FORD福特汽车研发流程介绍课件

FORD流程简介—1FORD福特汽车研发流程介绍早期参与团队标准化管理/汇报

采用唯一的，全球通用到，有纪律的流程尽量减少返工和重复。在产品开发过程早期，与供应商更融洽地合作利用福特跨功能团队与供应商一起在现场工作(4次拜访)使用共同的，明确的交付报告和结构化的管理评审模式GPDS（GlobalProductDevelopmentSystem）—是FORD公司全球产品开发体系，替代原FPDS福特产品开发体系

GPDS全球产品开发体系FORD福特汽车研发流程介绍GPDS供应商管理过程-总览PTC/M1DJPTCCPAFDJPECLR/FECM1VPTTPPMP1UnitPTCUnitPA33.5MBJ127MBJ125MBJ120.5MBJ127.5MBJ134MBJ117MBJ113MBJ18MBJ15.5MBJ15MBJ12.5MBJ10MBJ1供应商选点开始高影响供应商选择跨功能小组形成启动会议开始第一次现场评审第二次现场评审第三次现场评审第四次现场评审解决问题决定：是否进行试生产？更新供应商APQP/PPAP准备状态评估报告(A表)(655/654)3FORD福特汽车研发流程介绍PTC-ProgramTargetCompatibility项目目标整合PA-Program

Approval

项目批准

FDJ-Final

Data

Judgement工程数据发布VP-Verification

Prototype(OTS)样件验证PEC-Preliminary

EngineeringCompletion工程数据冻结项目节点（里程碑）FORD福特汽车研发流程介绍LR-Launch

Readiness生产准备就绪（可生产）TT-Tooling

Trial工装样件（PSW1）PP-Pilot

Production试生产（可售）(PSW2)MP1-Mass

Production1量产(PSW3)Job#1—

整车投产项目节点（里程碑）FORD福特汽车研发流程介绍PTC/M1DJPTCCPAFDJM1UnitPTCUnitPA33.5MBJ127MBJ125MBJ120.5MBJ127.5MBJ134MBJ117MBJ113MBJ15MBJ12.5MBJ10MBJ1(655/654)PECLR/FECVPTTPP8MBJ15.5MBJ1MP1供应商选点开始关键供应商选择跨功能小组形成启动会议开始第一次现场评审第二次现场评审第三次现场评审第四次现场评审解决问题决定：是否进行试生产？更新供应商APQP/PPAP准备状态评估报告(A表)OTSPPAPPhase0/1PPAPphase2PPAPphase3FORD项目跟踪（装车）节点项目批准工程数据发布手工样件OTS6FORD福特汽车研发流程介绍FORD项目开发节点FORD福特汽车研发流程介绍PPAP的18项DesignRecords设计记录EngineeringChangeDocuments工程变更文件EngineeringApproval工程批准DesignFMEA设计FMEAProcessFlowDiagrams过程流程图ProcessFMEA过程FMEAControlPlans控制计划MeasurementSystemAnalysisStudies测量系统分析研究DimensionalResults尺寸报告RecordsofMaterial/PerformanceTestResults材料和性能测试结果及纪录InitialProcessStudies初始过程能力研究QualifiedLaboratoryDocumentation有资格的实验室文件AppearanceApprovalReport外观批准报告SampleProductionParts生产样件MasterSample标准样件CheckingAids检查辅具Customer-SpecificRequirements顾客特殊要求ProductionPartApprovalProcessSubmissionWarrant(PSW)零件提交保证书FORD福特汽车研发流程介绍PhasedPPAP要求PhasedPPAP是FORD对PPAP流程管理的特殊要求主要目的是提高正式生产是的质量表现需要供应商证明以下要点：—制造能力—产品质量—产能能力FORD福特汽车研发流程介绍全球阶段性PPAP:是在怎样的基础上建立起来的Phase3CapacityVerification产能验证Phase2ProductionVerification生产验证Phase1QualityVerification质量验证Phase0Run-at-Rate节拍生产加强沟通一至性的沟通关注少数重要的优先点。言简意赅帮助使用者区分优先级去除障碍改善工作流程简化稳定化标准化节奏化持续性PhasedPPAPFORD福特汽车研发流程介绍供应商阶段性PPAP过程图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-设计记录2-工程变更文件3–顾客工程批准4-设计FMEA5-过程流程图6-过程FMEA7-控制计划8-测量系统分析16–检查辅具17–顾客特殊要求9-尺寸报告10–材料和性能检测报告11-初始过程能力研究12-有资格的实验室文件13–外观批准报告14–生产样件15–标准样件18–零件提交保证书phase1PSW零件提交保证书phase2PSW(要素18)所有的生产线进行节拍生产(要素1–8,16,17)对所有的生产线进行质量验证(要素9–15)产能分析报告零件提交保证书phase3PSW(要素18)产能分析报告HaveRun-at-Rates(Phase0)beenconductedandQualityVerifications(Phase1)beensatisfiedforALLproductionstreams?FORD福特汽车研发流程介绍PhasedPPAP与PPAP的比较PhasedPPAPorganizestheprocessintofourphasesPhase0:Run-at-Rate按节拍生产Phase1:QualityVerification质量确认（一条生产线）Phase2:ProductionVerification产品验证（多条生产线）Phase3:CapacityVerification产能验证PPAPX1PPFEUJob1PhasedPPAP Phase0 Phase1 Phase2 Phase3FORD福特汽车研发流程介绍阶段PPAP的要求1.Phase0：Run-at-Rate初始按节拍生产正式的生产场地、生产人员正式的设备、工装

夹具、模具、量检具文件齐全：EWO/DFMEA/FC/PFMEA/CP/培训记录/顾客特殊要求至少300件连续生产产能分析、MSAFORD福特汽车研发流程介绍BuildingontheBasics:Phase0STATUS:Phase2CompletedPhase2Warrant[#18]YesStatusTrackingDatabase234ProceedtonextpageSubmittoCustomerImportantnote:Phase2andPhase3canhappenconcurrentlyifallInputsandOutputsaresatisfiedNoSTATUS: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?NoYesNo3RequiredInputsPhase0Phase1Phase2Phase1QualityVerificationPhase2ProductionVerificationPhase3CapacityVerification9-DimensionalResults10-RecordsofMaterial/PerformanceTestResults11-InitialProcessStudies12-QualifiedLaboratoryDocumentation13-AppearanceApprovalReport14-SampleProductionParts15-MasterSample18-PPAPWarrantPPAPWarrant(element18)Run-at-Rateforallproductionstreams(element1–8,16,17)QualityVerificationforallproductionstreams(element9–15)CapacityAnalysisReport

PPAPWarrant(element18)HaveRun-at-Rates(Phase0)beenconductedandQualityVerifications(Phase1)beensatisfiedforALLproductionstreams?INPUTSReleaseddesign[#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]referstotheElementNumberinPPAP4thEditionthatwillassistinconfirmingrequirementsPhase0Run-at-Rate1-设计记录2-工程变更文件3–顾客工程批准4-设计FMEA5-过程流程图6-过程FMEA7-控制计划8-测量系统分析16–检查辅具17–顾客特殊要求产能分析报告FORD福特汽车研发流程介绍Phase0:节拍生产输入设计发布

(PPAP#1,2,3,4)供应商应该有可销售产品的设计记录，包括下层件的详细信息。所有的电子档数据，都需要有硬拷贝的文件来进行追踪，以及评审。StartReleasedDesign

[#1,2,3,4]TrainedsupplierproductionoperatorsSub-supplier(s)materialstatusfromTier-XRun-at-RateQuantityofpartsrequiredasdefinedbycustomer(default300consecutiveparts)Job1location(finalsiteandline)Productionprocessincludingcontrolplan,flowdiagraminstructions,andProcessParameters

[#5,6,7]Productiontools,facilities,andgauging

[#8,16,17]PlannedproductioncycletimesrequiredtosupportdailyproductionvolumeAretheRun-at-Rateinputrequirementsinplacefortheproductionstream?Wasthepre-launchControlPlanfollowed?Weretheprescribednumberofacceptablepartsproduced?Werethepartsproducedinthedefinedperiod?Didalloperationsmeettheirplannedcycletime?ImplementcorrectiveactiononinputEVENT:ConductRun-at-RateSTATUS:Phase0CompleteCapacityAnalysisReportStatusTrackingDatabase41YESNONONONONOYESYESYESSubmit

tocustomerOutputsfromtheeventYESFORD福特汽车研发流程介绍Phase0:节拍生产输入经过培训的操作员供应商必须出示证据，以证明所有涉及到的现场操作员，已经得到了针对新模具、设备、流程等方面的培训。StartReleasedDesign

[#1,2,3,4]TrainedsupplierproductionoperatorsSub-supplier(s)materialstatusfromTier-XRun-at-RateQuantityofpartsrequiredasdefinedbycustomer(default300consecutiveparts)Job1location(finalsiteandline)Productionprocessincludingcontrolplan,flowdiagraminstructions,andProcessParameters

[#5,6,7]Productiontools,facilities,andgauging

[#8,16,17]PlannedproductioncycletimesrequiredtosupportdailyproductionvolumeAretheRun-at-Rateinputrequirementsinplacefortheproductionstream?Wasthepre-launchControlPlanfollowed?Weretheprescribednumberofacceptablepartsproduced?Werethepartsproducedinthedefinedperiod?Didalloperationsmeettheirplannedcycletime?ImplementcorrectiveactiononinputEVENT:ConductRun-at-RateSTATUS:Phase0CompleteCapacityAnalysisReportStatusTrackingDatabase41YESNONONONONOYESYESYESSubmit

tocustomerOutputsfromtheeventYESFORD福特汽车研发流程介绍Phase0:节拍生产输入顾客定义的生产量一般默认为300件连续性的产品供应商必须使用计划的量产状态下的节拍，设备，人员和至少一套模具来进行此次生产。StartReleasedDesign

[#1,2,3,4]TrainedsupplierproductionoperatorsSub-supplier(s)materialstatusfromTier-XRun-at-RateQuantityofpartsrequiredasdefinedbycustomer(default300consecutiveparts)Job1location(finalsiteandline)Productionprocessincludingcontrolplan,flowdiagraminstructions,andProcessParameters

[#5,6,7]Productiontools,facilities,andgauging

[#8,16,17]PlannedproductioncycletimesrequiredtosupportdailyproductionvolumeAretheRun-at-Rateinputrequirementsinplacefortheproductionstream?Wasthepre-launchControlPlanfollowed?Weretheprescribednumberofacceptablepartsproduced?Werethepartsproducedinthedefinedperiod?Didalloperationsmeettheirplannedcycletime?ImplementcorrectiveactiononinputEVENT:ConductRun-at-RateSTATUS:Phase0CompleteCapacityAnalysisReportStatusTrackingDatabase41YESNONONONONOYESYESYESSubmit

tocustomerOutputsfromtheeventYESFORD福特汽车研发流程介绍底盘件：最少300件钣金件：最少30-100件内外饰件：最少30-100件电器件：最少300件

动力系统件：最少300件排气系统：最少300件燃油系统：最少300件节拍生产数量FORD福特汽车研发流程介绍Phase0:节拍生产输入供应商量产零件所使用的生产场地所有的量产件需要在计划的量产场地使用为量产开发的模具，检具，过程，材料，人员，环境和过程设置进行生产。所有的过程参数，必须在节拍生产前完成验证并确认。StartReleasedDesign

[#1,2,3,4]TrainedsupplierproductionoperatorsSub-supplier(s)materialstatusfromTier-XRun-at-RateQuantityofpartsrequiredasdefinedbycustomer(default300consecutiveparts)Job1location(finalsiteandline)Productionprocessincludingcontrolplan,flowdiagraminstructions,andProcessParameters

[#5,6,7]Productiontools,facilities,andgauging

[#8,16,17]PlannedproductioncycletimesrequiredtosupportdailyproductionvolumeAretheRun-at-Rateinputrequirementsinplacefortheproductionstream?Wasthepre-launchControlPlanfollowed?Weretheprescribednumberofacceptablepartsproduced?Werethepartsproducedinthedefinedperiod?Didalloperationsmeettheirplannedcycletime?ImplementcorrectiveactiononinputEVENT:ConductRun-at-RateSTATUS:Phase0CompleteCapacityAnalysisReportStatusTrackingDatabase41YESNONONONONOYESYESYESSubmit

tocustomerOutputsfromtheeventYES19FORD福特汽车研发流程介绍Phase0:节拍生产输入生产过程包括控制计划，过程流程图和过程参数[PPAP#5,6,7]供应商必须有一个能够清晰描述生产步骤和顺序的过程流程图供应商必须要有过程FMEA供应商必须要有过程控制计划StartReleasedDesign

[#1,2,3,4]TrainedsupplierproductionoperatorsSub-supplier(s)materialstatusfromTier-XRun-at-RateQuantityofpartsrequiredasdefinedbycustomer(default300consecutiveparts)Job1location(finalsiteandline)Productionprocessincludingcontrolplan,flowdiagraminstructions,andProcessParameters

[#5,6,7]Productiontools,facilities,andgauging

[#8,16,17]PlannedproductioncycletimesrequiredtosupportdailyproductionvolumeAretheRun-at-Rateinputrequirementsinplacefortheproductionstream?Wasthepre-launchControlPlanfollowed?Weretheprescribednumberofacceptablepartsproduced?Werethepartsproducedinthedefinedperiod?Didalloperationsmeettheirplannedcycletime?ImplementcorrectiveactiononinputEVENT:ConductRun-at-RateSTATUS:Phase0CompleteCapacityAnalysisReportStatusTrackingDatabase41YESNONONONONOYESYESYESSubmit

tocustomerOutputsfromtheeventYES20FORD福特汽车研发流程介绍Phase0:节拍生产输入量产模具，设备和检具[PPAP#8,16,17]供应商必须确认使用的设备、模具、检具状态是否为新开的，整修的还是迁移的用于量产的资源是否符合顾客要求的数量和质量标准StartReleasedDesign

[#1,2,3,4]TrainedsupplierproductionoperatorsSub-supplier(s)materialstatusfromTier-XRun-at-RateQuantityofpartsrequiredasdefinedbycustomer(default300consecutiveparts)Job1location(finalsiteandline)Productionprocessincludingcontrolplan,flowdiagraminstructions,andProcessParameters

[#5,6,7]Productiontools,facilities,andgauging

[#8,16,17]PlannedproductioncycletimesrequiredtosupportdailyproductionvolumeAretheRun-at-Rateinputrequirementsinplacefortheproductionstream?Wasthepre-launchControlPlanfollowed?Weretheprescribednumberofacceptablepartsproduced?Werethepartsproducedinthedefinedperiod?Didalloperationsmeettheirplannedcycletime?ImplementcorrectiveactiononinputEVENT:ConductRun-at-RateSTATUS:Phase0CompleteCapacityAnalysis

ReportStatusTrackingDatabase41YESNONONONONOYESYESYESSubmit

tocustomerOutputsfromtheeventYES21FORD福特汽车研发流程介绍Phase0:节拍生产输入供应商计划产能的生产节拍必须满足顾客的需求供应商必须提供证据证明在计划的量产现场都能满足要求的情况下，生产线能够生产出满足顾客日产量的产品。StartReleasedDesign

[#1,2,3,4]TrainedsupplierproductionoperatorsSub-supplier(s)materialstatusfromTier-XRun-at-RateQuantityofpartsrequiredasdefinedbycustomer(default300consecutiveparts)Job1location(finalsiteandline)Productionprocessincludingcontrolplan,flowdiagraminstructions,andProcessParameters

[#5,6,7]Productiontools,facilities,andgauging

[#8,16,17]PlannedproductioncycletimesrequiredtosupportdailyproductionvolumeAretheRun-at-Rateinputrequirementsinplacefortheproductionstream?Wasthepre-launchControlPlanfollowed?Weretheprescribednumberofacceptablepartsproduced?Werethepartsproducedinthedefinedperiod?Didalloperationsmeettheirplannedcycletime?ImplementcorrectiveactiononinputEVENT:ConductRun-at-RateSTATUS:Phase0CompleteCapacityAnalysisReportStatusTrackingDatabase41YESNONONONONOYESYESYESSubmit

tocustomerOutputsfromtheeventYES22FORD福特汽车研发流程介绍2.Phase1：质量确认零件尺寸报告

材料、性能检测报告

初始过程能力研究，Ppk=1.67生产样件

分供方的PSW已签署

提交Phase1PSW阶段PPAP的要求FORD福特汽车研发流程介绍3.Phase2：产品验证所有生产线按节拍生产（Phase0要求）所有生产线的质量验证（Phase1要求）分供方全部完成Phase2

提交Phase2PSW注：针对多条生产线生产同一产品，若只有一条线可省略。阶段PPAP的要求FORD福特汽车研发流程介绍4.Phase3：产能验证

Phase2认可的PSW

所有班次人员完成培训

分供方产能分析产能分析报告，GP9证明在5天/周和3班/天的情况下能满足顾客LCR提交Phase3PSW阶段PPAP的要求FORD福特汽车研发流程介绍每次提交PPAP时，需要向STA提交检查清单只有该检查清单的所有要素均备STA认可，才能签署PSW所有班次人员具体要求请联系STA阶段PPAP检查清单FORD福特汽车研发流程介绍所有CC/SC/HIC需要使用计量型量具所有CC/SC/HIC尽可能采用放错，如不能则需要SPC控制过程能力Cpk＞1.33，Ppk＞1.67所有过程控制需满足FORD特殊要求，如CQI-9过程能力要求FORD福特汽车研发流程介绍ThankYou!FORD福特汽车研发流程介绍项目管理项目管理三大要素—质量、进度、资源产品项目特点:项目时间性较强具备一定的要求或标准—顾客输入产品项目的开展遵循规定