FORD福特汽车研发流程介绍.ppt

单击此处编辑母版标题样式,单击此处编辑母版文本样式,第二级,第三级,第四级,第五级,*,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,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,）,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,3,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),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）,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）,6,PTC/,M1DJ,PTCC,PA,FDJ,M1,Unit,PTC,Unit,PA,33.5MBJ1,27MBJ1,25MBJ1,20.5MBJ1,27.5MBJ1,34MBJ1,17MBJ1,13MBJ1,5MBJ1,2.5MBJ1,0MBJ1,(655/654),PEC,LR/,FEC,VP,TT,PP,8MBJ1,5.5MBJ1,MP1,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,),OTS,PPAP,Phase0/1,PPAP,phase2,PPAP,phase3,FORD,项目跟踪（装车）节点,项目批准,工程数据发布,手工样件,OTS,FORD,项目开发节点,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,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,全球,阶段性,PPAP:,是在怎样的基础上建立起来的,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,加强沟通,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,改善工作流程,简化,稳定化,标准化,节奏化,持续性,Phased,PPAP,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,INPUTS,Released,design,#1,2,3&4,Trained,supplier,production,operators,Sub-supplier(s),material status,from Tier-x,RR,Job 1 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&7,Production,Tools,Facilities,&Gauging,#8,16&17,EVENT:,Conduct Run at,Rate,Planned,production,cycle times,required to,support Daily,Production,Volume,Outputs from,the event,STATUS:,Phase 0,Completed,Implement,Corrective,Action on Input,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,?,Yes,Yes,Yes,Yes,No,No,No,No,Are the,RunRate input,requirements in place,for the production,stream?,Yes,START,No,Capacity,Analysis,Worksheet,Status Tracking,Database,1,4,Proceed to next page,Required Inputs,Submit to,Customer,Note:,#x,refers to the Element Number in PPAP 4th Edition that,will assist in confirming requirements,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 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),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?,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 PPAP,Phase 0Phase 1Phase 2Phase 3,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,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),C,apacity 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?,INPUTS,Released,design,#1,2,3&4,Trained,supplier,production,operators,Sub-supplier(s),material status,from Tier-x,RR,Job 1 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&7,Production,Tools,Facilities,&Gauging,#8,16&17,EVENT:,Conduct Run at,Rate,Planned,production,cycle times,required to,support Daily,Production,Volume,Outputs from,the event,STATUS:,Phase 0,Completed,Implement,Corrective,Action on Input,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,?,Yes,Yes,Yes,Yes,No,No,No,No,Are the,RunRate input,requirements in place,for the production,stream?,Yes,START,No,Capacity,Analysis,Worksheet,Status Tracking,Database,1,4,Proceed to next page,Required Inputs,Submit to,Customer,Note:,#x,refers to the Element Number in PPAP 4th Edition that,will assist in confirming requirements,Phase 0,Run-at-Rate,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,产能分析报告,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。,Start,Released Design#1,2,3,4,Trained supplier production operators,Sub-supplier(s)material status from Tier-X Run-at-Rate,Quantity 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#5,6,7,Production tools,facilities,and gauging#8,16,17,Planned production cycle times required to support daily production volume,Are 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 produced in the defined period?,Did all operations meet their planned cycle time?,Implement corrective action on input,EVENT:Conduct Run-at-Rate,STATUS:Phase 0 Complete,Capacity Analysis,Report,Status Tracking Database,4,1,YES,NO,NO,NO,NO,NO,YES,YES,YES,Submitto customer,Outputs from the event,YES,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。,Start,Released Design#1,2,3,4,Trained supplier production operators,Sub-supplier(s)material status from Tier-X Run-at-Rate,Quantity 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#5,6,7,Production tools,facilities,and gauging#8,16,17,Planned production cycle times required to support daily production volume,Are 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 produced in the defined period?,Did all operations meet their planned cycle time?,Implement corrective action on input,EVENT:Conduct Run-at-Rate,STATUS:Phase 0 Complete,Capacity Analysis,Report,Status Tracking Database,4,1,YES,NO,NO,NO,NO,NO,YES,YES,YES,Submitto customer,Outputs from the event,YES,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。,Start,Released Design#1,2,3,4,Trained supplier production operators,Sub-supplier(s)material status from Tier-X Run-at-Rate,Quantity 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#5,6,7,Production tools,facilities,and gauging#8,16,17,Planned production cycle times required to support daily production volume,Are 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 produced in the defined period?,Did all operations meet their planned cycle time?,Implement corrective action on input,EVENT:Conduct Run-at-Rate,STATUS:Phase 0 Complete,Capacity Analysis,Report,Status Tracking Database,4,1,YES,NO,NO,NO,NO,NO,YES,YES,YES,Submitto customer,Outputs from the event,YES,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,件：最少,300,件,排气系统：最少,300,件,燃油系统：最少,300,件,节拍生产数量,19,Phase 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,Released Design#1,2,3,4,Trained supplier production operators,Sub-supplier(s)material status from Tier-X Run-at-Rate,Quantity 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#5,6,7,Production tools,facilities,and gauging#8,16,17,Planned production cycle times required to support daily production volume,Are 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 produced in the defined period?,Did all operations meet their planned cycle time?,Implement corrective action on input,EVENT:Conduct Run-at-Rate,STATUS:Phase 0 Complete,Capacity Analysis,Report,Status Tracking Database,4,1,YES,NO,NO,NO,NO,NO,YES,YES,YES,Submitto customer,Outputs from the event,YES,20,Phase 0:,节拍生产,输入,生产过程包括控制计划，过程流程图和过程参数,PPAP#5,6,7,供应商必须有一个能够清晰描述生产步骤和顺序的,过程流程图,供应商必须要有,过程,FMEA,供应商必须要有,过程控制计划,Start,Released Design#1,2,3,4,Trained supplier production operators,Sub-supplier(s)material status from Tier-X Run-at-Rate,Quantity 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#5,6,7,Production tools,facilities,and gauging#8,16,17,Planned production cycle times required to support daily production volume,Are 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 produced in the defined period?,Did all operations meet their planned cycle time?,Implement corrective action on input,EVENT:Conduct Run-at-Rate,STATUS:Phase 0 Complete,Capacity Analysis,Report,Status Tracking Database,4,1,YES,NO,NO,NO,NO,NO,YES,YES,YES,Submitto customer,Outputs from the event,YES,21,Phase 0:,节拍生产,输入,量产,模具，设备和检具,PPAP#8,16,17,供应商必须确认使用的设备、模具、检具状态是否为,新开,的，,整修,的还是,迁移,的,用于量产的资源是否符合顾客要求的,数量和质量标准,Start,Released Design#1,2,3,4,Trained supplier production operators,Sub-supplier(s)material status from Tier-X Run-at-Rate,Quantity of parts required as defined by customer(default 300 consecutive parts),Job 1 location(final site and line),Production process