FORD流程介绍

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交运制造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全球产品开发体系交运制造3GPDS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)交运制造PTC-ProgramTargetCompatibility项目目标整合PA-ProgramApproval项目批准FDJ-FinalDataJudgement工程数据发布VP-VerificationPrototype(OTS)样件验证PEC-PreliminaryEngineeringCompletion工程数据冻结项目节点（里程碑）交运制造LR-LaunchReadiness生产准备就绪（可生产）TT-ToolingTrial工装样件（PSW1）PP-PilotProduction试生产（可售）(PSW2)MP1-MassProduction1量产(PSW3)Job#1—整车投产项目节点（里程碑）交运制造6PTC/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OTS交运制造FORD项目开发节点交运制造PPAP的18项1.DesignRecords设计记录2.EngineeringChangeDocuments工程变更文件3.EngineeringApproval工程批准4.DesignFMEA设计FMEA5.ProcessFlowDiagrams过程流程图6.ProcessFMEA过程FMEA7.ControlPlans控制计划8.MeasurementSystemAnalysisStudies测量系统分析研究9.DimensionalResults尺寸报告10.RecordsofMaterial/PerformanceTestResults材料和性能测试结果及纪录11.InitialProcessStudies初始过程能力研究12.QualifiedLaboratoryDocumentation有资格的实验室文件13.AppearanceApprovalReport外观批准报告14.SampleProductionParts生产样件15.MasterSample标准样件16.CheckingAids检查辅具17.Customer-SpecificRequirements顾客特殊要求18.ProductionPartApprovalProcessSubmissionWarrant(PSW)零件提交保证书交运制造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—产能能力交运制造全球阶段性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1.一至性的沟通2.关注少数重要的优先点。3.言简意赅4.帮助使用者区分优先级5.去除障碍改善工作流程1.简化2.稳定化3.标准化4.节奏化5.持续性交运制造供应商阶段性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?交运制造PhasedPPAP与PPAP的比较PhasedPPAPorganizestheprocessintofourphasesPhase0: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PPAPX1PPFEUJob1PhasedPPAPPhase0Phase1Phase2Phase3交运制造阶段PPAP的要求1.Pha