FORD福特汽车研发流程介绍【深度讲解】

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,藤蔓课堂,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,GPDS 全球产品开发体系,2,藤蔓课堂,GPDS 供应商管理过程-总览,PTC/ M1DJ,PTCC,PA,FDJ,PEC,LR/ FEC,M1,VP,TT,PP,MP1,Unit PTC,Unit PA,33.5MBJ1,27MBJ1,25MBJ1,20.5MBJ1,27.5MBJ1,34MBJ1,17MBJ1,13MBJ1,8MBJ1,5.5MBJ1,5MBJ1,2.5MBJ1,0MBJ1,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),3,藤蔓课堂,PTC-Program Target Compatibility 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 Engineering Completion 工程数据冻结,项目节点（里程碑）,4,藤蔓课堂,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 Production 1 量产 (PSW3) Job #1 整车投产,项目节点（里程碑）,5,藤蔓课堂,13MBJ1,5MBJ1,2.5MBJ1,0MBJ1,(655/654),FORD项目跟踪（装车）节点,项目批准,工程数据发布,手工样件OTS,6,藤蔓课堂,FORD项目开发节点,7,藤蔓课堂,PPAP 的18项,Design Records设计记录 Engineering Change Documents工程变更文件 Engineering Approval 工程批准 Design FMEA设计FMEA Process Flow Diagrams过程流程图 Process FMEA过程FMEA Control Plans控制计划 Measurement System Analysis Studies测量系统分析研究 Dimensional Results尺寸报告,Records of Material / Performance Test Results材料和性能测试结果及纪录 Initial Process Studies初始过程能力研究 Qualified Laboratory Documentation有资格的实验室文件 Appearance Approval Report外观批准报告 Sample Production Parts生产样件 Master Sample标准样件 Checking Aids检查辅具 Customer-Specific Requirements顾客特殊要求 Production Part Approval Process Submission Warrant (PSW)零件提交保证书,8,藤蔓课堂,Phased PPAP 要求,Phased PPAP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,9,藤蔓课堂,全球阶段性PPAP:是在怎样的基础上建立起来的,10,藤蔓课堂,供应商阶段性PPAP过程图,STATUS:,Phase 2,Completed,Phase 2,Warrant,#18,Yes,Status Tracking,Database,2,3,4,Proceed to next page,Submit to,Customer,Important note:,Phase 2 and Phase 3 can happen,concurrently if all Inputs and,Outputs are satisfied,No,Phase 0 Run-at-Rate,Phase 1 Quality Verification,Phase 2 Production Verification,Phase 3 Capacity Verification,1 - 设计记录 2 - 工程变更文件 3 顾客工程批准 4 - 设计FMEA 5 - 过程流程图 6 - 过程FMEA 7 - 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 18),Have Run-at-Rates (Phase 0) been conducted and Quality Verifications (Phase 1) been satisfied for ALL production streams?,11,藤蔓课堂,Phased PPAP与PPAP的比较,Phased PPAP organizes the process into four phases Phase 0: Run-at-Rate 按节拍生产 Phase 1: Quality Verification 质量确认（一条生产线） Phase 2: Production Verification 产品验证 （多条生产线） Phase 3: Capacity Verification 产能验证,PPAP,X,1 PP,FEU,Job 1,Phased PPAPPhase 0Phase 1Phase 2Phase 3,12,藤蔓课堂,阶段PPAP的要求,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,13,藤蔓课堂,Building on the Basics: Phase 0,STATUS:,Phase 2,Completed,Phase 2,Warrant,#18,Yes,Status Tracking,Database,2,3,4,Proceed to next page,Submit to,Customer,Important note:,Phase 2 and Phase 3 can happen,concurrently if all Inputs and,Outputs are satisfied,No,STATUS:,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 Tests #12,- Appearance criteria #13,- Sample parts #14,- Master samples #15,- Customer Specific Requirements#17,- as defined by PPAP,Have the,PPAP elements been,satisfied?,Yes,Status Tracking,Database,1,4,2,4,Important note:,For suppliers with only one,production stream completion of,Phase 1 & 2 occur at the same,time,Proceed to next page,Return to,Phase 0 for,corrective,action,No,Submit to,Customer,Phase 1,Warrant,#18,Phase 2,Warrant,Scheduled,down time,defined (TPM,change over,Breaks etc.),Sub supplier,material status,from Tier-x,Phase 3,EVENT:,Conduct,Capacity,Verification Run,STATUS:,Phase 3,Completed,Quantity,required is,customer DPV,for one full day,All personnel,for all shifts,trained,Are the,CVR input,requirements in place,for all production,streams?,Yes,END,Status Tracking,Database,Return to,affected phase,and start,corrective action,Phase 3,Warrant,#18,& Capacity,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 required,DPV?,No,Yes,No,3,Required Inputs,Phase 0,Phase 1,Phase 2,Phase 1 Quality Verification,Phase 2 Production Verification,Phase 3 Capacity Verification,9 - Dimensional Results 10 - Records of Material / Performance Test Results 11 - Initial Process Studies 12 - Qualified Laboratory Documentation 13 - Appearance Approval Report 14 - Sample Production Parts 15 - Master Sample 18 - PPAP Warrant,PPAP Warrant (element 18),Run-at-Rate for all production streams (element 1 8, 16, 17),Quality Verification for all production streams (element 9 15),Capacity Analysis Report,PPAP Warrant (element 18),Have Run-at-Rates (Phase 0) been conducted and Qual