecustomerpriorto1PP

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1-45PrototypeBuildExpectations

样件制造期望PBCPsarefollowed.

按照PBCP进行Suppliersreceiveallnecessaryinformationandparticipateaccordingtotheprogram'sscheduleandtiming.

供方收到所有必要的信息并按照项目时间安排定时参与Thetimingforchangeswillbeinlinewiththenextbuildphase.

更改的时间选择应该符合下一个制造阶段。Allprototypematerialsmustmeet100percentofthedimensionalspecificationsandfunctionalrequirementsatdeliverytomeettheCPIn-PlantDate.

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。1-46PrototypeBuildExpectations(Continued)

样件制造期望（续）QualitylevelsarecheckedagainstthePBCP.

按照PBCP检查质量等级。Dimensionalandfunctionaldataisavailableforreviewbythecustomeroneachpart.

顾客可以获得每个零件的尺寸和功能数据以进行评审。Suppliersprovidecustomerswithanytestingandcheckingrequirementsforprove-outoftheirpartdesign.

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。An"ActionMatrix"isdevelopedtocaptureandresolveallconcernsfoundduringbuildandanysubsequentlab,plant,and/orroadtesting,andallconcernsarereviewedwiththeprogramteamandappropriatemanagement.

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。1-47PrototypeBuildChecklist样件件制制造造检检查查清清单单1-48ModuleIntroduction组成成部部分分介介绍绍ProcessDesignandDevelopment过程程设设计计和和开开发发1-49ProcessFlow过程程流流程程FeedbackAssessment&CorrectiveAction反馈馈、、评评估估和和纠纠正正措措施施Product&ProcessValidation产品品与与过过程程确确认认ProcessDesign&Development过程程设设计计和和开开发发ProductDesign&Development产品品设设计计和和开开发发PrototypeBuild样件件制制造造Plan&Define计划划与与定定义义1-50Elements要素素Facilities,Tools,andGauges1.设设施施、、工工具具和和量量具具2.ManufacturingProcessFlow2.制制造造过过程程流流程程3.ProcessFMEA3.过过程程FMEA4.MeasurementSystemEvaluation4.测测量量系系统统评评价价5.Pre-LaunchControlPlan5.试试生生产产控控制制计计划划6.OperatorProcessInstructions6.操操作作工过过程指指导书书7.PackagingSpecifications7.包包装装规范范1-51Facilities,Tools,andGauges(8)设施、、工具具和量量具(8)Thiselementidentifiesthenew,additional,refurbished,andrelocatedfacilitiesandresourcesnecessarytomanufacturethecustomer-specifiedproductatdesignatedquantityandqualitylevels.本要素素确定定了以以规定定的数数量和和质量量等级级制造造顾客客指定定的产产品所所需的的新的的、额额外的的、更更新的的和重重新部部署的的设施施和资资源。。Theelementalsoidentifiesthetoolsandgaugesusedinprocessmachinerytotransformrawmaterialintofinishedpartsorassemblies.本要素素还确确定了了用于于将原原材料料转换换为完完成的的零件件或组组装件件的机机械加加工过过程的的工具具和量量具。。1-52Expectations期望Theplanningandexecutionofthiselementmustalignwith:<SI>to<LR>milestonesPQOSDeliverables本要素素的计计划和和执行行必须须配合合里程碑碑<SI>到<LR>PQOS需交付付的事事务Facilitypermits,planningapproval,drawings,andutilitiesmustbeincludedontheManufacturingTimingPlan.Inaddition,fundingapprovalsmustbecompleted.制造时时间计计划中中必须须包括括设施施许可可、计计划批批准、、图样样和效效用。。另外外，必必须完完成资资金批批准。。Theprogramteammustapprovestatisticalrequirementsandacceptancecriteriabeforesourcingoftoolsorgaugescanbemade.在可以以进行行工具具和量量具的的外包包之前前，项项目小小组必必须批批准统统计要要求和和接收收准则则。1-53Expectations(Continued)期望（（续））AlltoolsandgaugesmustcomplywithToolingandEquipmentSupplementrequirements.所有工工具和和量具具必须须符合合工装装和设设备补补充要要求。。Trialrunsshouldoccuratthemachinebuilder'slocationtoqualifyalltools.应该在在机械械制造造者的的现场场进行行试运运行，，以验验证所所有工工具合合格。。Allcorrectiveactionsforfacilities,tools,andgaugesnotmeetingcustomerrequirementsmustbecompletedbeforetheProductionTrialRun.必须在在产品品试生生产前前完成成针对对不满满足顾顾客要要求的的设施施、工工具和和量具具的所所有纠纠正措措施。。Toolsandgaugesmustbedelivered,setup,andapprovedintheirspecifiedfacilitiesbeforetheProductionTrialRun.产品试试生产产前工工具和和量具具必须须以制制定的的设施施交付付、安安装和和批准准。1-54Facilities,Tools,andGaugingChecklist设施、、工具具和量量具检检查清清单1-55ManufacturingProcessFlow(13)制造过过程流流程（（13）Thiselementisagraphicrepresentationofthecurrentorproposedsequenceofthemanufacturingprocesstoensurethattheprocessdefinition,PFMEA,andControlPlanscanbecreatedandanalyzedintheappropriatesequence.本要素素制造造过程程的当当前的的或建建议的的次序序的图图解表表示，，以确确保以以适当当的次次序建建立和和分析析过程程定义义、PFMEA和控制制计划划。1-56ManufacturingProcessFlowExpectations制造过过程流流程期期望ManufacturingProcessFlowgeneralexpectationsarethat:制造过过程流流程总总的期期望是是：Across-functionalteamledbyVOEngineeringdevelopsaManufacturingProcessflowcharttoserveasaninputtoPFMEAs.由VO工程领领导的的横向向职能能小组组开发发制造造过程程流程程图作作为PFMEA的输入入。TheprocessflowchartsaredevelopedusingPFMEAsandsurrogateprocessestoserveasinputfornewprocessesandtechnologies.使用PFMEA和替代代的过过程开开发过过程流流程图图，作作为新新过程程和技技术的的输入入。Thecurrentproductionflowchartsmaybemodifiedtoshowrevisionstotheprocessflow.可以修修改当当前的的生产产流程程图，，以显显示对对过程程流程程的修修改。。1-57ManufacturingProcessFlowChecklist制造过过程流流程检检查清清单1-58ProcessFMEA(14)过程FMEA(14)ThePFMEAisasystematicapproachusedbyamanufacturing-responsibleteamtoensurethatpotentialprocess-relatedfailuremodesandtheirassociatedcauseshavebeenconsideredandresolved.PFMEA是制造造职责责小组组使用用的确确保已已经考考虑并并解决决了潜潜在的的与过过程相相关的的失效效模式式及其其相关关原因因的系系统化化的方方法。。1-59Expectations期望AllProcessFMEAsarepreparedbyacross-functionalteamledbyManufacturingEngineeringfollowingthestepsdefinedintheFMEAguideline.所有过过程FMEA以制造造工程程为领领导的的横向向职能能小组组按照照FMEA指南中中定义义的步步骤进进行准准备。。ProcessFMEAsmustbeestablishedanytimethat:当存在在如下下事项项时，，必须须建立立过程程FMEA：：Newprocesses,technologies,products,orproductfeaturesareintroduced.引入新新的过过程、、技术术、产产品或或产品品特征征。Qualityrisksareidentifiedthatcannotberesolvedthroughdesignchanges.确定质质量风风险不不能通通过设设计变变更加加以解解决。。Majorqualityconcernshavenotbeenresolvedduringthecurrentproductionmodelyear.在当前前的生生产模模型年年中，，没有有解决决重大大的涉涉及质质量的的问题题。1-60Expectations(Continued)期望（（续））Listof"recommendedactions"andlessonslearnedisincorporatedintheprocess(continuousimprovement).将列出出的““建议议措施施”和和学到到的经经验和和并在在过程程（持持续改改进））中。。Poke-a-Yokehasbeenusedinaddressingcorrectiveactions.制定纠纠正措措施中中使用用防错错方法法（Poke-a-Yoke）。。1-61ProcessFMEAChecklist过程FMEA检查清清单ProcessFMEA1-62MeasurementSystemEvaluation(15)测量系系统评评价（（15）Thiselementassessesthevariationofthemeasurementsystem,anddetermineswhetheritisacceptableformonitoringtheproductionprocess.本要素素评估估测量量系统统的变变差，，确定定是否否可以以接受受测量量系统统监控控生产产过程程。1-63Expectations期望Correlationstandardsarereachedandagreedtowiththecustomerforduplicategaugesortestequipment.已达到到相同同的测测量或或试验验设备备的相相关标标准和和顾客客的批批准。。Gaugeinstructionsandvisualaidstoensureappropriateuseofgaugeandtestequipmentinproduction.测量指导导书和目目视辅具具确保在在生产中中适当的的使用测测量和试试验设备备。Allmeasurementsystems(gaugesandtestequipment)mustbemodifiedtoreflectthelatestengineeringpartlevelbeforetheProductionTrialRun.在产品试试生产前前必须修修改所有有测量系系统（测测量和试试验设备备）以反反映最新新工程零零件等级级。1-64Expectations(Continued)期望（续续）Theuser/customermustbegiventheopportunitytoreviewandconcurwiththegaugesandtestequipmentstudyresultsbeforetheProductionTrialRun.产品试生生产前使使用者/顾客,必须有有机会评评审和批批准测量量和试验验设备研研究结果果。TheMeasurementSystemEvaluationmustberepeatedandapprovedfollowingallgaugeandtestequipmentmodifications.所有测量量和试验验设备更更改后,必须重重新进行行测量系系统评价价并获得得批准。。TheProductionControlPlanmustalignwiththeMeasurementSystemsDevelopmentplan.生产控制制计划必必须配合合测量系系统开发发计划。。GaugeRepeatabilityandReproducibilitystudiesmustbeconductedonallmeasurementsystems.所有测量量系统必必须进行行量具重重复性和和再现性性研究。。1-65MeasurementSystemEvaluationChecklist测量系统统评价检检查清单单1-66Pre-LaunchControlPlan(16)试生产控控制计划划（16）Thisisadescriptionofthedimensionalmeasurementsandmaterial/functionalin-processtestsorchecksthatoccurafterprototypebuilds,butbeforefullproduction对发生在在样件制制造后，，全面生生产前的的尺寸测测量、过过程中材材料/功功能试验验或检查查的描述述。1-67Expectations期望Legitimate/appropriateinspectionsamplesizes,frequencies,controlmethod,etc.inclusivetopre-launchphaseofproductionareincluded.在生产的的试生产产阶段包包含合理理/适当当的检验验样本容容量、频频率、控控制方法法等。Allproduct&processcharacteristicsforpre-launchcontrolplansareidentifiedandreviewed.确定和评评审试生生产控制制计划的的所有产产品和过过程特性性。ResultsfromthePBCPandDFMEAprovidetheoutlineforthePre-LaunchControlPlan.PBCP和DFMEA的结果提提供了试试生产控控制计划划的概要要。TheProductionControlPlanforthecurrentproductionmodelisusedtoassistinthedevelopmentofthePre-LaunchControlPlanifAPQPElements8and13havenotbeeninitiated.如果APQP要素8和13还还未启启动，使使用当前前生产模模式的生生产控制制计划协协助开发发试生产产控制计计划。1-68Pre-LaunchControlPlanChecklist试生产控控制计划划检查清清单1-69OperatorProcessInstructions(17)操作工过过程指导导书（17）Thiselementdescribesthedetailsofthecontrolsandactionsthatoperatingpersonnelmustperformtoproducequalityproducts.本要素描描述操作作人员为为生产质质量合格格的产品品所必须须执行的的控制和和措施的的详细情情况。Theseinstructionsaredividedintotwomajorcomponents:这些指导导书分为为两个主主要部分分：Descriptionoftheprocess过程描述述Operatorinstructions操作供指指导书1-70Expectations期望AcompletedOperatorProcessInstructionspackage.完成的整整套操作作工过程程指导书书。Instructionsdevelopedtobeusedduringaproductiontrialruntoensuretheprocessperformsasintended.在产品试试生产中中使用开开发的指指导书以以确保过过程按预预期执行行。OperatorProcessInstructionsdescribeallprocessstepsnecessarytoproduceaqualityproduct.Thetraininginstructionsmustinclude:操作工过过程指导导书描述述了生产产质量合合格的产产品所需需的所有有过程步步骤。培培训指导导书必须须包括：：Detailedinstructions详细的指指导书Visualaids目视辅具具Anyotherqualitymaterialsnecessarytosupporttheproductionoperator支持生产产操作工工所需的的任何质质量材料料1-71OperatorProcessInstructionsChecklist操作工过过程指导导书检查查清单1-72PackagingSpecifications(18)包装规范范（18）Thiselementdescribesthedesignanddevelopmentoftheend-itemshipmentpackaging,includinginteriorpartitions.本要素描描述产品品最后出出货包装装的设计计与开发发，包括括包装内内部的分分隔配置置。1-73Expectations期望Pastissuesonsimilarorsurrogatepackagingarediscussedandresolvedbytheteam.小组讨论论和解决决相似或或替代的的包装中中过去发发生的问问题。Correctiveactionsexistforanypackagingissuesidentifiedthataffectproductperformanceandcharacteristics.确定对对于任任何影影响产产品性性能和和特性性的包包装问问题的的现存存纠正正措施施。Supplierandthereceivingplantagreeuponpackagingrequirements.供方和和接收收工厂厂就包包装要要求达达成一一致。。Packagingevaluationmusttestthepackagingundertheexpectedconditionsoftransportandmaterialhandling.包装评评价必必须在在运输输和材材料处处理期期望的的条件件下测测试包包装Packagingdesignmustensurethattheproductperformanceandcharacteristicswillremainunchangedduringpacking,shipping,andunpacking.包装设设计必必须确确保在在包装装、运运输和和打开开包装装过程程中，，产品品性能能和特特性保保持不不变。。1-74PackagingSpecificationsChecklist包装规规范检检查清清单1-75ModuleIntroduction组成部部分介介绍ProductandProcessValidation产品和和过程程确认认1-76ProcessFlow过程流流程FeedbackAssessment&CorrectiveAction反馈、、评估估和纠纠正措措施Product&ProcessValidation产品与与过程程确认认ProcessDesign&Development过程设设计和和开发发ProductDesign&Development产品设设计和和开发发PrototypeBuild样件制制造Plan&Define计划与与定义义1-77Elements要素ProductionTrialRun产品试试生产产2.ProductionControlPlan生产控控制计计划3.PreliminaryProcessCapability初始过过程能能力4.ProductionValidationTesting生产确确认试试验5.PartSubmissionWarrant零件提提交保保证书书1-78ProductionTrialRun(19)产品试试生产产（19））TheProductionTrialRunisavalidationoftheeffectivenessofthemanufacturingandassemblyprocess,usingproductiontooling,equipment,environment(includingproductionoperators),facilities,andcycletimes.产品试试生产产是对对制造造和装装配过过程、、使用用的生生产工工具、、设备备、环环境（（包括括生产产操作作工））、设设施和和生产产周期期时间间的有有效性性的确确认。。1-79Expectations期望Productionfacility,tooling,equipment,personnel,packaging,operators,PSW-1parts,andPre-LaunchControlPlansareusedontrialrun.在试生产中中使用生产产设施、工工具、设备备、人员、、包装、操操作工、PSW-1零件和试生生产控制计计划。ConcernsfromthetrialrunthatcouldpreventRun-at-Rateandcapacitybydaterequiredarelisted.列出在生产产试运行中中可能影响响到“节拍拍生产”与与“产能””的关注点点。Correctivedesignandprocessactionsareestablished.建立设计和和过程纠正正措施。ThePre-LaunchControlPlanisfollowedduringthe1PPProductionTrialRun.1PP产品试生产产中按照试试生产控制制计划进行行。TheProductionTrialRunisusedtoconfirmoraddalignmentbetweenproductandprocesscharacteristics.产品试生产产用来在产产品和过程程特性之间间进行确认认或加强调调整。OperatorProcessInstructionsarefollowedduringtheProductionTrialRun.在产品试生生产中按照照操作工过过程指导书书执行。1-80ElementChecklist要素检查清清单1-81ProductionControlPlan(20)生产控制计计划（20）TheProductionControlPlanisawrittenplanofthesystemsforcontrollingpartsandprocessesduringfullproduction.生产控制计计划是在全全面生产中中控制零件件和过程的的系统的书书面计划。。ThisdocumentisbasedonthePre-LaunchControlPlanandisalivingdocumentthatmustbeupdatedtoreflecttheadditionsanddeletionsofcontrols,basedonexperiencegainedintheprocessofproducingparts.本文件基于于试生产控控制计划，，是一份动动态文件，，必须基于于从零件生生产过程中中获得经验验，加以更更新以反映映对控制的的增加和删删减。1-82Expectations期望ReactionPlansspecifycorrectiveandcontainmentactionsnecessarytoavoidoperatingout-of-controlorproducingnonconformingproducts.反应计划明明确规定纠纠正和限制制措施，以以避免操作作失去控制制或生产不不合格产品品。TheProductionControlPlanisdevelopedbyacross-functionalteamledbyManufacturingEngineering.由以制造工工程为领导导的横向职职能小组开开发生产控控制计划。。TheProductionControlPlanfollowsthemethodologydocumentedintheAIAG/APQPandControlPlanReferencemanual.生产控制计计划遵循AIAG/APQP和控制计划划参考手册册中提供的的方法。TheoutcomesofthefinalPBCPprovidethebasisforthePre-LaunchControlPlanthatinturnbecomesthesourcefortheProductionControlPlan.最终PBCP的输出给试试生产控制制计划提供供了基础，，然后顺次次成为生产产控制计划划的资源。。1-83ElementChecklist要素检查清清单1-84PreliminaryProcessCapability(21)初始过程能能力(21)ThePreliminaryProcessCapabilityisastatisticalstudyandassessmentoftheabilitytoproduceproductwithinspecifications.初始过程能能力是对按按照规范生生产产品的的能力的统统计研究和和评估。1-85Expectations期望Resultsareanalyzedtoverifystatisticalstabilityaswellascapability.分析结果以以验证统计计稳定性和和能力。Thestatisticalandanalyticaltechniquesusedtodeterminecapabilitymustbeacceptabletothecustomer.顾客必须接接受用来确确定能力的的统计和分分析工具。。PreliminaryProcessCapabilitystudiesmustbeperformedinawaythatalignswiththedevelopmentofthePre-LaunchControlPlan.初始过程能能力研究必必须以配合合试生产控控制计划的的开发的方方式进行。。PreliminaryProcessCapabilitystudiesmustbecompleted:初始过程能能力研究必必须完成：：ThecustomermusthavetheopportunitytoreviewthestudiesbeforeProductionPartApproval.在生产件批批准前，顾顾客必须有有机会对研研究进行评评审。1-86ElementChecklist要素检查清清单1-87ProductionValidationTesting(22)生产确认试试验（22）Engineeringtestsvalidatethattheproductsmadefromtheproductiontoolsandprocessesmeetengineeringspecifications工程试验确确认生产工工具和过程程制造的产产品满足工工程规范。。InternalandexternalsupplierstoFordMotorCompanymustcompleteProductionValidationTestingasarequirementofaPSWfor1PP作为1PP的PSW要求，福特特汽车公司司的内、外外部供方必必须完成生生产确认试试验。1-88Expectations期望APVTestPlan,includingprogressachieved,isestablished.建立PV试验计划，，包括取得得的改进。。ConcernsidentifiedduringPVTestingareassigned,resolutionsareimplemented,andsolutionsaretrackedthroughclosureoftheconcern.指出在PV试验阶段识识别的关注注事项，解解决方案被被实施，而而且跟踪解解决方案，，彻底解决决了关注事事项。Allparts,end-itemsorcomponents,subsystems,andsystemsforPVTestingmustbecompletedbeforetheFEUBuildaccordingtotheengineeringspecificationsinthePre-LaunchControlPlan.必须在根据据工程规范范建立PEU前，在试生生产控制计计划中完成成所有零件件，产品最最终阶段基基组成部分分，子系统统和系统的的PV试验。Allcustomer-specifieddimensional,material,functional,andreliabilitytestsmustbecompletedbeforeProductionPartApproval.生产件批准准前必须完完成所有顾顾客规定的的尺寸、材材料、功能能和可靠性性试验。1-89ElementChecklist要素检查清清单1-90PartSubmissionWarrant(23)零件提交保保证书（23）ThePSWensuresthatengineeringdesignrequirementsaremetbythesupplier,andthattheprocessusediscapableofproducingpartsthatmeettheserequirements.PSW确保供方满满足工程设设计要求，，使用的过过程有能力力生产满足足这些要求求的零件。。ThePSWisthefinalsign-offverifyingthattheProductionPartApprovalProcess(PPAP)hasbeenfollowed.PSW是按照生产产件批准过过程进行的的最终批准准验证。1-91Expectations期望望ConcernsidentifiedduringPPAPandPSWhavebeenresolved.在PPAP和PSW中确确定定的的关关注注事事项项已已经经被被解解决决。。Thecustomer'smaterialIPDmustbeincludedinthesupplier'stimingplan.顾客客材材料料IPD必须须包包含含在在供供方方时时间间计计划划中中。。ProductionPartApprovalrequirementsmustbecompletedpriortotheIPDoftheuserplant.在使使用用者者工工厂厂IPD