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Phased PPAP Requirements Handbook Ford
GLOBAL PURCHASING
Supplier Technical Assistance
Phased PPAP Requirements Handbook
Phased Production Part Approval Process
Phased PPAP Requirements Handbook
Ford Motor Company Supplier Technical Assistance
December 2004
Acknowledgements: The Phased PPAP development represents the efforts of Ford and its suppliers. Acknowledgement should be made to the core team which comprised of: Erin Bates, Chris Burford, Volker Domdei, Matthias Duex, Timo Golzio, Brian Grandstaff, Russ Hopkins, Tim Jolly, Debra Keller, Tom Miller, Jim Polman, Ranga Rajan, Aricka Long, Hans Pettersson, Julian Taylor and Steve Walsh. This core team gratefully acknowledges the contributions made by employees at Ford and its suppliers who have developed and continue to support effective implementation of Phased PPAP.
Phased PPAP Requirements Handbook Ford
Table of Contents
Page
Phased PPAP Introduction 3
Phased PPAP Overview 4
Process Flow Overview 5
Phased PPAP Key Definitions 6
Phase 0 PPAP – Run–at-Rate 7
Phase 1 PPAP – Quality Verification 8
Phase 2 PPAP – Production Verification 9
Phase 3 PPAP – Capacity Verification 10
Customer Approval of Phased PPAP 11
Expectations 12
Appendix A - STA Roles & Responsibilities 13
Appendix B – Exception Management Process 14 – 17
Appendix C – Phased PPAP Submission Warrant 18
Appendix D – PPAP Requirements Listing 19
Appendix E - Acronym List 20
Phased PPAP Requirements Handbook Ford
Phased PPAP Introduction In order to improve launch performance, Ford has structured the Production Part Approval Process (PPAP) into a phased approach that will require an organization to demonstrate manufacturing capability, product quality and production capacity prior to Job #1. Phased PPAP will provide Ford and the supplier with an improved understanding of supplier manufacturing process and part readiness.
Phased PPAP organizes the Production Part Approval Process into four phases: Phase 0: 'Run-at-Rate' Phase 1: 'Quality Verification' Phase 2: ‘Production Verification' Phase 3: ‘Capacity Verification’.
Benefits of Phased PPAP Phased PPAP will benefit Ford and its Suppliers by:
• Dividing PPAP activities into more manageable segments • Providing a structured approach aligned with manufacturing process development • Providing a program team with earlier and additional measures to forecast
program/product readiness • Providing a consistent mechanism for a supplier to demonstrate their ability to
support Ford production volume requirements/capacity Teamwork Ford Motor Company and its Suppliers must work together to deliver a quality part, produced on-time, that meets all Ford engineering requirements. To drive flawless execution in launching and delivering products that surpass customer expectations, Ford and its suppliers must place trust, integrity and accuracy above all else in the Production Part Approval Process.
What Phased PPAP Means to Ford Motor Company Successful completion of Phased PPAP:
• Confirms that all customer engineering design record and specification requirements are properly understood by the supplier, and that ALL production streams have the potential to produce product consistently meeting these requirements during an actual production run at the quoted production rate.
AND
• Verifies that the supplier's production system can support the Daily Production Volume declared by the customer.
3
Phased PPAP Requirements Handbook Ford
Phased PPAP Overview Scope
• Phased PPAP must be completed for any of the situations already specified by the current edition AIAG PPAP Manual. In addition, any increase in the Daily Production Volume declared by the customer above the verified declared DVP will require the supplier to re-complete any affected Phased PPAP phases.
Summary Phase 0: Run-at-Rate Objectives: To confirm that all production input requirements are available and understood, and can support a limited production run.
To provide an early indicator that the design of the process/tool/facility has the potential to produce at rate the required number of acceptable parts as determined by the pre-launch control plan.
Phase 1: Quality Verification Utilizes parts produced during Phase 0. Objectives: To confirm all customer design record and specification requirements are properly understood by the supplier.
To provide an early indicator that the design of the process/tool/facility has the potential to produce product consistently meeting these requirements during an actual production run at the quoted production rate by operating a minimum of one selected production stream. Phase 2: Production Verification Objectives: To confirm all customer engineering design record and specification requirements are properly understood by the supplier, and that ALL production streams have the potential to produce product consistently meeting these requirements during an actual production run at the quoted production rate. Phase 3: Capacity Verification Objective: Verify the supplier's production system can support customer declared DPV while meeting Phase 2 requirements.
4
Pha
sed
PP
AP
Req
uire
men
ts H
andb
ook
F
ord
Proc
ess O
verv
iew
This
pro
cess
flow
(an
extra
ct fr
om F
ord
Inte
rnal
Pro
cedu
re P
SP
-011
) is
inte
nded
to li
nk th
e ac
tiviti
es in
Pha
sed
PPA
P to
incl
ude
4-P
anel
Pro
cess
Fl
ow, R
oles
& R
espo
nsib
ilitie
s M
atric
es &
Exc
eptio
n M
anag
emen
t Pro
cess
with
the
AIA
G P
PA
P R
efer
ence
Man
ual a
nd a
ny re
late
d Fo
rd In
tern
al
proc
edur
es.
F
PD
S
Tim
elin
e
La
unc
h
Te
am
c)
Sup
plie
r d)
,e)
ST
A S
ite
Eng
ine
er
a),
d),
e
)
ST
A P
rog
ram
E
ng
ine
er
Bu
yer
Pha
se 0
ST
AR
T
Co
mp
lete
s so
urc
ing
of s
up
plie
r si
te p
er
Pu
rch
asin
g P
roce
du
re 2
.1 o
r lo
cal p
ract
ice
<
Job
#1
>
Ph
ase
3
No
te: I
n s
om
e r
eg
ion
s th
e P
rogr
am
me
En
gin
eer
m
ay b
e r
esp
ons
ible
for
ass
ign
ing
site
PP
AP
su
bm
issi
on
leve
l and
m
ay
be
the
re
spon
sibl
e
Par
t Ap
pro
val A
ctiv
ity.
Are
all
Ph
ase
s c
om
ple
te?
EN
D
Ye
s
Th
e p
roce
ss b
elo
w is
no
t to
sca
le b
etw
een
tim
ing
po
ints
<P
lea
se r
efe
r to
Ph
ase
d P
PA
P H
and
boo
k fo
r T
imin
g E
xpe
cta
tion
s b
y P
ha
se>
Ass
ign
s P
PA
P
leve
l to
Su
ppl
ier
Site
(p
er P
SP
-01
1:
Ta
ble
1).
Agr
ee
s w
ith P
rog
ram
e
ngin
ee
r o
n H
igh
-Im
pac
t Pa
rts
Ha
vin
g c
om
ple
ted
PS
W-
009
, agr
ees
Hig
h Im
pa
ct
Pa
rts
de
sig
nat
ion
with
S
ite E
ngi
nee
r. I
nfo
rms
affe
cte
d s
up
plie
rs o
f HI
pa
rt s
tatu
s an
d
de
sign
atio
n o
f PP
AP
S
ubm
issi
on
Le
vel 5
Inpu
ts P
hase
d P
PA
P
Pro
mis
e d
ate
s in
to
VP
P p
er P
has
ed
PP
AP
Ha
ndb
ook
En
ters
"R
" (R
eje
cted
) in
V
PP
with
in
24
hou
rsE
nte
rs "
A"
(Ap
pro
ved
) in
V
PP
with
in
24
ho
urs
Re
fer
to th
e P
ha
sed
PP
AP
Exc
eptio
n
Ma
na
gem
en
t Pro
cess
, el
em
ent
4.2
.3 in
the
Pha
sed
PP
AP
H
and
boo
k b
)
No
tes
a)
Ref
er
to R
ole
s a
nd R
espo
nsi
bilit
ies
Mat
rice
s to
det
erm
ine
min
imu
m e
xpe
cta
tions
by
sub
mis
sio
n le
vel a
nd p
has
e.b)
P
rod
uct
Dev
elo
pmen
t (C
rea
tion
) h
ave
the
au
tho
rity
to a
uth
ori
se a
n A
lert
(o
r re
gio
na
l eq
uiva
len
t) w
he
re a
de
viat
ion
to s
pe
cific
atio
n e
xist
s, a
nd
Inte
rim
App
rova
l is
req
uire
d.
c)
Lau
nch
team
typ
ica
lly c
on
sist
s o
f ST
A,
Pu
rch
asi
ng
, Pro
du
ct D
eve
lop
me
nt (
Cre
atio
n), N
ew
Mo
del
La
un
ch a
nd
Ma
teria
l Pla
nn
ing
& L
ogis
tics
(M
P&
L).
d)
Dat
a in
pu
t in
to V
PP
may
be
co
ndu
cte
d b
y an
adm
inis
tra
tion
tea
m c
onsi
ste
nt a
s d
efin
ed
by
loca
l pro
cedu
re. I
f ST
A d
ecis
ion
on
Ph
ased
PP
AP
Wa
rra
nt i
s e
nte
red
by
the
sup
plie
r, S
TA
ma
y o
verr
ide
su
ppl
ier
VP
P e
ntr
y a
t an
y tim
e.
Th
is a
lso
ap
plie
s in
the
ca
ses
of P
PA
P S
ub
mis
sio
n L
evel
1 (
"Sup
plie
r S
elf
Ce
rtifi
catio
n")
, whe
re A
pp
rova
l is
reg
iste
red
in V
PP
au
tom
atic
ally
whe
n th
e su
pp
lier
ente
rs "
Y"
cod
e
e)
Doc
umen
tatio
n is
no
t lim
ited
to th
at d
efin
ed
in th
is P
roce
ss F
low
char
t. T
he F
ord
Ph
ase
d P
PA
P 4
-Pa
ne
l Pro
cess
Ma
p (
see
Ph
ased
PP
AP
Han
dbo
ok)
de
fine
s th
e d
ocu
me
nta
tion
tha
t is
req
uire
d to
be
co
mp
lete
d
at e
ach
Ph
ase
. S
ubm
issi
on
to th
e C
usto
mer
Ap
prov
al A
uth
ority
(S
TA
) is
de
fine
d in
the
AIA
G P
PA
P M
anu
al.
En
ter
"Y"
cod
e in
V
PP
for
Pha
se &
su
bmit
do
cum
en
tatio
n
de
fine
d fo
r P
ha
se to
ST
A
Do
cum
en
tatio
n
de
fine
d fo
r P
ha
se
Re
view
&
Sig
n D
ocu
me
nta
tion
d
efin
ed
for
Pha
se
Wer
e al
l req
uire
men
ts
of t
he
Ph
ase
me
t?
No
Ye
s
Ph
ase
0 -
Ca
pa
city
A
nal
ysis
Re
po
rtP
has
e 1
- W
arra
nt
Ph
ase
2 -
War
rant
Ph
ase
3 -
War
rant
&
Ca
paci
ty A
naly
sis
Re
port
Com
ple
tes
Ph
ased
P
PA
P R
equ
ire
me
nts
(Ph
ase
0, 1
, 2 o
r 3)
&
Do
cum
en
tatio
n d
efin
ed
for
Ph
ase
be
low
No
Ph
ase
1
<1
PP
>
Pha
se 2
<F
EU
>
Tim
ing
of P
has
e 0
is d
ete
rmin
ed b
y lo
ng
est l
ea
d a
ctiv
ity th
at m
ust
be
com
ple
ted
to m
ee
t Ph
ase
1
Req
uire
men
ts
Was
the
D
ocu
me
nta
tion
A
pp
rove
d?
No
Sig
ned
-off
Do
cum
ent
atio
n
as d
efin
ed
by
Pha
se
Th
e p
roce
ss b
elo
w is
no
t to
sca
le b
etw
een
tim
ing
po
ints
<P
lea
se r
efe
r to
Pha
sed
PP
AP
Ha
ndb
oo
k fo
r T
imin
g E
xpe
ctat
ions
by
Ph
ase>
Re
cord
s S
TA
De
cisi
on
in
VP
P
Rej
ect
App
rove
Ye
s
5
Phased PPAP Requirements Handbook Ford
6
Definitions: Production Stream A single production stream is a sequence of a minimum of one line, machine, tool, cavity, facility, equipment, gage, operator and other required items at the intended location and with the intended layout that will be used to produce parts that meet Ford specifications.
All production streams must include any additional items not included in the single production stream that are required to meet the Ford Capacity Planning Volume (CPV) requirements of the intended program being launched (e.g. additional tools, cavities, lines, conveyors, machines)
Conveyor EOL Tester
Others Stream
Operators
Gages
Facilities
Cavity
Tool
Line
CPV (Capacity Planning Volumes) Capacity Planning Volumes are the volumes for which Ford requires suppliers to facilitize and tool-up for. CPV's are approximately 10 percent higher than "production planning volumes," in order to cover spares (service requirements) and volume spikes. The CPV is communicated to Suppliers on a part level basis through the Ford Purchasing “Request for Quotation” (RfQ).
CPV's are typically expressed as weekly volumes. Suppliers are expected to satisfy the production weekly demand based on a maximum 5 days/3 shifts manufacturing operating pattern.
DPV (Daily Planning Volume) DPV's are the maximum planned requirement for this part per day and are broken down by plant and Brand (e.g. Volvo).
Acceptable Parts (referenced in Phase 0 objectives) Acceptable Parts are defined as parts produced using the required PPAP inputs for Phase 0 as identified on the Process Map and manufactured in conformance with the relevant control plan, either Pre-Launch or Production.
Interim Accepted Part meets customer specifications and includes valid Temporary Engineering Specification for temporary exception.
Temporary Engineering Specification Temporary specification provided by the customer engineering release organization. The Ford Brand specific method for communicating these specifications is as follows:
• WERS Alert (Ford/Jaguar); • Temporary Part Change Management (Land Rover); • Temporary Part Deviation (Volvo).
Phased PPAP Requirements Handbook Ford
7
Process Map Phase 0 Run-at-Rate Objectives: To confirm that all production input requirements are available and understood, and can support a limited production run. To provide an early indicator that the design of the process/tool/facility has the potential to produce at rate the required number of acceptable parts as determined by the Pre-Launch control plan.
Refer to web link https://web.qpr.ford.com/sta/Capacity_Analysis_Report.xls for Capacity Analysis Report and supporting documentation.
INPUTSReleased
design[#1,2,3 & 4]
Trained supplier
production operators
Sub-supplier(s) material status
from Tier-x Run-at-Rate
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 Run-at-Rate input
requirements in place for the production
stream?
Yes
START
No
Capacity Analysis Report
Status Tracking Database
1
4
Phase 0Run-at-Rate
Proc
eed
to n
ext p
age
Req
uire
d In
puts
Submit to Customer
Sup
plie
r
Note: refer to Appendix D which lists the PPAP requirements number (#x) noted in the 4-Panel Process Map
Phased PPAP Requirements Handbook Ford
Process Map Phase 1 Quality Verification Objectives: To determine if all customer engineering design record and specification requirements are properly understood by the supplier. To provide an early indicator that the design of the process/tool/facility has the potential to produce product consistently meeting these requirements during an actual production run at the quoted production rate by operating a minimum of one selected production stream.
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 requirements
been satisfied?
Yes
Status Tracking Database
1
4
2
4
Phase 1 Quality Verification
Important notes: For suppliers with only one production stream completion of Phase 1 & 2 occur at the same time utilizing the Production Control Plan.It is required that prior to Phase 1 submission that sub-supplier(s) material status from Tier-x has also achieved Phase 1.
Proc
eed
to n
ext p
age
Return to Phase 0 for corrective
action
No
Submit to Customer
Phase 1 Warrant
[#18]
8
Phased PPAP Requirements Handbook Ford
Process Map Phase 2 Production Verification Objectives: To determine if all customer engineering design record and specification requirements are properly understood by the supplier, and that ALL production streams have the potential to produce product consistently meeting these requirements during an actual production run at the quoted production rate. Note: The approach adopted for PPAP of multiple production streams is scenario-specific and must be agreed between the Supplier and STA. In general terms each production stream should be assessed for Run-at-Rate and Quality Verification separately. Consideration should also be given to the risk that the introduction of further production streams may impact the validity of the Phase 1 approval. (e.g. Phase 1 achieved on cavity #1 of a four cavity tool - the introduction of cavity #2, 3 & may impact the cavity #1 part and it may no longer be to specification). 4
STATUS:Phase 2
Completed
Phase 2 W arrant
[#18]
Have Run-at-Rates (Phase 0) been conducted
and Q uality Verifications (Phase 1) been satisfied for
ALL production streams ?
Y es
Status Tracking Database
2 3
4
Phase 2 Production Verification
Proc
eed
to n
ext p
age
Submit to Customer
Im portant note:Phase 2 and Phase 3 can happen concurrently if all Inputs and Outputs are satisfied.Expectation that the Production Control Plan is follow ed during this Phase.
No
9
Phased PPAP Requirements Handbook Ford
Process Map Phase 3 Capacity Verification Objective: Verify the supplier's production system can support customer declared DPV while meeting Phase 2 requirements. Update process flow with latest version to include nomenclature 'Capacity Analysis Report'
Refer to web link https://web.qpr.ford.com/sta/Capacity_Analysis_Report.xls for Capacity Analysis eport and supporting documentation. R
P has e 2 W arrant
S cheduled down t im e
defined (TP M , c hange over, B reak s etc .)
S ub s upplier m aterial s tatus
from Tier-x P has e 3
E V E NT: Conduc t Capac ity
V erific ation Run S TA TUS :P hase 3
Com pleted
Quantity required is
c us tom er DP V for one full day
A ll pers onnel for all s hifts ,
trained
A re the CV input
requirem ents in plac e for all produc tion
s tream s ?
Y es
E ND
S tatus Trac k ing Database
Return to affec ted phas e
and s tart correc tive ac tion
P hase 3 W arrant
[#18]& Capac ity A nalys is
Report
Determ ine Root Caus e & P lan Correc tive
A c tion
W as the P roduc tion c ontrol
plan followed & acc eptable parts
produced?
D id th e vo lu m e o f a cce p ta b le
p a rts p ro d u ce d m e e t o r e xce e d th e re q u ire d
D P V?
No
Y es
No
3
Phase 3C apacity Verification
Req
uire
d In
puts
P hase 0 P has e 1 P has e 2 P has e 3
S ubm it to C ustom er
Com plete Capac ity A naly s is
W ork s heet
Y es
10
Phased PPAP Requirements Handbook Ford
Customer Approval of Phased PPAP
Phased PPAP Approval Phase 0 does not require a Phased PPAP Submission Warrant, however a Capacity Analysis Report (Refer to web link https://web.qpr.ford.com/sta/Capacity_Analysis_Report.xls for Capacity Analysis Report and supporting documentation) must be submitted with the Run-at-Rate box ticked indicating Phase 0. In addition, the supplier should have results from Run-at-Rate readily available for STA Engineer review and approval where required (see roles & responsibilities section, appendix A).
Phase 1, 2 and 3 each require a Phased PPAP Submission Warrant and customer approval in line with the AIAG PPAP submission level requirements or as otherwise specified by STA (see roles & responsibilities section, appendix A).
Phase 3 requires Suppliers to complete the Capacity Analysis Report in addition to the Phased PPAP Submission Warrant.
Suppliers to Ford and its affiliates will utilize the Phased PPAP warrant (Appendix C). For suppliers designated as non-Q1 and suppliers/parts identified as High-Impact, STA will review and either approve or reject the PPAP submission warrant within 48 hours of the supplier indicating the PPAP is "Ready-for-STA-Inspection" in the Vehicle Parts Progress (VPP) database. Once STA has determined the PPAP status and signed the Warrant (Phase 1, 2 and 3) and Capacity Analysis Report (Phase 0 and 3), the supplier or STA's designate will enter the PPAP decision status in the Vehicle Parts Progress (VPP) database within 24 hours of receiving a STA's signed copy of the warrant.
Any temporary exception due to non-compliance with a PPAP element or build timing requirement is handled in line with the Exception Management Process (refer to Appendix B).
Transition: Phase 1 Approval to Phase 2 Approval - Status and Part Supply In cases where more than two production streams are to be used to support Ford's capacity requirements, the degree of complexity regarding the declaration of Phased PPAP Status and the ability to supply parts during the transition from Phase 1 to Phase 2 inevitably increases. In order to illustrate how this should be managed please consider the following example:
• A supplier will be introducing a total of four production streams. In line with Phased PPAP methodology, the supplier will only be ready to submit the Phase 2 Warrant when they are able to prove that the PPAP requirements have been met for all 4 production streams.
• 3 months prior to 1PP the supplier has achieved Phase 1 Warrant approval for one production stream.
• As 1PP approaches the PPAP requirements for the second and third production streams have been satisfied, and the supplier wants to supply parts for 1PP from the three streams.
• In order to supply these parts the supplier must have an approved, updated, Phase 1 Warrant, that declares that the PPAP requirements for the 3 production streams have been met (plus supporting data as per submission level requirements). The date for which Phase 1 requirements were achieved is not affected in reporting metrics.
11
Phased PPAP Requirements Handbook Ford
Expectations
Phased PPAP Achievement by Build Milestone
1PP (PV1) Phase 1 100% Completed FEU (PV2) Phase 2 100% Completed Job #1 Phase 3 100% Completed
The decision to progress through the FPDS Milestones is determined by the Global Launch QOS; refer to New Model Launch Team for latest version. Note: Phased PPAP achievement by Volvo build event is Phase 1: Tryout, Phase 2 and Phase 3: Job 1. Phased PPAP Reporting Expectations The preferred system to track and report Phased PPAP is VPP (Vehicle Parts Progress in CMMS3).
Phased PPAP now requires suppliers to track and report on multiple promise dates. Suppliers operating in VPP must enter any remaining open Phased PPAP promise dates (Phase 0 – 3) within one full working day of the part appearing in the supplier work queue. Supplier's Approval submission via VPP is the electronic equivalent to a signed PPAP Warrant.
Tier 1 Suppliers shipping to Ford must use a production part approval process for their sub-suppliers. Additionally, suppliers are required to verify their sub-supplier can meet required volumes at the required time; suppliers and/or sub-suppliers may use the Ford Capacity Analysis Report and documentation.
12
Phased PPAP Requirements Handbook Ford
Appendix A
STA Phased PPAP Roles & Responsibilities
Minimum STA Review Requirements a, b)
Site Status Part Status
PPAP Submisssion
Level c)
Phase 0 Run-At-Rate
Phase 1 Quality
Verification
Phase 2 Production Verification
Phase 3 Capacity
Verification
Regardless of Site Status d)
High-Impact 5
Review must be
on site At least a desktop review
Review must be
on site
Non-Q1 Site
Non High-Impact
3 Phase 0, 1, 2 and 3 must be at least a desktop review
Q1 Site f) Non High-Impact
1 None
Documentation
Capacity Analysis Report
PPAP submission Warrant (Phase 1), Supporting Documentation and Sample Parts
PPAP submission Warrant (Phase 2), Supporting Documentation and Sample Parts
Capacity Analysis Report and PPAP Submisssion Warrant (Phase 3)
PPAP Outcome d, e)
Approve or Reject
Warrant requiring an Temporary Engineering Specification
No change to the assessment requirements as defined in table above.
a) For Programs utilizing Supply Base launch Teams (SBLT's) 100% of STA Tier 1 reviews will be conducted On Site for a minimum of 3 of 4 Phases. Any deviation from the minimum requirements listed above must receive STA management authorization. b) For ongoing running changes, MCR, or resourcing action: Phase 0 (Run-at-Rate), Phase 1 (Quality Verification),
Phase 2 (Production Verification) and Phase 3 (Capacity Verification) will follow the minimum STA review requirements stated in the table. c) PPAP submission level is assigned per STA procedure PSP-011.
d) Site may be designated Q1 or Non-Q1.
e) Input into VPP is executed by the Supplier, or their Ford internal administrator, upon receipt of a signed warrant. f) Submission Level 1 suppliers self approve submission
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Phased PPAP Requirements Handbook Ford
Appendix B
Exception Process Purpose The purpose of this instruction is to identify the supplier and customer responsibilities when PPAP is not complete and approved material is required to support customer manufacturing. Also, this instruction defines the process steps for achieving Interim Accepted of a part with a valid Temporary
ngineering Specification. E
Team Supplier Product Development New Model Launch /Manuf. Plant STA
* Notes: Temporary EngineeringSpecification: Ford = WERS AlertLand Rover = Temporary PCMVolvo = Temporary Part Deviation
**Notes: If Phased PPAP timing has not been achieved as per customer requirements (normally specified in the Launch QOS) refer to NML Team for clarification on requirement for Temporary Engineering Specification.
***Notes: For programs following FPDS this refers to IB build and after.
Process Flow -- Deviations to PPAP Element(s) or Timing
Deviation to PPAP Element(s) or PPAP Timing requirements
Correctable prior to Build
need?
Develop, Agree and Implement Corrective action Plan
Raise Temporary Engineering Specification*
Update control plan & implement process control
changes accordingly
Submit Warrant to the Temporary Engineering
Specification with Documentation
Approve or Reject
TemporaryEngrg. Spec.?
No
Yes
Complete PPAP process and address Temporary
Engineering Specification
Does this Temporary Engrg.
Spec. apply to parts required for Integrated Build
***?No
Yes
Consider risks that affect successful completion
and monitor accordinglyNo
Is there a deviation to
PPAP Elements?
Does Local Practice require Temporary Engrg. Spec. for
part status that fails to support customer
Timing requirements?**
No
No
No
Supplier develops Support/Containment Plan and
submits to NML
Approve Support Plan in 'Open-to-Go'? NML & Chief
Engineer
Yes
Permission to Ship for Build
Supplier inputs plan information into VPP
Yes
Yes
Approve Warrant
per PPAP Submission
Level?
Yes
No
No
Consider risks that affect successful completion and
monitor accordinglyImplement Corrective Action Plan
Refer to web-link: https://web.qpr.ford.com/sta/Exception_Management.pdf
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Phased PPAP Requirements Handbook Ford
Appendix B
Definitions "Approved Material" – parts with Warrant declaring "Approved" in the customer use block of the PPAP Warrant.
"Temporary Engineering Specification" – temporary specification provided by the customer engineering release organization. The Ford Brand specific method for communicating these specifications is as follows:
• WERS Alert (Ford/Jaguar); • Temporary Part Change Management (Land Rover); • Temporary Part Deviation (Volvo).
"Full Approval" – part meets all customer specifications and requirements.
"Interim Accepted" – part meets customer specifications and includes valid Temporary Engineering Specification for deviation.
"Process Flow Diagram" – Deviation to PPAP Element(s) or Timing
Process Flow Description Deviation to PPAP Requirements: It is the responsibility of the supplier to complete the 19 requirements of PPAP prior to the date when the customer requires approved material. Typically, there are four situations that prohibit PPAP completion:
• Incomplete PPAP Element – e.g. PV testing not complete; • Deviation to requirement – e.g. dimension out of tolerance; • Parts not produced using intended production flow – e.g. rework due to urgent change,
use of temporary tooling/facility, not all equipment on home-line. • Deviation to required cycle time.
The team should develop, agree and implement a corrective action plan. If this plan is not complete prior to the build requirements then a Temporary Engineering Specification is needed.
Deviation from PPAP Timing: It is the responsibility of the supplier to complete the appropriate Phase by the required timing as determined by the customer. If this timing is not achieved then the team should develop, agree and implement a Corrective action plan. If this plan is not complete prior to the build requirement then a support plan should be developed. Local practice determines whether a Temporary Engineering Specification is required for Deviations to PPAP Timing.
Corrective Action Plan: It is the responsibility of the supplier to develop a corrective action plan that achieves Approved Material status by the required part submission date. The supplier should seek input from the customer's product development, manufacturing, and launch management to assure their concurrence with the planned corrective actions.
Support Plan: If the PPAP is not complete on time a Support Plan must be developed that identifies how the supplier will support the build volume requirements, as well as, the activities to support Full Approval
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Phased PPAP Requirements Handbook Ford
Appendix B
Temporary Engineering Specification: Shipment of production level parts with an incomplete PPAP requires a supplier's PPAP Warrant consistent with the requirements stated in a Temporary Engineering Specification. The Temporary Engineering Specification must describe the specific PPAP Element(s) (or timing deviations per local practice) that are not completed, the modified specification(s) that the part satisfies and the justification why the modified specification is acceptable.
Additionally, the Temporary Engineering Specification shall describe how the supplier will assure quality of parts (e.g. extra ordinary controls/inspection process and robust measurement system) to the modified specification. The Temporary Engineering Specification is effective for a limited period of time, typically reflected in terms of days, quantity, or specific launch build event.
Examples of Temporary Engineering Specifications: • Geometry – expanded tolerance or mean shift • PV Testing – partial completion • Functional Testing - Use of surrogate test results
The Temporary Engineering Specification processes and originators differ by brand as follows:
Brand Process Originator Ford Worldwide Engineering
Release System (WERS) Alert
Ford Product Development or Supplier with WERS access
Jaguar Worldwide Engineering Release System (WERS) Alert
Ford Product Development or Supplier with WERS access
Land Rover Temporary Product Change Management (Temporary PCM)
Land Rover Product Development
Volvo Temporary Part Deviation (TPD)
Volvo Research & Development, Purchasing, or Manufacturing
Approve/Release Temporary Engineering Specification: The customer is responsible to approve and release engineering deviations. Typically, the customer's Product Development, Launch Management, and Manufacturing will (electronically) sign-off on the deviation, and it will be approved by the releasing activity. This approval is authorization to the supplier to proceed with the corrective actions necessary to achieve Approved Material status on a time-limited basis.
Update quality control documents: Upon receiving the approved Temporary Engineering Specification from the customer, the supplier is responsible to update all affected quality control documents. The PFMEA shall be updated to determine if there are any new or changed failure modes. Additionally, items such as Gage R&R, Controls Plans, Operator Instructions and Visual Aids shall be reviewed.
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Phased PPAP Requirements Handbook Ford
Appendix B
Provide PPAP Warrant: It is the responsibility of the supplier to complete a PPAP Warrant per the specifications provided in the Temporary Engineering Specification. The purpose of this Warrant is for the supplier to declare that inspections and tests on production parts show conformance to customer specifications including the Temporary Engineering Specification.
The supplier must indicate the following on the PPAP Warrant section addressing Interim Status: • In the Interim Status section, check the box indicating Interim Submission • Enter the Temporary Engineering Specification number against Engineering Authorization • Provide a brief description of the reason(s) for the Temporary Engineering Specification
Approve or Reject Warrant: If the Temporary Engineering Specification applies to parts to parts required for Integrated Build and subsequent builds (or Brand equivalent Build Phase) then the customer approval authority is required to either Approve or Reject the submission. Prior to this build phase the customer approval authority may choose to review the documentation at their discretion. Approval of the Warrant is the supplier's permission to ship products for a specified time period or quantity. Rejection of the Warrant means customer requirements were not fulfilled and requires the supplier to make corrections and submit a new warrant.
Upon review of the Warrant and supporting evidence, the Customer Part Approval Activity completes the Customer Use section of the Warrant.
• If Interim Accepted, check Interim Accepted against Phased Part Warrant Status • If Reject, check Reject against Part Warrant Disposition
Warrant disposition is communicated by local practice.
If a submission at any phase is due to be, or has been, rejected the STA Program Manager should be notified. The STA Program Manager may choose to utilize this Exception Management process to gain approval for the submission
Actions to achieve Full Approval: The supplier is responsible to implement the corrective actions necessary to achieve a Full Approval. If Full Approval is not complete by the next launch build event, the customer should process a new or updated Temporary Engineering Specification. If the conditions within the Temporary Engineering Specification are changed, a new Warrant is required from the supplier.
Timing Approved material requirements vary based upon customer as follows:
• Ford, Jaguar, and Land Rover vehicle programs by the 1PP build event. • Ford, Jaguar, and Land Rover Powertrain programs by the PV (or "Powertrain 1PP") build
event. • Volvo Vehicle and Powertrain programs by Try-out.
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Phased PPAP Requirements Handbook Ford
Appendix C Phased PPAP Submission Warrant 1/
PPAP Submission Warrant StatusPART INFORMATION
Part Name
Shown on Drawing Number Organization Part Number
Engineering Change Level Date
Additional Engineering Changes Date
Optional Tracking Number
Safety and/or Government Regulation Purchase Order No. Weight (kg)
Checking Aid Number Checking Aid Change Level Dated
ORGANIZATION MANUFACTURING INFORMATION
Organization Name and Supplier Code Customer Name/Division
Street Address Buyer/Buyer Code
City Zip Country Application
REASON FOR SUBMISSION
Initial submission Change to Optional Construction or Material
Engineering Change(s) Sub-Supplier or Material Source Change
Tooling: Transfer, Replacement, Refurbishment, or additional Change in Part Processing
Correction of Discrepancy Parts produced at Additional Location
Tooling Inactive > than 1 year Other - please specify below
REQUESTED SUBMISSION LEVEL (Check one)
Level 1 - Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to customer.
Level 2 - Warrant with product samples and limited supporting data submitted to customer.
Level 3 - Warrant with product samples and complete supporting data submitted to customer.
Level 4 - Warrant and other requirements as defined by customer.
Level 5 - Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location.
DECLARATION and SUBMISSION RESULTSI affirm that the samples represented by this warrant are representative of our parts which were made by a process which meets all
current edition Production Part Approval Process Manual requirements including all Ford-specific requirements. I further affirm that these samples were produced at the production rate of ________ / hours using production streams. I also certify that
documented evidence of such compliance is on file and is available for review. I have noted any exceptions from this declaration below.
EXPLANATION/COMMENTS
List Molds / Cavities / Production Processes: (Attach a separate page if additional space is necessary)
Supplier Authorized Signature Date
Print Name Phone No. Fax
Title Email
FOR FORD USE ONLY PPAP . Non-PPAP a/ .
Authorization: Alert, Temp. PCM, TPD Number
Print Name
Customer Signature . Date
Interim Accepted
Customer Part Number
.
State/County/Province
Interim Status (to be completed by Supplier)
Interim Submission:
. Description: (Open Issues) .
Engineering .
a/ Non-PPAP indicates the part does not satisfy one or more PPAP requirements and is considered incomplete until all PPAP requirements are satisfied.
Phased PPAP Warrant Status: Rejected
.
Yes No
Approved
Phase 1 Phase 2 Phase 3
1/ Refer to web-link: https://web.qpr.ford.com/sta/Phased_PPAP_Warrant.xls
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Phased PPAP Requirements Handbook Ford
19
Appendix D
PPAP Requirements as Noted in the Phased PPAP Process Map 1/
# Requirement
1 Design Records
2 Engineering Change Documents
3 Customer engineering Approval
4 Design FMEA
5 Process Flow Diagrams
6 Process FMEA
7 Control Plans
8 Measurement System Analysis Studies
9 Dimensional Results
10 Records of Material/Performance Test Results
11 Initial Process Studies
12 Qualified Laboratory Documentation
13 Appearance Approval Reports
14 Sample Production Parts
15 Master Sample
16 Checking Aids
17 Customer-Specific Requirements
18 PPAP Warrant
1/ Bulk Material expectations are not addressed within Global Phased PPAP requirements.
Phased PPAP Requirements Handbook Ford
20
Appendix E
Acronym List
STA - Supplier Technical Assistance
PPAP - Production Part Approval Process
PSW - PPAP Submission Warrant
TACT - Total Actual Cycle Time
EOL - End of Line
DPV - Daily Production Volume
CPV - Capacity Planning Volume
IPD - In Plant Date (to a program build event)
1PP - 1st Production Prove-Out Units (at customer plant)
FEU - Field Evaluation Units (at customer plant)
VPP - Vehicle Parts Progress
AIAG - Automotive Industry Action Group
FPDS - Ford Product Development System
WERS - Worldwide Engineering Release System
PM Parts - Part Process Modification
TIKO - TidsInformationKöpOrder (Part Information and Order System)
PTIS - Part Tracking Information System