FORD福特汽车研发流程介绍.ppt
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1、交运制造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 全球产品开发体系交运制造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
2、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/
3、654)交运制造PTC-Program Target Compatibility 项目目标整合PAPA-Program Approval 项目批准 FDJ-FDJ-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)(PSW
4、2)MP1MP1-Mass Production 1 量产(PSW3)Job#1Job#1 整车投产项目节点(里程碑)交运制造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
5、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FORD项目开发节点交运制造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
6、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.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 Studi
7、esStudies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 ResultsTest 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 Documentatio
8、nQualified 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 Production 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 RequirementsC
9、ustomer-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)零件提交保零件提交保证书证书交运制造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
10、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全球阶段性PPAP:是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-
11、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 concurrently i
12、f 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 control p
13、lan,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-Launch Con
14、trol 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 WorksheetSt
15、atus 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 measurements#9
16、-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 producti
17、on 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 Verif
18、ication 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&Capacity
19、 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 2Production V
20、erificationPhase 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 18)产能
21、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Phased PPAP与PPAP的比较Phased PPAP organizes the process into four phasesPhased PPAP organizes the process into four phasesPhase 0:Run-at-Rate 按节拍生产按节拍生产Phase 1:Quality Verificati
22、on 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
23、交运制造Building on the Basics:Phase 0STATUS:Phase 2Completed Phase 2 Warrant#18YesStatus Tracking Database234Proceed to next pageSubmit to CustomerImportant note:Phase 2 and Phase 3 can happen concurrently if all Inputs and Outputs are satisfiedNoSTATUS:Phase 1 Completed Continue Production Part Approv
24、al 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 PPAPHave the PPAP elements been satisfied?YesStatus Track
25、ing Database1424Important note:For suppliers with only one production 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 suppl
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