第二部分：某汽车AQ状态报告程序

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样件制制造检检查清清单1-48ModuleIntroduction组成部部分介介绍ProcessDesignandDevelopment过程设设计和和开发发1-49ProcessFlow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1-50Elements要素素Facilities,Tools,andGauges1.设设施施、工具具和量具具2.ManufacturingProcessFlow2.制制造造过程流流程3.ProcessFMEA3.过过程FMEA4.MeasurementSystemEvaluation4.测测量系统统评价5.Pre-LaunchControlPlan5.试试生产控控制计划划6.OperatorProcessInstructions6.操操作工过过程指导导书7.PackagingSpecifications7.包包装规范范1-51Facilities,Tools,andGauges(8)设施、工工具和量量具(8)Thiselementidentifiesthenew,additional,refurbished,andrelocatedfacilitiesandresourcesnecessarytomanufacturethecustomer-specifiedproductatdesignatedquantityandqualitylevels.本要素确确定了以以规定的的数量和和质量等等级制造造顾客指指定的产产品所需需的新的的、额外外的、更更新的和和重新部部署的设设施和资资源。Theelementalsoidentifiesthetoolsandgaugesusedinprocessmachinerytotran

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期望望Theplanningandexecutionofthiselementmustalignwith:<SI>to<LR>milestonesPQOSDeliverables本要要素素的的计计划划和和执执行行必必须须配配合合里程程碑碑<SI>到<LR>PQOS需交交付付的的事事务务Facilitypermits,planningapproval,drawings,andutilitiesmustbeincludedontheManufacturingTimingPlan.Inaddition,fundingapprovalsmustbecompleted.制造造时时间间计计划划中中必必须须包包括括设设施施许许可可、、计计划划批批准准、、图图样样和和效效用用。。另另外外，，必必须须完完成成资资金金批批准准。。Theprogramteammustapprovestatisticalrequirementsandacceptancecriteriabeforesourcingoftoolsorgaugescanbemade.在可可以以进进行行工工具具和和量量具具的的外外包包之之前前，，项项目目小小组组必必须须批批准准统统计计要要求求和和接接收收准准则则。。1-53Expectations(Continued)期望望（（续续））AlltoolsandgaugesmustcomplywithToolingandEquipmentSupplementrequirements.所有有工工具具和和量量具具必必须须符符合合工工装装和和设设备备补补充充要要求求。。Trialrunsshouldoccuratthemachinebuilder'slocationtoqualifyalltools.应该该在在机机械械制制造造者者的的现现场场进进行行试试运运行行，，以以验验证证所所有有工工具具合合格格。。Allcorrectiveactionsforfacilities,tools,andgaugesnotmeetingcustomerrequirementsmustbecompletedbeforetheProductionTrialRun.必须在产品试试生产前完成成针对不满足足顾客要求的的设施、工具具和量具的所所有纠正措施施。Toolsandgaugesmustbedelivered,setup,andapprovedintheirspecifiedfacilitiesbeforetheProductionTrialRun.产品试生产前前工具和量具具必须以制定定的设施交付付、安装和批批准。1-54Facilities,Tools,andGaugingChecklist设施、工具和和量具检查清清单1-55ManufacturingProcessFlow(13)制造过程流程程（13）Thiselementisagraphicrepresentationofthecurrentorproposedsequenceofthemanufacturingprocesstoensurethattheprocessdefinition,PFMEA,andControlPlanscanbecreatedandanalyzedintheappropriatesequence.本要素制造过过程的当前的的或建议的次次序的图解表表示，以确保保以适当的次次序建立和分分析过程定义义、PFMEA和控制计划。。1-56ManufacturingProcessFlowExpectations制造过程流程程期望ManufacturingProcessFlowgeneralexpectationsarethat:制造过程流程程总的期望是是：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（续续）Listof"recommendedactions"andlessonslearnedisincorporatedintheprocess(continuousimprovement).将列出的的“建议议措施””和学到到的经验验和并在在过程（（持续改改进）中中。Poke-a-Yokehasbeenusedinaddressingcorrectiveactions.制定纠正正措施中中使用防防错方法法（Poke-a-Yoke）。。1-61ProcessFMEAChecklist过程FMEA检查清单单ProcessFMEA1-62MeasurementSystemEvaluation(15)测量系统统评价（（15））Thiselementassessesthevariationofthemeasurementsystem,anddetermineswhetheritisacceptableformonitoringtheproductionprocess.本要素评评估测量量系统的的变差，，确定是是否可以以接受测测量系统统监控生生产过程程。1-63Expectations期望Correlationstandardsarereachedandagreedtowiththecustomerforduplicategaugesortestequipment.已达到相相同的测测量或试试验设备备的相关关标准和和顾客的的批准。。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））Theuser/customermustbegiventheopportunitytoreviewandconcurwiththegaugesandtestequipmentstudyresultsbeforetheProductionTrialRun.产品试生产产前使用者者/顾客,必须有机机会评审和和批准测量量和试验设设备研究结结果。TheMeasurementSystemEvaluationmustberepeatedandapprovedfollowingallgaugeandtestequipmentmodifications.所有测量和和试验设备备更改后,必须重新新进行测量量系统评价价并获得批批准。TheProductionControlPlanmustalignwiththeMeasurementSystemsDevelopmentplan.生产控制计计划必须配配合测量系系统开发计计划。GaugeRepeatabilityandReproducibilitystudiesmustbeconductedonallmeasurementsystems.所有测量系系统必须进进行量具重重复性和再再现性研究究。1-65MeasurementSystemEvaluationChecklist测量系统评评价检查清清单1-66Pre-LaunchControlPlan(16)试生产控制制计划（16）Thisisadescriptionofthedimensionalmeasurementsandmaterial/functionalin-processtestsorchecksthatoccurafterprototypebuilds,butbeforefullproduction对发生在样样件制造后后，全面生生产前的尺尺寸测量、、过程中材材料/功能能试验或检检查的描述述。1-67Expectations期望Legitimate/appropriateinspectionsamplesizes,frequencies,controlmethod,etc.inclusivetopre-launchphaseofproductionareincluded.在生产的试试生产阶段段包含合理理/适当的的检验样本本容量、频频率、控制制方法等。。Allproduct&processcharacteristicsfor

pre-launchcontrolplansareidentifiedandreviewed.确定和评审审试生产控控制计划的的所有产品品和过程特特性。ResultsfromthePBCPandDFMEAprovidetheoutlineforthePre-LaunchControlPlan.PBCP和DFMEA的结果提供供了试生产产控制计划划的概要。。TheProductionControlPlanforthecurrentproductionmodelisusedtoassistinthedevelopmentofthePre-LaunchControlPlanifAPQPElements8and13havenotbeeninitiated.如果APQP要素8和和13还未启启动，使用用当前生产产模式的生生产控制计计划协助开开发试生产产控制计划划。1-68Pre-LaunchControlPlanChecklist试生产控制制计划检查查清单1-69OperatorProcessInstructions(17)操作工过程程指导书（（17）Thiselementdescribesthedetailsofthecontrolsandactionsthatoperatingpersonnelmustperformtoproducequalityproducts.本要素描述述操作人员员为生产质质量合格的的产品所必必须执行的的控制和措措施的详细细情况。Theseinstructionsaredividedintotwomajorcomponents:这些指导书书分为两个个主要部分分：Descriptionoftheprocess过程描述Operatorinstructions操作供指导导书1-70Expectations期望AcompletedOperatorProcessInstructionspackage.完成的整套套操作工过过程指导书书。Instructionsdevelopedtobeusedduringaproductiontrialruntoensuretheprocessperformsasintended.在产品试生生产中使用用开发的指指导书以确确保过程按按预期执行行。OperatorProcessInstructionsdescribeallprocessstepsnecessarytoproduceaqualityproduct.Thetraininginstructionsmustinclude:操作工过程程指导书描描述了生产产质量合格格的产品所所需的所有有过程步骤骤。培训指指导书必须须包括：Detailedinstructions详细的指导导书Visualaids目视辅具Anyotherqualitymaterialsnecessarytosupporttheproductionoperator支持生产操操作工所需需的任何质质量材料1-71OperatorProcessInstructionsChecklist操作工过程程指导书检检查清单1-72PackagingSpecifications(18)包装规范（（18）Thiselementdescribesthedesignanddevelopmentoftheend-itemshipmentpackaging,includinginteriorpartitions.本要素描述述产品最后后出货包装装的设计与与开发，包包括包装内内部的分隔隔配置。1-73Expectations期望Pastissuesonsimilarorsurrogatepackagingarediscussedandresolvedbytheteam.小组讨论和和解决相似似或替代的的包装中过过去发生的的问题。Correctiveactionsexistforanypackagingissuesidentifiedthataffectproductperformanceandcharacteristics.确定对于任何何影响产品性性能和特性的的包装问题的的现存纠正措措施。Supplierandthereceivingplantagreeuponpackagingrequirements.供方和接收工工厂就包装要要求达成一致致。Packagingevaluationmusttestthepackagingundertheexpectedconditionsoftransportandmaterialhandling.包装评价必须须在运输和材材料处理期望望的条件下测测试包装Packagingdesignmustensurethattheproductperformanceandcharacteristicswillremainunchangedduringpacking,shipping,andunpacking.包装设计必须须确保在包装装、运输和打打开包装过程程中，产品性性能和特性保保持不变。1-74PackagingSpecificationsChecklist包装规范检查查清单1-75ModuleIntroduction组成部分介绍绍ProductandProcessValidation产品和过程确确认1-76ProcessFlow过程流程FeedbackAssessment&CorrectiveAction反馈、评估和和纠正措施Product&ProcessValidation产品与过程确确认ProcessDesign&Development过程设计和开开发ProductDesign&Development产品设计和开开发PrototypeBuild样件制造Plan&Define计划与定义1-77Elements要素ProductionTrialRun产品试生产2.ProductionControlPlan生产控制计划划3.PreliminaryProcessCapability初始过程能力力4.ProductionValidationTesting生产确认试验验5.PartSubmissionWarrant零件提交保证证书1-78ProductionTrialRun(19)产品试生产（（19）TheProductionTrialRunisavalidationoftheeffectivenessofthemanufacturingandassemblyprocess,usingproductiontooling,equipment,environment(includingproductionoperators),facilities,andcycletimes.产品试生产是是对制造和装装配过程、使使用的生产工工具、设备、、环境（包括括生产操作工工）、设施和和生产周期时时间的有效性性的确认。1-79Expectations期望Productionfacility,tooling,equipment,personnel,packaging,operators,PSW-1parts,andPre-LaunchControlPlansareusedontrialrun.在试生产中使使用生产设施施、工具、设设备、人员、、包装、操作作工、PSW-1零件和试生产产控制计划。。ConcernsfromthetrialrunthatcouldpreventRun-at-Rateandcapacitybydaterequiredarelisted.列出在生产试试运行中可能能影响到“节节拍生产”与与“产能”的的关注点。Correctivedesignandprocessactionsareestablished.建立设计和过过程纠正措施施。ThePre-LaunchControlPlanisfollowedduringthe1PPProductionTrialRun.1PP产品试生产中中按照试生产产控制计划进进行。TheProductionTrialRunisusedtoconfirmoraddalignmentbetweenproductandprocesscharacteristics.产品试生产用用来在产品和和过程特性之之间进行确认认或加强调整整。OperatorProcessInstructionsarefollowedduringtheProductionTrialRun.在产品试生产产中按照操作作工过程指导导书执行。1-80ElementChecklist要素检查清单单1-81ProductionControlPlan(20)生产控制计划划（20）TheProductionControlPlanisawrittenplanofthesystemsforcontrollingpartsandprocessesduringfullproduction.生产控制计划划是在全面生生产中控制零零件和过程的的系统的书面面计划。ThisdocumentisbasedonthePre-LaunchControlPlanandisalivingdocumentthatmustbeupdatedtoreflecttheadditionsanddeletionsofcontrols,basedonexperiencegainedintheprocessofproducingparts.本文件基于试试生产控制计计划，是一份份动态文件，，必须基于从从零件生产过过程中获得经经验，加以更更新以反映对对控制的增加加和删减。1-82Expectations期望ReactionPlansspecifycorrectiveandcontainmentactionsnecessarytoavoidoperatingout-of-controlorproducingnonconformingproducts.反应计划明确确规定纠正和和限制措施，，以避免操作作失去控制或或生产不合格格产品。TheProductionControlPlanisdevelopedbyacross-functionalteamledbyManufacturingEngineering.由以制造工程程为领导的横横向职能小组组开发生产控控制计划。TheProductionControlPlanfollowsthemethodologydocumentedintheAIAG/APQPandControlPlanReferencemanual.生产控制计划划遵循AIAG/APQP和控制计划参参考手册中提提供的方法。。TheoutcomesofthefinalPBCPprovidethebasisforthePre-LaunchControlPlanthatinturnbecomesthesourcefortheProductionControlPlan.最终PBCP的输出给试生生产控制计划划提供了基础础，然后顺次次成为生产控控制计划的资资源。1-83ElementChecklist要素检查清单单1-84PreliminaryProcessCapability(21)初始过程能力力(21)ThePreliminaryProcessCapabilityisastatisticalstudyandassessmentoftheabilitytoproduceproductwithinspecifications.初始过程能力力是对按照规规范生产产品品的能力的统统计研究和评评估。1-85Expectations期望Resultsareanalyzedtoverifystatisticalstabilityaswellascapability.分析结结果以以验证证统计计稳定定性和和能力力。Thestatisticalandanalyticaltechniquesusedtodeterminecapabilitymustbeacceptabletothecustomer.顾客必必须接接受用用来确确定能能力的的统计计和分分析工工具。。PreliminaryProcessCapabilitystudiesmustbeperformedinawaythatalignswiththedevelopmentofthePre-LaunchControlPlan.初始过过程能能力研研究必必须以以配合合试生生产控控制计计划的的开发发的方方式进进行。。PreliminaryProcessCapabilitystudiesmustbecompleted:初始过过程能能力研研究必必须完完成：：ThecustomermusthavetheopportunitytoreviewthestudiesbeforeProductionPartApproval.在生产产件批批准前前，顾顾客必必须有有机会会对研研究进进行评评审。。1-86ElementChecklist要素检检查清清单1-87ProductionValidationTesting(22)生产确确认试试验（（22）Engineeringtestsvalidatethattheproductsmadefromtheproductiontoolsandprocessesmeetengineeringspecifications工程试试验确确认生生产工工具和和过程程制造造的产产品满满足工工程规规范。。InternalandexternalsupplierstoFordMotorCompanymustcompleteProductionValidationTestingasarequirementofaPSWfor1PP作为1PP的PSW要求，，福特特汽车车公司司的内内、外外部供供方必必须完完成生生产确确认试试验。。1-88Expectations期望APVTestPlan,includingprogressachieved,isestablished.建立PV试验计计划，，包括括取得得的改改进。。ConcernsidentifiedduringPVTestingareassigned,resolutionsareimplemented,andsolutionsaretrackedthroughclosureoftheconcern.指出在在PV试验阶阶段识识别的的关注注事项项，解解决方方案被被实施施，而而且跟跟踪解解决方方案，，彻底底解决决了关关注事事项。。Allparts,end-itemsorcomponents,subsystems,andsystemsforPVTestingmustbecompletedbeforetheFEUBuildaccordingtotheengineeringspecificationsinthePre-LaunchControlPlan.必须在根根据工程程规范建建立PEU前，在试试生产控控制计划划中完成成所有零零件，产产品最终终阶段基基组成部部分，子子系统和和系统的的PV试验。Allcustomer-specifieddimensional,material,functional,andreliabilitytestsmustbecompletedbeforeProductionPartApproval.生产件批批准前必必须完成成所有顾顾客规定定的尺寸寸、材料料、功能能和可靠靠性试验验。1-89ElementChecklist要素检查查清单1-90PartSubmissionWarrant(23)零件提交交保证书书（23）ThePSWensuresthatengineeringdesignrequirementsaremetbythesupplier,andthattheprocessusediscapableofproducingpartsthatmeettheserequirements.PSW确保供方方满足工工程设计计要求，，使用的的过程有有能力生生产满足足这些要要求的零零件。ThePSWisthefinalsign-offverifyingthattheProductionPar