FORD福特汽车研发流程介绍ppt课件.pptx

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1、交运制造为深入学习习近平新时代中国特色社会主义思想和党的十九大精神,贯彻全国教育大会精神,充分发挥中小学图书室育人功能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交运制造为深入学习习近平新时代中国特色社会主义思想和党的十九大精神,贯彻全国教育大会精神,充分发挥中小学图书室育人功能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（Global Product Development System

2、）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为深入学习习近平新时代中国特色社会主义思想和党的十九大精神,贯彻全国教育大会精神,充分发挥中小学图书室育人功能3GPDS 供应商管理过程供应商管理过程-总览总览 PTC/M1DJPTCC PA FDJ PEC LR/FEC M1 VP TT PP MP1 UnitPTC UnitPA33.5MBJ127MBJ125MBJ120.5MBJ127.5MBJ134MBJ117MBJ113MBJ18MBJ15.5MBJ15MBJ12.5MBJ10MBJ1供应商选供应商选点开始点开始高影响供高影响供应商选

3、择应商选择跨功能小组形成跨功能小组形成启动会议启动会议开始开始第一次现场第一次现场评审评审第二次现场第二次现场评审评审第三次现场第三次现场评审评审第四次现场第四次现场评审评审解决问题解决问题决定：决定：是否进是否进行试生行试生产？产？更新供应商更新供应商 APQP/PPAP 准备状态评估报告准备状态评估报告 (A表表)(655/654)交运制造为深入学习习近平新时代中国特色社会主义思想和党的十九大精神,贯彻全国教育大会精神,充分发挥中小学图书室育人功能PTC-Program Target Compatibility 项目目标整合PAPA-Program Approval 项目批准 FDJ-FD

4、J-Final Data Judgement 工程数据发布VPVP-Verification Prototype(OTS)样件验证PEC-PEC-Preliminary Engineering Completion 工程数据冻结项目节点（里程碑）交运制造为深入学习习近平新时代中国特色社会主义思想和党的十九大精神,贯彻全国教育大会精神,充分发挥中小学图书室育人功能LR-Launch Readiness 生产准备就绪（可生产）TTTT-Tooling Trial 工装样件（PSW1）PPPP-Pilot Production 试生产（可售）(PSW2)MP1MP1-Mass Production

5、1 量产(PSW3)Job#1Job#1 整车投产项目节点（里程碑）交运制造为深入学习习近平新时代中国特色社会主义思想和党的十九大精神,贯彻全国教育大会精神,充分发挥中小学图书室育人功能6 PTC/M1DJPTCC PA FDJ M1 UnitPTC UnitPA33.5MBJ127MBJ125MBJ120.5MBJ127.5MBJ134MBJ117MBJ113MBJ15MBJ12.5MBJ10MBJ1(655/654)PEC LR/FEC VP TT PP8MBJ15.5MBJ1 MP1供应商选供应商选点开始点开始关键供关键供应商选择应商选择跨功能小组形成跨功能小组形成启动会议启动会议开始开

6、始第一次现场第一次现场评审评审第二次现场第二次现场评审评审第三次现场第三次现场评审评审第四次现场第四次现场评审评审解决问题解决问题决定：决定：是否进是否进行试生行试生产？产？更新供应商更新供应商 APQP/PPAP 准备状态评估报告准备状态评估报告 (A表表)OTSPPAPPhase0/1PPAPphase2PPAPphase3FORD项目跟踪（装车）节点项目批准项目批准工程数据发布手工样件OTS交运制造为深入学习习近平新时代中国特色社会主义思想和党的十九大精神,贯彻全国教育大会精神,充分发挥中小学图书室育人功能FORD项目开发节点交运制造为深入学习习近平新时代中国特色社会主义思想和党的十九大

7、精神,贯彻全国教育大会精神,充分发挥中小学图书室育人功能PPAP 的18项1.1.Design RecordsDesign Records设计记录设计记录2.2.Engineering Change DocumentsEngineering Change Documents工工程变更文件程变更文件3.3.Engineering Approval Engineering Approval 工程批准工程批准4.4.Design FMEADesign FMEA设计设计FMEAFMEA5.5.Process Flow DiagramsProcess Flow Diagrams过程流程过程流程图图6.6

8、.Process FMEAProcess FMEA过程过程FMEAFMEA7.7.Control PlansControl Plans控制计划控制计划8.8.Measurement System Analysis Measurement System Analysis StudiesStudies测量系统分析研究测量系统分析研究9.9.Dimensional ResultsDimensional Results尺寸报告尺寸报告10.10.Records of Material/Performance Records of Material/Performance Test ResultsTes

9、t Results材料和性能测试结果及纪材料和性能测试结果及纪录录11.11.Initial Process StudiesInitial Process Studies初始过程能初始过程能力研究力研究12.12.Qualified Laboratory DocumentationQualified Laboratory Documentation有资格的实验室文件有资格的实验室文件13.13.Appearance Approval ReportAppearance Approval Report外观批准外观批准报告报告14.14.Sample Production PartsSample P

10、roduction Parts生产样件生产样件15.15.Master SampleMaster Sample标准样件标准样件16.16.Checking AidsChecking Aids检查辅具检查辅具17.17.Customer-Specific RequirementsCustomer-Specific Requirements顾客顾客特殊要求特殊要求18.18.Production Part Approval Process Production Part Approval Process Submission Warrant(PSW)Submission Warrant(PSW)零

11、件提交保零件提交保证书证书交运制造为深入学习习近平新时代中国特色社会主义思想和党的十九大精神,贯彻全国教育大会精神,充分发挥中小学图书室育人功能Phased PPAP 要求Phased PPAPPhased PPAP是是FORDFORD对对PPAPPPAP流程管理的特殊流程管理的特殊要求要求主要目的是提高正式生产是的质量表现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：需要供应商证明以下要点：制造能力制造能力 产品质量产品质量 产能能力产能能力交运制造为深入学习习近平新时代中国特色社会主义思想和党的十九大精神,贯彻全国教育大会精神,充分发挥中小学图书室育人功能全球阶段性PPAP:是

12、在怎样的基础上建立起来的Phase 3 Phase 3 Capacity VerificationCapacity Verification产能验证产能验证产能验证产能验证Phase 2Phase 2Production VerificationProduction Verification生产验证生产验证生产验证生产验证Phase 1Phase 1Quality VerificationQuality Verification质量验证质量验证质量验证质量验证Phase 0Phase 0Run-at-RateRun-at-Rate节拍生产节拍生产节拍生产节拍生产加强沟通1.一至性的沟通2.关注

13、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.持续性交运制造为深入学习习近平新时代中国特色社会主义思想和党的十九大精神,贯彻全国教育大会精神,充分发挥中小学图书室育人功能供应商阶段性PPAP过程图STATUS:Phase 2Completed Phase 2 Warrant#18YesStatus Tracking Database234Proceed to next pageSubmit to CustomerImportant note:Phase 2 and Phase 3 can happen concurren

14、tly if all Inputs and Outputs are satisfiedNoINPUTSReleased design#1,2,3&4Trained supplier production operatorsSub-supplier(s)material status from Tier-x RRJob 1 Location(final site&line)Quantity of parts required as defined by customer(default 300 consecutive parts)Production process including cont

15、rol plan,flow diagram instructions&Process parameters#5,6&7Production Tools,Facilities&Gauging#8,16&17EVENT:Conduct Run at RatePlanned production cycle times required to support Daily Production VolumeOutputs from the eventSTATUS:Phase 0 CompletedImplement Corrective Action on InputWas the Pre-Launc

16、h Control Plan followed?Were the prescribed number of acceptable parts produced?Were the parts produced in the defined period?Did all operations meet their planned cycle time?YesYesYesYesNoNoNoNoAre the RunRate input requirements in place for the production stream?YesSTARTNo Capacity Analysis Worksh

17、eetStatus Tracking Database14Proceed to next pageRequired InputsSubmit to CustomerNote:#x refers to the Element Number in PPAP 4th Edition that will assist in confirming requirementsSTATUS:Phase 1 Completed Continue Production Part Approval Process(PPAP)using parts from Phase 0-Dimensional measureme

18、nts#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 PPAPHave the PPAP elements been satisfied?YesStatus Tracking Database1424Important note:For suppliers with only one pro

19、duction stream completion of Phase 1&2 occur at the same timeProceed to next pageReturn to Phase 0 for corrective actionNoSubmit to CustomerPhase 1 Warrant#18Phase 2 WarrantScheduled down time defined(TPM,change over,Breaks etc.)Sub supplier material status from Tier-x Phase 3EVENT:Conduct Capacity

20、Verification RunSTATUS:Phase 3 Completed Quantity required is customer DPV for one full dayAll personnel for all shifts,trained Are the CVR input requirements in place for all production streams?YesENDStatus Tracking DatabaseReturn to affected phase and start corrective action Phase 3 Warrant#18&Cap

21、acity Analysis Report Determine Root Cause&Plan Corrective Action Was the control plan followed&acceptable parts produced?Did the volume of acceptable parts produced meet or exceed the requiredDPV?NoYesNo3Required InputsPhase 0Phase 1Phase 2Phase 0Run-at-RatePhase 1Quality VerificationPhase 2Product

22、ion VerificationPhase 3Capacity Verification1-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phase1 PSW零件提交保证书 phase2 PSW(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phase3 PSW(要素

23、18)产能分析报告Have Run-at-Rates(Phase 0)been conducted and Quality Verifications(Phase 1)been satisfied for ALL production streams?交运制造为深入学习习近平新时代中国特色社会主义思想和党的十九大精神,贯彻全国教育大会精神,充分发挥中小学图书室育人功能Phased PPAP与PPAP的比较Phased PPAP organizes the process into four phasesPhased PPAP organizes the process into four ph

24、asesPhase 0:Run-at-Rate 按节拍生产按节拍生产Phase 1:Quality Verification 质量确认（一条生产线）质量确认（一条生产线）Phase 2:Production Verification 产品验证产品验证（多条生产线）（多条生产线）Phase 3:Capacity Verification 产能验证产能验证PPAPX1 PPFEUJob 1Phased PPAPPhase 0Phase 1Phase 2Phase 3交运制造为深入学习习近平新时代中国特色社会主义思想和党的十九大精神,贯彻全国教育大会精神,充分发挥中小学图书室育人功能阶段PPAP的要

25、求1.Phase 0：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、MSA交运制造为深入学习习近平新时代中国特色社会主义思想和党的十九大精神,贯彻全国教育大会精神,充分发挥中小学图书室育人功能Building on the Basics:Phase 0STATUS:Phase 2Completed Phase 2 Warrant#18YesStatus Tracking Database234Proceed to next pageSubm

26、it to CustomerImportant note:Phase 2 and Phase 3 can happen concurrently if all Inputs and Outputs are satisfiedNoSTATUS:Phase 1 Completed Continue Production Part Approval Process(PPAP)using parts from Phase 0-Dimensional measurements#9-Material Tests#10-Statistical process package#11-Performance T

27、ests#12-Appearance criteria#13-Sample parts#14-Master samples#15-Customer Specific Requirements#17-as defined by PPAPHave the PPAP elements been satisfied?YesStatus Tracking Database1424Important note:For suppliers with only one production stream completion of Phase 1&2 occur at the same timeProceed

28、 to next pageReturn to Phase 0 for corrective actionNoSubmit to CustomerPhase 1 Warrant#18Phase 2 WarrantScheduled down time defined(TPM,change over,Breaks etc.)Sub supplier material status from Tier-x Phase 3EVENT:Conduct Capacity Verification RunSTATUS:Phase 3 Completed Quantity required is custom

29、er DPV for one full dayAll personnel for all shifts,trained Are the CVR input requirements in place for all production streams?YesENDStatus Tracking DatabaseReturn to affected phase and start corrective action Phase 3 Warrant#18&Capacity Analysis Report Determine Root Cause&Plan Corrective Action Wa

30、s the control plan followed&acceptable parts produced?Did the volume of acceptable parts produced meet or exceed the requiredDPV?NoYesNo3Required InputsPhase 0Phase 1Phase 2Phase 1Quality VerificationPhase 2Production VerificationPhase 3Capacity Verification9-Dimensional Results10-Records of Materia

31、l/Performance Test Results11-Initial Process Studies12-Qualified Laboratory Documentation13-Appearance Approval Report14-Sample Production Parts15-Master Sample18-PPAP WarrantPPAP Warrant(element 18)Run-at-Rate for all production streams(element 1 8,16,17)Quality Verification for all production stre

32、ams(element 9 15)Capacity Analysis Report PPAP Warrant(element 18)Have Run-at-Rates(Phase 0)been conducted and Quality Verifications(Phase 1)been satisfied for ALL production streams?INPUTSReleased design#1,2,3&4Trained supplier production operatorsSub-supplier(s)material status from Tier-x RRJob 1

33、Location(final site&line)Quantity of parts required as defined by customer(default 300 consecutive parts)Production process including control plan,flow diagram instructions&Process parameters#5,6&7Production Tools,Facilities&Gauging#8,16&17EVENT:Conduct Run at RatePlanned production cycle times requ

34、ired to support Daily Production VolumeOutputs from the eventSTATUS:Phase 0 CompletedImplement Corrective Action on InputWas the Pre-Launch Control Plan followed?Were the prescribed number of acceptable parts produced?Were the parts produced in the defined period?Did all operations meet their planne

35、d cycle time?YesYesYesYesNoNoNoNoAre the RunRate input requirements in place for the production stream?YesSTARTNo Capacity Analysis WorksheetStatus Tracking Database14Proceed to next pageRequired InputsSubmit to CustomerNote:#x refers to the Element Number in PPAP 4th Edition that will assist in con

36、firming requirementsPhase 0Run-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交运制造为深入学习习近平新时代中国特色社会主义思想和党的十九大精神,贯彻全国教育大会精神,充分发挥中小学图书室育人功能Phase 0: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。StartReleased Design#1,2,3,4Trai

37、ned supplier production operatorsSub-supplier(s)material status from Tier-X Run-at-RateQuantity of parts required as defined by customer(default 300 consecutive parts)Job 1 location(final site and line)Production process including control plan,flow diagram instructions,and Process Parameters#5,6,7Pr

38、oduction tools,facilities,and gauging#8,16,17Planned production cycle times required to support daily production volumeAre the Run-at-Rate input requirements in place for the production stream?Was the pre-launch Control Plan followed?Were the prescribed number of acceptable parts produced?Were the p

39、arts produced in the defined period?Did all operations meet their planned cycle time?Implement corrective action on inputEVENT:Conduct Run-at-RateSTATUS:Phase 0 CompleteCapacity AnalysisReportStatus Tracking Database41YESNONONONONOYESYESYESSubmitto customerOutputs from the eventYES交运制造为深入学习习近平新时代中国特

40、色社会主义思想和党的十九大精神,贯彻全国教育大会精神,充分发挥中小学图书室育人功能Phase 0: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。StartReleased Design#1,2,3,4Trained supplier production operatorsSub-supplier(s)material status from Tier-X Run-at-RateQuantity of parts required as defined by customer(default 300 consecut

41、ive parts)Job 1 location(final site and line)Production process including control plan,flow diagram instructions,and Process Parameters#5,6,7Production tools,facilities,and gauging#8,16,17Planned production cycle times required to support daily production volumeAre the Run-at-Rate input requirements

42、 in place for the production stream?Was the pre-launch Control Plan followed?Were the prescribed number of acceptable parts produced?Were the parts produced in the defined period?Did all operations meet their planned cycle time?Implement corrective action on inputEVENT:Conduct Run-at-RateSTATUS:Phas

43、e 0 CompleteCapacity AnalysisReportStatus Tracking Database41YESNONONONONOYESYESYESSubmitto customerOutputs from the eventYES交运制造为深入学习习近平新时代中国特色社会主义思想和党的十九大精神,贯彻全国教育大会精神,充分发挥中小学图书室育人功能Phase 0: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。StartReleased Design#1,2,3,4Trained supp

44、lier production operatorsSub-supplier(s)material status from Tier-X Run-at-RateQuantity of parts required as defined by customer(default 300 consecutive parts)Job 1 location(final site and line)Production process including control plan,flow diagram instructions,and Process Parameters#5,6,7Production

45、 tools,facilities,and gauging#8,16,17Planned production cycle times required to support daily production volumeAre the Run-at-Rate input requirements in place for the production stream?Was the pre-launch Control Plan followed?Were the prescribed number of acceptable parts produced?Were the parts pro

46、duced in the defined period?Did all operations meet their planned cycle time?Implement corrective action on inputEVENT:Conduct Run-at-RateSTATUS:Phase 0 CompleteCapacity AnalysisReportStatus Tracking Database41YESNONONONONOYESYESYESSubmitto customerOutputs from the eventYES交运制造为深入学习习近平新时代中国特色社会主义思想和

47、党的十九大精神,贯彻全国教育大会精神,充分发挥中小学图书室育人功能底盘件：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 动力系统动力系统件：最少件：最少300件件排气系统：最少300件燃油系统：最少300件节拍生产数量交运制造为深入学习习近平新时代中国特色社会主义思想和党的十九大精神,贯彻全国教育大会精神,充分发挥中小学图书室育人功能19Phase 0: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。Start

48、Released Design#1,2,3,4Trained supplier production operatorsSub-supplier(s)material status from Tier-X Run-at-RateQuantity of parts required as defined by customer(default 300 consecutive parts)Job 1 location(final site and line)Production process including control plan,flow diagram instructions,and

49、 Process Parameters#5,6,7Production tools,facilities,and gauging#8,16,17Planned production cycle times required to support daily production volumeAre the Run-at-Rate input requirements in place for the production stream?Was the pre-launch Control Plan followed?Were the prescribed number of acceptabl

50、e parts produced?Were the parts produced in the defined period?Did all operations meet their planned cycle time?Implement corrective action on inputEVENT:Conduct Run-at-RateSTATUS:Phase 0 CompleteCapacity AnalysisReportStatus Tracking Database41YESNONONONONOYESYESYESSubmitto customerOutputs from the