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Ford APQP Guideline.pdf

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FORD APQP GUIDELINE
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Advanced Product Quality Planning ?Release Level: 3.2 Page 1 of 85 ?Ford APQP Guideline (copyright ?, 2003) ?August 2003 Uncontrolled Copy Advanced Product Quality Planning (APQP) ?Status Reporting Guideline This document is located on the Ford Intranet at: ?http://www.quality.ford.com/apqp/ ?or the FSN Website at: ?https://web.bli.ford.com/ This Guideline is published by Ford Motor Company, Quality Office ?Copyright ? 2003 Ford Motor Company. ? Advanced Product Quality Planning ?Release Level: 3.2 Page 2 of 85 ?Ford APQP Guideline (copyright ?, 2003) ?August 2003 Uncontrolled Copy All rights reserved ?Foreword ?Ford Motor Company launched an Advanced Product Quality Planning Status Reporting ?Guideline (APQP) Fast Start Initiative in December 1994. ?A cross-functional APQP team was ?formed to review the existing FAO Procedures and target best practices. ?The 1994 version of ?this document was created at that time, to be in line with the AIAG Advanced Product Quality ?Planning and Control Plan Manual. Since that time, the external suppliers to Ford Motor Company, and internal suppliers within ?Ford have used the FAO APQP Status Reporting Guideline to monitor their own systems with ?regard to APQP. A cross-functional team was formed in 1999/2000, which continues today to periodically review ?this manual and update it accordingly to current best practices, and FPDS processes. ?This ?manual contains references (at the time of publishing) to the FPDS Process Sheets. ?All of this ?has been done to clarify further the appropriateness of the APQP process, and its direct tie to ?the existing systems/process Ford currently has in place. Furthermore, it is intended that the updated APQP process and FPDS timing information will ?assist the external supply base in understanding the differences between their own timing ?requirements, and those which need to be met by the entire Vehicle Program in the delivery of ?a new vehicle. This Guideline documents the Ford APQP evaluation and status reporting process. ?It does not ?replace the AIAG Advanced Product Quality Planning and Control Plan Reference Manual as ?the basis for quality planning. ? Questions regarding this process, please contact the following: Supplier APQP concerns: ? ? NAT - Ranga Rajan ?(313) 33-75383 ?? NAC - Debra Keller (313) 32-31735 New Model Programs: ?? Craig Fike (313) 32-21765 PTO Program Launches: ?? Internal Make Parts/Internal Suppliers – Larry Berard (313) 32-29256 ?(note: PT internal suppliers refer to PTP 07-137) Stamping Business Unit Program Launches (SBU): ?? Jesse Jou (313) 39-03246 APQP Guideline changes: ? ?? Steve Opaleski (313) 32-20941 Advanced Product Quality Planning ?Release Level: 3.2 Page 3 of 85 ?Ford APQP Guideline (copyright ?, 2003) ?August 2003 Uncontrolled Copy Table of Contents ?FOREWORD ..............................................................................................................................................................2 ?APQP FUNDAMENTALS ..........................................................................................................................................5 ?APQP Process Flow Map.............................................................................................................................6 ?Fundamentals of the APQP Process ...........................................................................................................7 ?APQP REPORTING ?PROCESS .............................................................................................................................10 ?APQP Status Reporting Process Flow Chart.............................................................................................11 ?APQP Status Report ..................................................................................................................................12 ?APQP Status Report Form.........................................................................................................................13 ?Filling Out the Status Report Form.............................................................................................................14 ?Quality of Event Checklists ........................................................................................................................15 ?Risk Assessment........................................................................................................................................15 ?APQP TIMING..........................................................................................................................................................17 ?Ford / Supplier Systems “V“ Model............................................................................................................18 ?APQP Generic Program Timing Gantt Chart .............................................................................................19 ?APQP ELEMENTS...................................................................................................................................................21 ?Sourcing Decision ......................................................................................................................................22 ?Customer Input Requirements ...................................................................................................................23 ?Craftsmanship ............................................................................................................................................24 ?Design Failure Mode and Effects Analysis (DFMEA) ................................................................................25 ?Design / Manufacturing Reviews................................................................................................................27 ?Design Verification Plan & Report (DVP&R)..............................................................................................28 ?Sub-Contractor APQP Status.....................................................................................................................29 ?Facilities / Tools / Gauges..........................................................................................................................30 ?Prototype Build Control Plan......................................................................................................................32 ?Prototype Builds .........................................................................................................................................33 ?Drawings & Specifications..........................................................................................................................34 ?Team Feasibility Commitment....................................................................................................................36 ?Manufacturing Process Flow......................................................................................................................37 ?Process Failure Mode and Effects Analysis (PFMEA)...............................................................................38 ?Measurement System Evaluation ..............................................................................................................40 ?Pre-Launch Control Plan............................................................................................................................41 ?Operator Process Instructions....................................................................................................................42 ?Packaging Specifications ...........................................................................................................................43 ?Production Trial Run ..................................................................................................................................44 ?Production Control Plan .............................................................................................................................46 ?Preliminary Process Capability ..................................................................................................................47 ?Production Validation Testing ....................................................................................................................48 ?Part Submission Warrant (PSW)................................................................................................................50 Advanced Product Quality Planning ?Release Level: 3.2 Page 4 of 85 ?Ford APQP Guideline (copyright ?, 2003) ?August 2003 Uncontrolled Copy APPENDIX SECTION ..............................................................................................................................................52 ?APPENDIX A: ? ? ? ? ? ? ? ? ? ?APQP ROLES & RESPONSIBILITIES ........................................................................53 ?VO – PD APQP Lead/Support Responsibilities – Relationship Table .......................................................54 Powertrain Roles and Responsibilities Matrix…………………………………………………………………..55 ?Powertrain Program Review Process ........................................................................................................56 ?STA Roles & Responsibilities.....................................................................................................................57 ?EXTERNAL SUPPLIERS.........................................................................................................................................67 ?APPENDIX B: ? ? ? ? ? ? ? ? RELATED FORMS ..........................................................................................................69 ?APPENDIX C: ? ? ? ? ? ? ?GLOSSARY OF TERMS ....................................................................................................72 ?APPENDIX D: ? ? ? ? ?REFERENCES AND WEBSITES ...........................................................................................79 APPENDIX E: ? ? ? ? ? ? ? ? ? CHANGE INDEX ……………………………………………………………………………..84 Advanced Product Quality Planning ?Release Level: 3.2 Page 5 of 85 ?Ford APQP Guideline (copyright ?, 2003) ?August 2003 Uncontrolled Copy APQP FundamentalsAdvanced Product Quality Planning ?Release Level: 3.2 Page 6 of 85 ?Ford APQP Guideline (copyright ?, 2003) ?August 2003 Uncontrolled Copy ? ? A AP PQ QP P ?P PR RO OC CE ES SS S ?F FL L0 0W W ?CRAFTSMANSHIP SOURCING ?DECISION CUSTOMER I NPUT ?REQUIREMENTS DRAWINGS/SPECIFICATIONS P-Diagram Failure Modes & Error ?States Specifications & ?Targets ?(VDS/SDS/CDS) TEAM ?FEA SIB ILITY ?COMMITMENT Designing of the ?Vehicle/ System/ ?Subsystem/ ?Component FACILITIES/ ?TO O LS/ ? ? ? ? GAUGES DESI GN FAI LURE ?MODE EFFECT ?ANALYSI S ( DFMEA) MANUFACTURING ?PROCESS FLOW OPERATOR ?PROCESS ?INSTRUCTIONS ?(Process ?Definition) PROTOTYPE ?BUILD ?MEASUREMENT ?SYSTEM ?EVALUATION ?(Dimensional ?Control) PRODUCTI ON TRI AL ?RUN OPERATOR ?PROCESS ?INSTRUCTIONS ?(Verification & ?Tra ining) PRODUCTION ?CONTROL ?PLAN PRELIMINARY ?PROCESS ?CAPABILITY PRODUCTION ?VALIDATION ?TESTING PART ?SUBMISSION ?WARRANT ( PSW) DRAWINGS / ?SPECIFICATIONS (Paper ?/ Electronic) DESI GN / ?MANUFACTURING ?REVIEWS (affect all APQP ?elements) FEED I NFORMATI ON FORWARD FEED I NFORMATI ON BACK PROTOTYPE ?BUI LD CONTROL ?PLAN PROCESS ?FAI LURE MODE ?EFFECT ?ANALYSIS ?(PFM EA) PRE-LAUNCH ?CONTROL PLAN DESIGN ?VERIFICATION ?PLAN ( DVP) TIME ?APQP Process Flow Map Advanced Product Quality Planning ?Release Level: 3.2 Page 7 of 85 ?Ford APQP Guideline (copyright ?, 2003) ?August 2003 Uncontrolled Copy Fundamentals of the APQP Process Advanced Product Quality Planning (APQP) ?Advanced Product Quality Planning (APQP) is a structured method for defining and ?executing the actions necessary to ensure a product satisfies the customer. ?APQP is ?program and supplier-led and is required of all system, subsystem and component ?manufacturing locations. ?This includes both internal and external suppliers to Ford. The Goal of APQP ?The goal of APQP is to facilitate communication between all persons and activities ?involved in a program and ensure that all required steps are completed on time, with a ?high quality-of-event, at acceptable cost and quality levels. The Purpose of APQP ?The purpose of this status reporting guideline is to establish: Common APQP expectations for the internal and external suppliers to Ford ?Motor Company Common APQP process metrics A common program status reporting format Roles and responsibilities for APQP elements A better understanding of how the APQP elements relate to the Ford Product ?Development System (FPDS), specific FPDS milestones, and their timing The Approach of APQP ?This status reporting guideline describes 23 key APQP disciplines. ?Ford Motor ?Company expectations are defined for these key disciplines in definitions, and detailed ?checklists. ?The status for these disciplines is summarized using metrics described in ?the Reporting section. This status reporting guideline is written from a supplier standpoint. ?A supplier is an ?internal or external supplier of materials, components, subsystems, systems, designs or ?processes that will be delivered to a customer. ?A customer is the recipient of the ?supplier's product or process. ?Besides customers, every supplier will have ?subcontractors. ?A subcontractor is the provider of material or parts to a supplier. The Applicability of APQP ?APQP status reporting is a requirement of all internal and external suppliers to Ford ?(including Ford Product Development). ?APQP must be done for new programs/parts ?and major part changes as appropriate. ?In addition, Product Development Teams are to ?monitor the status of internal and external engineering and process development ?disciplines and assess the “Quality-of-Event“ as well as the timing and completion of ?each of the 23 elements. Advanced Product Quality Planning ?Release Level: 3.2 Page 8 of 85 ?Ford APQP Guideline (copyright ?, 2003) ?August 2003 Uncontrolled Copy Teams ?The first step in the Advanced Product Quality Planning Process is to assign ?responsibility to a cross-functional team. ?Effective product quality planning ?requires the involvement from all areas within a corporation. ?The team includes ?representatives from engineering, manufacturing, material control, purchasing, ?quality, sales, field service, subcontractors, and customers as appropriate. ? ? Elements ?This Status Reporting Guideline describes 23 key APQP disciplines, identified as ?Ford APQP elements. ?Please note that there is a slight difference in the 23 ?elements in this updated version. ?These elements, when summarized and ?reported, communicate the status of different levels of a program. Of the 23 Ford APQP elements, 19 are requirements of the AIAG Advanced ?Product Quality Planning and Control Plan manual. ?The four additional elements ?meet unique Ford requirements for APQP status report

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