全球阶段性PPAP:是在怎样的基础上建立起来的
交运制造
加强沟通
1. 2. 3. 4. 5. 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
Phase 3 Capacity Verification 产能验证 Phase 2 Production Verification 生产验证 Phase 1 Quality Verification 质量验证 Phase 0 Run-at-Rate 节拍生产
7. Control Plans控制计划
8. Measurement System Analysis Studies测量系统分析研究 9. Dimensional Results尺寸报告
15. Master Sample标准样件
16. Checking Aids检查辅具 17. Customer-Specific Requirements 顾 客特殊要求
STATUS: Phase 1 Completed
2
2
Have Run-at-Rates (Phase 0) been conducted and Quality Verifications (Phase 1) been satisfied for ALL production streams?
Yes
Yes
No
Yes Phase 2 Warrant
No
Were the prescribed number of acceptable parts produced?
CapacitBiblioteka Analysis Worksheet
Phase 1 Warrant [#18]
Yes
Submit to Customer
交运制造
FORD流程简介
—上海交运集团股份有限公司汽车零部件制造分公司
1
GPDS 全球产品开发体系
GPDS（ Global Product Development System）
—是FORD公司全球产品开发体系，替代原FPDS福特产品开发体系
交运制造
早期参与
团队
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) 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。 使用共同的，明确的交付报告和结构化的 管理评审模式
MP1
0MBJ1
25MBJ1
供应商选 点开始
高影响供 应商选择
跨功能小组形成
解决问题
第一次现场 评审 第二次现场 评审
决定： 是否进 行试生 产？
启动会议 开始
第三次现场 评审
第四次现场 评审
更新供应商 APQP/PPAP 准备状态评估报告 (A表)
3
项目节点（里程碑）
PA-Program Approval 项目批准
Have the PPAP elements been satisfied?
Yes
Proceed to next page
Trained supplier production operators
Outputs from the event
STATUS: Phase 0 Completed
- Dimensional measurements [#9] - Material Tests [#10] - Statistical process package [#11] - Performance Tests [#12] - Appearance criteria [#13] - Sample parts [#14] - Master samples [#15] - Customer Specific Requirements[#17] - as defined by PPAP
No
Were the parts produced in the defined period?
Submit to Customer
Status Tracking Database Status Tracking Database Sub supplier material status from Tier-x Phase 3 Determine Root Cause & Plan Corrective Action
Return to Phase 0 for corrective action
Important note: Phase 2 and Phase 3 can happen concurrently if all Inputs and Outputs are satisfied 4 4
Return to affected phase and start corrective action
FORD项目跟踪（装车）节点
Unit PTC 34MBJ1 PTCC 33.5MBJ1 (655/654) Unit PA 27.5MBJ1
交运制造
项目批准 工程数 据发布
PTC/ M1DJ 27MBJ1 M1 PA 20.5MBJ1 FDJ
手工样 件OTS
VP PEC 8MBJ1 LR/ FEC 5.5MBJ1 TT 5MBJ1 PP 2.5MBJ1 MP1 0MBJ1
改善工作流程
1. 简化 2. 稳定化 3. 标准化 4. 节奏化 5. 持续性
供应商阶段性PPAP过程图
START
交运制造
INPUTS Released
design [#1,2,3 & 4]
No No Was the Pre-Launch Control Plan followed?
1
1
Proceed to next page
Yes
EVENT: Conduct Capacity Verification Run
STATUS: Phase 3 Completed
END
3
3
Quantity required is customer DPV for one full day
No
Was the control plan followed & acceptable parts produced? Phase 3 Warrant [#18] & Capacity Analysis Report
项目节点（里程碑）
TT-Tooling Trial 工装样件 （PSW1）
交运制造
LR-Launch Readiness 生产准备就绪（可生产）
PP-Pilot Production 试生产（可售）(PSW2)
MP1-Mass Production 1 量产 (PSW3) Job #1— 整车投产
GPDS 供应商管理过程-总览
Unit PTC
34MBJ1
交运制造
Unit PA
27.5MBJ1
PTCC
33.5MBJ1 (655/654)
PTC/ M1DJ
27MBJ1
M1
PA
20.5MBJ1
FDJ
17MBJ1
VP
13MBJ1
PEC
8MBJ1
LR/ FEC
5.5MBJ1
TT
5MBJ1
PP
2.5MBJ1
Continue Production Part Approval Process (PPAP) using parts from Phase 0
All personnel for all shifts, trained
Are the CVR input requirements in place for all production streams?
Submit to Customer
Phase 2 Warrant [#18]
Scheduled down time defined (TPM, change over, Breaks etc.)
No
Did the volume of acceptable parts produced meet or exceed the required DPV?
No
Proceed to next page
Sub-supplier(s) material status from Tier-x R@R Quantity of parts required as defined by customer (default 300 consecutive parts) Job 1 Location (final site & line) Production process including control plan, flow diagram instructions & Process parameters [#5,6 & 7] Production Tools, Facilities & Gauging [#8,16 & 17] Planned production cycle times required to support Daily Production Volume
25MBJ1
17MBJ1
13MBJ1
OTS
PPAP Phase0/1
PPAP phase2
PPAP phase3
供应商选 点开始
关键供 应商选择
跨功能小组形成
解决问题
第一次现场 评审 第二次现场 评审
决定： 是否进 行试生 产？
启动会议 开始
第三次现 场评审
第四次现场 评审
6
更新供应商 APQP/PPAP 准备状态评估报告 (A表)
FORD项目开发节点