某汽车公司APQP教程.pptx

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1、1Use of Ford APQP Status Report福特APQP使用的报告Tong LeiSupplier Technical AssistanceFord Motor Company2Use of Ford APQP Status Report福特APQP使用的报告 APQP OverviewAPQP概述 Introduction to Ford APQP Status Reporting System介绍福特APQP使用报告系统 How to use Ford APQP Status Reporting System怎样使用福特APQP报告系统 Q&A问答3APQP Overvi

2、ewnAPQP is a structured method for guiding an organization to execute the necessary actions to ensure that the product satisfies the customers. nAPQP is a supplier-led program that is applicable for all systems, subsystems and components levels.4APQP Overview- The Goal of APQPnThe goal of APQP is to

3、 facilitate communication between all involved personnel and disciplines in a program by completing all required steps on time, at acceptable cost and quality levels. Flawless product launch will result.5Elements of APQP (AIAG)n19 are from the AIAG APQP and Control Plan manual.Facilities / Tools / G

4、augesPrototype BuildsDrawings and SpecificationsTeam Feasibility CommitmentMeasurement Systems EvaluationPackaging SpecificationsProduction Trial RunPreliminary Process Capability StudyProduction Validation TestingProduction Part Approval (PSW)Design FMEADesign Verification Plan & ReportPrototype Bu

5、ild Control PlanManufacturing Process Flow ChartProcess FMEAPre-Launch Control PlanOperation Process InstructionsProduction Control PlanDesign & Mfg. Review(s)6AIAG APQP Timing ChartFeedback Assessment & Corrective Action反馈、评估和纠正措施反馈、评估和纠正措施Product & Process Validation产品与过程确认产品与过程确认Process Design &

6、Development过程设计和开发过程设计和开发Product Design & Development产品设计和开发产品设计和开发Prototype Build样件制造样件制造Plan & Define计划与定义计划与定义7Ford APQP Status Reporting SystemnAn improvement of the AIAG APQP system.nFour additional elementsnElements start and finish are tied to program milestones.8Purpose of APQP Status Report

7、nCommon APQP expectations for internal and external suppliers to Ford Motor CompanynCommon APQP process metricsnA common program status reporting formatnRoles and responsibilities for those involved in APQP element implementation.Establishing: 9Ford APQP Status Reporting Systemn23 elements.19 elemen

8、ts from AIAG APQP, plus4 Ford unique elements. They are:nSourcing DecisionnCustomer Input RequirementsnSubcontractor APQP StatusnCraftsmanship10Approach of Ford APQPnThis status reporting guideline describes 23 key APQP elements.nFord Motor Company expectations are defined for these key elements in

9、definitions, and detailed checklists.nThe status for these elements is summarized using metrics described in the Reporting section.nThis status reporting guideline is written from a supplier standpoint.11The Applicability of Ford APQPnAPQP status reporting is a requirement of all internal and extern

10、al suppliers to FordnAPQP must be done for new programs/parts and major part changes as appropriate.12APQP Process Flow13The APQP Process includes 5 main functions:1.Planning of the APQP elements2.Execution of the APQP elements3.Monitoring the Quality-of-Event of the execution of the elements, as we

11、ll as the timing, by the team in-between milestones4.Issues Resolution5.Status Reporting (minimum at each milestones)14Use of Ford APQP Status Report How to use Ford APQP Status Report for Emerging Market Re-sourcing Programs.15Backgrounds of APQP for Emerging Market Re-sourcing Programs - Ford APQP

12、 v3.2nFord APQP Status Report v3.2 is one Excel file with 26 work sheets.n2 Summary sheets1)APQP Status Report (linked)2)APQP Status Report (manual)n1 Information sheetn23 worksheets for 23 Ford APQP elements. One sheet for each element.nFord APQP Status Report v3.2 uses milestones from Ford FPDS Fo

13、rd Product Development System.16Backgrounds of APQP for Emerging Market Re-sourcing Programs - Ford APQP v3.217Backgrounds of APQP for Emerging Market Re-sourcing Programs - FPDSnFPDS Ford Product Development System Ford uses FPDS to Plan, Design, Develop and Launch new vehicles.Championed by Ford P

14、D.Contains 15 milestones. 12 of them are used in Ford APQP Status Report v3.2.18FPDSOptimizeVehicleSystemSubsystemComponentProduct/ProcessDesignCascadeVerifyDesign/Mfg. ConfirmationLaunch/Mass Prod.ConfirmationUpdateCorporateMemoryMANAGEDefineArchitectureProgram InputDEFINEDESIGNVERIFY AND LAUNCHPS1

15、KOPS2SIPASCPHSTPRCPJ1FSLSLRCC14.5041301925.5-35019FPDS Definitions 15 Milestones Kick-Off (The beginning of program specific work)开球-项目具体工作的开展 Pre#1 (Mission/vision & target customers defined)任务/愿景&目标顾客的定义 Pre#2 (Target ranges assessed)评估指标范围 Strategic Intent (Initial program direction established)最

16、初的计划方向建立 Strategic Confirmation (Teams confirms strategy/viability)团队确认策略/可行性 Proportions & Handpoints (Vehicle proportion frozen)车辆比例的冻结 Program Approval (All targets become objectives)项目批准-所有目的成为目标(ST) Surface Transfer (Interior/exterior surface provided)外观面的转移（内外饰外观） Product Readiness (Designs re

17、ady for CP builds)产品准备就绪（准备设计CP结构）(CP) Confirmation Prototype (First CP vehicle available)确认模型（第一次CP车辆可行性分析）20FPDS Definitions 15 Milestones (contd) Change Cut-Off (Commitment to Job #1 timing) Launch Readiness (Engineering Sign-off complete) Launch Sign-Off (Ready to Launch) Job #1 Achieved (Start

18、Production) Final Status21Backgrounds of APQP for Emerging Market Re-sourcing Programs - EMLPnEMLP Emerging Market Launch PlanDeveloped to track status of Emerging Market re-sourcing programs within Ford.Championed by Ford EMS PD.22Backgrounds - EMLP (contd)nEMLP Emerging Market Launch Plan7 milesto

19、nes, from program approval to part arrival at Ford receiving plant.nGSSM+2W GSSM+2 weeks. EMLP kick-off; issue sourcing agreement. nPR Product Readiness. 2D drwgs/3D model/DFMEA received by supplier.nCP Confirmation Prototype. Prototype parts built; “DV” test started.nESO Engineering Sign Off. “DV”

20、test completed; nPSW/LS PSW/Launch Sign. PSW and functional sign-off completed.nSJ1 Supplier Job 1. Supplier ships out first production shipment.nIPD In Plant Date. Parts received at Ford plant(s).23Two Systems, One Objective Flawless Launch!APQP feeds EMLPEMLP(Championed by Ford PD)APQP(Championed

21、by Supplier)24APQP for Emerging Market Re-sourcingvs. Ford APQP v3.2nAPQP for EM Re-sourcing uses 7 EMLP milestones (for re-sourcing programs); nAPQP v3.2 uses 12 FPDS milestones (for new programs). 25APQP for Emerging Market Re-sourcingvs. Ford APQP v3.2FPDS Milestones Remain for ReferenceEMLP Mile

22、stones Added26APQP for Emerging Market Re-sourcingvs. Ford APQP v3.2nAPQP for EM Re-sourcing uses 7 EMLP milestones (for re-sourcing programs); APQP v3.2 uses 12 FPDS milestones (for new programs). nAPQP for EM eliminates New Program specific requirements, which are not required for Re-sourcing Prog

23、rams, from APQP v3.2. Maintains original APQP requirements as guideline.27APQP for Emerging Market Re-sourcingvs. Ford APQP v3.2Eliminates New Program specific requirementsMaintains original APQP requirements as guideline28APQP for Emerging Market Re-sourcingvs. Ford APQP v3.2nAPQP for EM Re-sourcin

24、g uses 7 EMLP milestones (for re-sourcing programs); APQP v3.2 uses 12 FPDS milestones (for new programs). nAPQP for EM eliminates New Program specific requirements, which are not required for Re-sourcing Programs, from APQP v3.2. Maintains original APQP requirements as guideline.nChecklist includes

25、 additional EMLP unique Supplier responsible requirements for the 23 elements. (At bottom of the checklist for each element.)29APQP for Emerging Market Re-sourcingvs. Ford APQP v3.2Additional EMLP unique Supplier responsible requirements30APQP for Emerging Market Re-sourcingvs. Ford APQP v3.2nAPQP f

26、or EM Re-sourcing uses 7 EMLP milestones (for re-sourcing programs); APQP v3.2 uses 12 FPDS milestones (for new programs). nAPQP for EM eliminates New Program specific requirements, which are not required for Re-sourcing Programs, from APQP v3.2. Maintains original APQP requirements as guideline.nCh

27、ecklist includes additional EMLP unique Supplier responsible requirements for the 23 elements. (At bottom of the checklist for each element.)nWorksheet of “Action Plan” has been added to APQP for EM, to reduce “copies and pastes” of action plans from 23 elements to the summary sheet.31APQP for Emerg

28、ing Market Re-sourcingvs. Ford APQP v3.2Sheet of “Action Plan” has been added.32APQP for Emerging Market Re-sourcingvs. Ford APQP v3.2nAPQP for EM Re-sourcing uses 7 EMLP milestones (for re-sourcing programs); APQP v3.2 uses 12 FPDS milestones (for new programs). nAPQP for EM eliminates New Program

29、specific requirements, which are not required for Re-sourcing Programs, from APQP v3.2. Maintains original APQP requirements as guideline.nChecklist includes additional EMLP unique Supplier responsible requirements for the 23 elements. (At bottom of the checklist for each element.)nWorksheet of “Act

30、ion Plan” has been added to APQP for EM, to reduce “copies and pastes” of action plans from 23 elements to the summary sheet.nFor forward model (new) programs, Ford APQP v3.2 should be used.33Complete APQP Status Report For EM Re-sourcing programs1.Complete Information SheetInput milestone dates. Sh

31、ould be same as timing plan.Input Part Number and PPAP information.Input team information, for both supplier and Ford.Input program change history, if any.34Complete APQP Status Report For EM Re-sourcing programs - continue2.Complete Program Information on sheet of “APQP Status Report (linked)”.35Co

32、mplete APQP Status Report For EM Re-sourcing programs - continue3.Review status of 23 elements.Next slide uses status review of element 11, drawing and specs, at PR as an example.36Sample Check sheet at PRLight Gray shaded cells: Review expectation at these milestones. If R or Y, this issue requires

33、 corrective actionIf R or Y, review at next milestone (until its G), even if “Finish Target” date is passed.Overall status is worst rating of all expectations. Manual input is NOT required.Record identified issue and corrective action here.Status Can be updated continuously until Milestone Date is m

34、etPrior Milestone Status is FrozenInput actual start and finish dates for each expectation. 37Rating and Assessment G/Y/R StatusRiskColorDefinitionHighRed Target dates and/or deliverables are at risk. A recovery work plan is not available and/or implemented, or the work plan does not achieve program

35、 targets.ModerateYellow Target dates and/or deliverables are at risk, but a resourced recovery work plan has been developed to achieve program targets, and has been approved by the appropriate Management Team.LowGreen Target dates and deliverables are on track and meeting objectives.38Complete APQP

36、Status Report For EM Re-sourcing programs - continue4.Complete the summary sheet on “APQP Status Report (linked)”.Auto-linked to the overall status of the checksheet for this element. Overall status is worst rating of all elements. Manual input is NOT required.39Complete APQP Status Report For EM Re

37、-sourcing programs - continue4.Complete action plan on summary sheet.Do not input action plans on the bottom part of “APQP Status Report (linked)”. 40Complete APQP Status Report For EM Re-sourcing programs - continue4.Complete action plan on summary sheet - continue.Header information is linked from

38、 “APQP Status Report (linked)” sheet.Copy and paste action plans for all R and Y issues from 23 elements.Input Element #.41APQP Status ReportnSupplier must submit Status Report to the CSO STA every month, and two weeks before each milestone.nSTA Site Engineer verifies supplier APQP status and report

39、-outs meet milestone timing.nFord Cross functional team must hold regular APQP reviews (minimum at each milestones) with Supplier to evaluate overall program health.nSupplier must maintain evidence book for each element. Submit supporting documentation upon request.42Use of Ford APQP Status Report Q&A43APQP Reference Information44Use of Ford APQP Status Report Thank You!Thank You!