APQP/PPAP External Supplier Evidence SPECIAL CHARACTERISTICS CHARACTERISTICS Satisfies Schedule A Deliverable #9 / Schedule B Element #4
Special Characteristics
ro o ype All Measurement Results
ro uc on Process Control Results
Go to Evidence Form
Program Code
Date
Product Name
B. Production Supplier / Product Information Tier 1 Supplier Name
Site Code
Tier 1 Supplier Location
City / Region / Country
Part Name
Ford Part Number
Engineering Change Level
1
port Special Characteristic
Formatted to Print US Lett Letter er/L /Le e al
A. Program Information Model Year
Production Process Capability Results
New Tooled End Item(Y/N)
APQP/PPAP External Supplier Evidence SPECIAL CHARACTERISTICS Satisfies Schedule A Deliverable #9 / Schedule B Element #4 F9:
5 digit GSDB code for Manufacturing Location
K12:
(e.g. Print Revision Level)
G27:
(e.g. Red Border Notice)
B30:
(PPAP Ppk = 1.67 or Production Ppk = 1.33)
G30:
(PPAP Ppk < 1.67 or Production Ppk < 1.33)
APQP/PPAP External Supplier Evidence SPECIAL CHARACTERISTICS Satisfies Schedule A Deliverable #9 / Schedule B Element #4 F9:
5 digit GSDB code for Manufacturing Location
K12:
(e.g. Print Revision Level)
G27:
(e.g. Red Border Notice)
B30:
(PPAP Ppk = 1.67 or Production Ppk = 1.33)
G30:
(PPAP Ppk < 1.67 or Production Ppk < 1.33)
APQP/PPAP External Supplier Evidence SPECIAL CHARACTERISTICS Satisfies Schedule A Deliverable #9 / Schedule B Element #4 GPDS: Due at
Supplier Code: Part Number:
Approvers
Source of Approval Evidence
Name
email
Date
Ford Design & Release Engineer Ford STA Engineer Ford Craftsmanship / Systems Engineering Supplier Plant Quality Manager
Key: For Special Characteristic definitions refer to Ford FMEA Handbook.
From DFMEA: YC --
YS
Sev 9,10. Potential Critical Characteristic (YC) Sev 5-8 Potential Special Characteristic
From PFMEA: CC
Sev 9,10 (Part). Critical Characteristic (CC)
OS
Sev 9,10 (Process). Operator Safety (OS)
SC
Sev 5-8 AND Occ 4-10 (or Ford D&R approval) Significant Characteristic (SC) Sev 5-8 AND Occ 4-10. High
Print Cover Page & Evidence Form
APQP/PPAP External Supplier Evidence SPECIAL CHARACTERISTICS ROLES AND RESPONSIBILITIES What
Who
When
Drawing and Specification released to supplier (Deliverable #25)
Ford Product Development (PD)
GPDS: 1 month before
Failure Mode Avoidance - Special Characteristics cascaded to suppliers (Deliverable #9) through the Special Characteristics Agreement Procedure (FAP 03-111)
Ford PD
GPDS:
Complete - Special Characteristics worksheet as evidence of special characteristics cascaded to s uppliers (Deliverable #9)
Supplier
GPDS:
Review Special Characteristics worksheet as evidence of special characteristics cascaded to suppliers (Deliverable #9) Note: Form FAF 03-111-2 may also demonstrate evidence of special characteristics agreement
Supplier / Ford STA / Ford PD
GPDS:
PROGRAM, SUPPLIER, PRODUCT, AND MANUFACTURING INFORMATION TERMS AND DEFINITIONS TERMS A. Program Information
DEFINITIONS
Model Year Program Code
The model year the vehicle is released The program code represents the Ford designation for the Vehicle or PTO program
Product Name
Product name is for the 'Vehicle' or 'PTO' name
APQP/PPAP External Supplier Evidence SPECIAL CHARACTERISTICS SPECIAL CHARACTERISTICS LIST SPECIAL NOTES This information satisfies External Supplier APQP/PPAP Readiness Assessment - Schedule A Deliverable #9 / Schedule B Element #4 Include all special characteristics TERMS AND DEFINITIONS TERMS DEFINITIONS Approvers Ford Design & Release Engineer
Ford D&R Engineer approval is mandatory per FAP 03-111
Ford STA Engineer
Ford STA Engineer approval of Process Control Methods is mandatory for external supplier manufactured parts when requested by the Ford D&R Engineer per FAP 03-111
Ford Craftsmanship / Systems Engineering
Ford Craftsmanship / Systems Engineering approval is mandatory when requested by the Ford D&R Engineer per FAP 03-111
Supplier Plant Quality Manager
External Supplier Plant Quality Manager approval mandatory for external supplier manufactured parts per FAP 03-111
Source of Approval Evidence
Identify the information source as evidence of approval. Ford Corporate Procedure FAP 03-111 requires that special characteristics approval be recorded on from FAF 03-111-2 for external manufactured parts.
Characteristic Description
Print specification item to be measured
Specification & Tolerance
Specification for the characteristic defined on the design record (print or E.S.) including the tolerance requirement
APQP/PPAP External Supplier Evidence Special Characteristics Process Flow Lead for activity
When (VO/PTO)
Input
Process
Output
SPECIAL CHARACTERISTICS Ford PD
GPDS: 1 month before FDJ
Drawing and Specification released to supplier (Deliverable #25)
System design requirements
Falure Mode Avoidance - Special Characteristics cascaded to suppliers (Deliverable #9) through the Special Characteristics Agreement procedure FAP 03-111
Design Record Ford PD
GPDS:
DFMEA/ PFMEA Engineering Specifications FAP 03-111
Supplier
GPDS:
Drawing and Engineering Specifications
Special Char Agreement Form or FAF 03-111-2
FAF 03-111-2 Complete - Special Characteristics worksheet with special characteristics cascaded to suppliers (Deliverable #9)
Utilize import function macro or manual data entry
EXTERNAL SUPPLIER SPECIAL CHARACTERISTICS worksheet
DATA STORAGE AND MANAGEMENT REVIEW Program STA
Initial selection of Priority sites will occur by Unit / +90 Days (unless otherwise identified)
Priority Supplier List New Tooled End Item Site Readiness Part Criticality Program Induced Risk
Priority Supplier or Non-priority Supplier
No
Priority Supplier
Yes
Ford PD / Site STA / Supplier
GPDS: VP
Results maintained with APQP records and next deliverable evidence form
Review the results of the Special Charcteristics list during GPDS on-site visit #1
EXTERNAL SUPPLIER SPECIAL CHARACTERISTICS worksheet
APQP/PPAP External Supplier Evidence Special Characteristics Process Flow Supplier
Ongoing
Update External Supplier Characteristics worksheet
EXTERNAL SUPPLIER SPECIAL CHARACTERISTICS worksheet
APQP/PPAP External Supplier Evidence SPECIAL CHARACTERISTICS Satisfies Schedule A Deliverable #9 / Schedule B Element #4
GPDS: Due at
Approvers
Source of Approval Evidence
Name
email
Date
Ford Design & Release Engineer
FAF 03-111-2
John Young
[email protected]
Ford STA Engineer
FAF 03-111-2
Ben Anderson
[email protected] 2-Jun-09
Ford Craftsmanship / Systems Engineering
FAF 03-111-2
Michelle Darwin
[email protected] 1-Jun-09
Supplier Plant Quality Manager
FAF 03-111-2
Sam Miller
[email protected]
Key: For Special Characteristic definitions refer to Ford FMEA Handbook.
From DFMEA: YC --
YS
Special Characteristic Totals: Note: Auto calculation of totals
YC
1-Jun-09
15-Jun-09
From PFMEA:
Sev 9,10. Potential Critical Characteristic (YC) Sev 5-8 Potential Special Characteristic (YS)
YS
CC
Sev 9,10 (Part). Critical Characteristic (CC)
OS
Sev 9,10 (Process). Operator Safety (OS)
SC
Sev 5-8 AND Occ 4-10 (or Ford D&R approval) Significant Characteristic (SC)
HI
Sev 5-8 AND Occ 4-10. High Impact Characteristic (HI)
CC
OS
SC
HI
APQP/PPAP External Supplier Evidence PROTOTYPE / ALL MEASUREMENT RESULTS Satisfies Schedule A Deliverable #23 / Schedule B Element #17
GPDS: Due at
Supplier Code: Part Number:
Page & Evidence r
e b m u N
1 2 3 4
Characteristic
Summary Results
Executive Specification
DFMEA Classification (YC, YS)
PFMEA Classification (CC, SC, HI, Other)
On Prototype Process Control Control Method Plan (Y/N)
Inspection Frequency
Quantity Inspected (pcs.)
X-Bar
Range
All Parts Meet Specification (Y/N)
Comments / Actions Taken
1
2
3
Actual Results
Actual Results
Actual Results
APQP/PPAP External Supplier Evidence PROTOTYPE / ALL MEASUREMENT RESULTS Satisfies Schedule A Deliverable #23 / Schedule B Element #17
GPDS: Due at
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
Actual Results
Actual Results
Actual Results
Actual Results
Actual Results
Actual Results
Actual Results
Actual Results
Actual Results
Actual Results
Actual Results
Actual Results
Actual Results
Actual Results
Actual Results
Actual Results
Actual Results
Actual Results
Actual Results
Actual Results
Actual Results
Actual Results
Actual Results
APQP/PPAP External Supplier Evidence PRODUCTION PROCESS CAPABILITY RESULTS Supplier Code: Part Number:
Page & Study Parameters
Characteristic r e b m u N
Characteristic
Specific ation
DFMEA Classification (YC, YS)
PFMEA On Manufacturing Classification Production Operation (CC, SC, HI, Control Identifier Other) Plan (Y/N)
Pass Through Characteristic (PTC) (Y/N)
Error Proofed (Y/N)
Process Control Method
Characteristic dependent on sub-supplier (Include PTC) (Y/N)
Population Sample Size Size
Gauge R&R % Study Variation (Target ≤ 10%)
% Tolerance (Target ≤ 10%)
Process Control Demonstrated Method of Stability and Control
Evidence: Number of Points Not in Control
Distribution Analysis
Distribution Type
Resultant P-value or Best Fit Coefficient
Capability Results PPAP Ppk Values Production Ppk Values
Meets Capability Requirement PPAP Ppk ≥ 1.67 Production Ppk ≥ 1.33 (Y/N)
Actions Taken
APQP/PPAP External Supplier Evidence PROTOTYPE / ALL MEASUREMENT RESULTS Instructions ROLES AND RESPONSIBILITIES What Drawing and Specification released to supplier (Deliverable #25)
Who
When (Vehicle Operations)
Ford Product Development (PD)
GPDS: 1 month before
ns, Process Flow, and
When (X0, XM, M1 - Powertrain Only)
to 1 month after based on the Plan for Every Part
Within 2 weeks after Build Phase DJ event PO-S-25 for X0 PO-T-55 for XM PO-T-70 for M1
to PP-U-50 for VP
to 1 month after based on the Plan for Every Part PP-S-05 for X0 PP-T-20 for XM PP-T-35 for M1
Prototype Inspection Requirements Identified
Ford PD
Failure Mode Avoidance - Special Characteristics cascaded to suppliers (Deliverable #9) through the Special Characteristics Agreement (FAP 03-111)
Ford PD
GPDS:
uM1DJ to uDC based on the Plan for see terms and Definitions below for applic ability Every Part per Powertrain Unit build phase
Prototype Tool Orders release to suppliers in support of Prototype Build Phase (Deliverable #21)
Ford PD
GPDS:
to uDC based on the Plan for Per Powertrain Unit Build phase based on the Plan Every Part for Every Part
Prototype Parts order with quantity and timing to suppliers in support of Prototype Build Phase (Deliverable #22)
Ford PD
GPDS:
to uDC based on the Plan for Every Part to uDC based on the Plan for PP-S-05 for X0 Every Part PP-T-20 for XM PP-T-35 for M1
Supplier / Ford PD
GPDS:
uDC
N/A
Produce Prototype Parts
Supplier
GPDS: In support of Build
GPDS: In support of uVP In Plant Date (IPD)
GPDS: In support of Powertrain Unit rough or purchased finish In Plant Date (IPD)
Conduct inspection method of Prototype Parts per Prototype Control Plan
Supplier
GPDS: In support of Build
GPDS: In support of uVP IPD
GPDS: In support of Powertrain Unit Build Phase IPD. All required X0, XM and M1 prototype inspection is performed as agreed upon by the Product Engineer and the Supplier
Completes the EXTERNAL SUPPLIER PROTOTYPE INSPECTION RESULTS proforma as evidence of Deliverable #23
Supplier
GPDS: Prior to shipment of Build parts
GPDS: Prior to shipment of uVP Build parts
GPDS: Prior to shipment of prototype parts to Powertrain Unit build Phase
Ford PD / Supplier Technical Assistance (STA)
GPDS: Prior to shipment of Build parts
GPDS: Prior to shipment of uVP Build parts
GPDS: Prior to shipment of prototype parts to Powertrain Unit build Phase
Ford PD
GPDS: Prior to shipment of Build parts
GPDS: Prior to shipment of uVP Build parts
GPDS: Prior to shipment of prototype parts to Powertrain Unit build Phase
Prototype Control Plan Completed (Deliverable #20)
Review the results of the Prototype Parts produced Prototype Parts achieved 100% of the required p rint specifications identified for each build phase
N/A
When (VP Powertrain)
APQP/PPAP External Supplier Evidence PROTOTYPE / ALL MEASUREMENT RESULTS Instructions Engineering Notification
Provide the Deviation Notification: approved Alert number for the specification deviations. Note: North American Powertrain deviations for prototype builds prior VP are identified on -
EXTERNAL SUPPLIER PROTOTYPE / ALL MEASUREMENTS RESULTS PAGE
SPECIAL NOTES This information satisfies External Supplier APQP/PPAP Readiness Assessment - Schedule A Deliverable #23 / Shedule B Element#17 Providedata the print specifications item by itemengineering requirements and/or process characteristics. Supplier must have all information available for Report for all required printdata specifications, review. For presentations the(X0 executive summary to Ford to put the 20 most important characteristics at the top ofcompliance the Early Powertrain prototypeand builds - M1): print Suppliers will report themanagement results of thesort prototype measurements using this format to demonstrate of completed template. the functional and dimensional results for the part level ordered. Ford North America Powertrain requires approved e-Warrant deviation for each characteristic that does not meet the requirements prior to shipment of the part. TERMS AND DEFINITIONS TERMS Characteristic (For VP Builds and beyond) Characteristic (X0, XM and M1) Specification DFMEA Classification (YS, YC) PFMEA Classification (CC, SC, HI, Other) Process Control Method (VP and beyond) Process Control Method (X0, XM, and M1) On Prototype Control Plan (Y/N) Quantity Inspected (pcs.) Results: X-bar Results: Range All Parts Meet Specification (Y/N) Comments / Actions Taken Data Reporting
DEFINITIONS All required print specification, engineering requirements and/or process characteristics are to be measured reported onengineering this template. For the simple print, sort ascharacteristics appropriate, for All required printand specification, requirements and/or process as agreed upon by Engineer and theon Supplier are record to be measured and reported on Specification forthe theProduct inspection item defined the design (print or E.S.) Classification as identified on the DFMEA as "Potential Critical Characteristic" (YC) or "Potential Signficant Characteristic" (YS). Other characteristics are print requirements that Classification as identified by the PFMEA. are Special Characteristics. Hownot areidentified the partsas inspected or measured as defined in the Prototype Control Plan? If the control is different the method on the Special Characteristics How aremethod the parts inspectedthan or measured asidentified agreed upon with the Product Engineer for prototype build: X0, contained XM, M1? Ifon the control method is different the method identified Is the characteristic the prototype control plan of than the reporting supplier for the parts produced supporting this build How many pieces are contained in theevent? inspection results data set? Prototype part quantity to be inspected as required by Ford Productresults Engineer Calculated average (mean) from inspection data set. The mean (arithmetic average) is the sum of the all the observations divided by theand number of observations Calculates difference between the largest smallest data values All parts measured meet the characteristic specification Make comments specific to the inspection item and include the action plan if the inspection item does notmust meetcomplete the specification The supplier the measurements and report for all characteristics. Note: For North American Powertrain prototype builds prior to VP include results with the
APQP/PPAP External Supplier Evidence PRODUCTION PROCESS CAPABILITY RESULTS Instructions ROLES AND RESPONSIBILITIES What
Who
When
Drawing and Specification released to supplier (Deliverable #25)
Ford Product Development (PD)
GPDS: 1 month before
Failure Mode Avoidance - Special Characteristics cascaded to suppliers (Deliverable #9) through the Special Characteristics Agreement (FAP 03-111)
Ford PD
GPDS:
Supplier / Ford STA / Ford PD
GPDS:
Production Control Plan is completed and has linkages to DFMEA and PFMEA (Deliverable #20) Measurement System Analysis Gauge R&R results ≤ 10% per PPAP Ford customer specifics (Deliverable #30)
Supplier / Ford STA
GPDS:
Conduct a valid production trial run(s) per the Phase PPAP requirements. Phase 0 PPAP occurs at TT Build (Deliverable #36) and Phase II PPAP occurs at PP Build (Deliverable #42) for GPDS.
Supplier
GPDS: and GPDS:
Perform inspection method and collect data for analysis
Supplier
GPDS: and GPDS:
Analyze data set for statistical process control of the specified special characteristics
Supplier
GPDS: and GPDS:
Analyze the data set for normality (normal distribution) of the specified special characteristics
Supplier
GPDS: and GPDS:
Perform capability calculation using Ppk Formula
Supplier
GPDS: and GPDS:
APQP/PPAP External Supplier Evidence PRODUCTION PROCESS CAPABILITY RESULTS Instructions Engineering Change Level (e.g. Print Revision Level)
Engineering change level for a part is the design record revision level (i.e. Part Print) as identified by a 4-part alphanumeric code (typically 14 characters in length) containing the following: a) Change Level Indicator (CLI) identifying the releasing authority b) Part drawing revision letter (single letter) c) Electronic Release System code (WERS = 8-digit concern number) d) Release Status of the part in the electronic release system (WERS = 3-digit increments of any notices attached to th e part) Engineering Change Level is also reported on the PSW. Example: WPTSE12178961024 a) WPTS = Powertrain Systems Engine Mounts b) E = engineering release c) 12178961 = WERS notice d) 024 = 24 WERS notices attached to this concern
New Tooled End Item (Y/N)
Is the component, sub-assembly or assembly a new design for the given Program Code?
C. Manufacturing Information Manufacturing Site
Location where the end item is manufactured for the build event
Carry-over production site
Same location as previous model year or common platform
New Production site
New facility designated as production intent to produce the end item
Prototype site
Facility responsible for producing the end item for the specific build events (i.e.
APQP/PPAP External Supplier Evidence PRODUCTION PROCESS CAPABILITY RESULTS Instructions Action taken for non-capable process (PPAP Ppk < 1.67 or Production Ppk < 1.33)
The modified control method shall include techniques to incorporate mistake proofing methods into the manufacturing process to prevent the shipment of non compliant product to Ford facilities. Note: examples of mistake proofing methods include the modification of manufacturing processes to detect and discard non compliant product (e.g., poke-yoke), or a gauge to ensure product compliance to specification where the process does not meet the capability requirements. This is not the addition of a temporary manual inspection process at the end of the line.
Engineering notification
Provide the Deviation Notification. Example: approved WERS Alert number for the specification deviations with the interim PPAP submission.
EXTERNAL SUPPLIER PRODUCTION PROCESS CAPABILITY RESULTS PAGE SPECIAL NOTES This information satisfies External Supplier APQP/PPAP Readiness Assessment - Schedule A Deliverable #38 / Schedule B Element #35 Include all special characteristics When specified by Ford, submit completed process control capability evidence at a weekly frequency from MP1 to MP1 + 90 days TERMS AND DEFINITIONS DEFINITIONS TERMS Characteristic Print specification item to be measured Specification
Specification for the characteristic defined on the design record (print or E.S.)
DFMEA Classification (YS, YC)
Classification as identified on the DFMEA as "Potential Critical Characteristic"
APQP/PPAP External Supplier Evidence PRODUCTION PROCESS CAPABILITY RESULTS Instructions % Study Variation
Measurement System Standard Deviation as a percentage of Total Observed Process Standard Deviation (using Standard Deviation)
% Tolerance
Measurement Error as a percentage of Tolerance
Demonstrated Method of Stability and Control
Identify the method of statistical process control evaluation. Statistical process control evaluation techniques include X-bar and R, or X-bar and S, or I-MR. Note: For charting, X-bar and R or X- bar and S, 25 subgroups of 3 to 5 pcs
Evidence: Number of Points Not in Control
Report the number of data points not in control. Out of control coniditions occur when there is data outside the control limits. An out of control condition for the X-bar chart is defined as 1 point greater or less than 3 standard deviations from the mean. If more that 1 data point is not in-control then action is required.
Distribution Analysis
The data distribution needs to be evaluated and identified for the appropriate capability analysis calculation. For example, a normal distribution test requires a P-value greater than 0.05 to assume normality. Non-normal data requires data transformation
Distribution Type
Select the type of distribution identified for the capability analysis. Refer to a known distributions based on the physics or specific types of process available through your STA engineer.
Resultant P-value or Best Fit Coefficient
Report the distribution fit statistical hypothesis p-value or the best fit coefficient from the distribution identification fit technique as appropriate
Results: PPAP Ppk or Production Ppk
Process Capability Formula: Ppk Example below is a calculation for a normal distribution
APQP/PPAP External Supplier Evidence PROTOTYPE / ALL MEASUREMENT RESULTS Process Flow Lead for activity
When (VO/PTO)
Input
Process
Output
PROTOTYPE CONTROL PLAN Ford PD
GPDS: 1 month before FDJ
System design requirements
Design Record Ford PD
GPDS:
DFMEA Engineering Specifications FAP 03-111
Ford PD
GPDS: FDJ
Program requirements
Ford PD
GPDS: FDJ
Program requirements
Supplier / Ford PD
GPDS: FDJ
Prototype Parts Order: quantity and timing Special Char Agreement (FAF 03111-2) Prototype Control Plan
Supplier
GPDS: In support of VP Build
Drawing and Specification released to supplier (Deliverable #25)
Falure Mode Avoidance - Special Characteristics cascaded to suppliers (Deliverable #9) through the Special Characteristics Agreement within this workbook or FAF 03-111-2
Prototype Tool Orders release to suppliers in support of Verification Prototype (VP) Build (Deliverable #21)
Prototype Parts order with quantity and timing to suppliers in support of VP Build (Deliverable #22)
Prototype Control Plan Completed (Deliverable #20)
PRODUCE PROTOYPE PARTS
Drawing and Engineering Specifications
Special Char Agreement Form or FAF 03-111-2
Prototype Tool Order
Prototype Parts Order: quantity and timing
Including process parameter, gauges, inspection methods, tolerances, reaction plan(s) in the Control Plan.
APQP/PPAP External Supplier Evidence PROTOTYPE / ALL MEASUREMENT RESULTS Process Flow
Supplier
GPDS: Prior to Prototype part inspection and shipment of parts measurement data for VP MRD
Completes the EXTERNAL SUPPLIER PROTOTYPE / ALL MEASUREMENT RESULTS proforma as evidence of Deliverable #23
EXTERNAL SUPPLIER PROTOTYPE INSPECTION RESULTS proforma Include COMMENTS / ACTIONS TAKEN when all parts do not meet specification for the given characteristic
PROTOTYPE DATA REVIEW
Program STA
Ford PD / Supplier Technical Assistance
Initial selection of Priority sites will occur PTO - 2months before Unit PTC UN - PTCC UP - PTC/M-1DJ (unless otherwise identified)
Priority Supplier List New Tooled End Item Site Readiness Part Criticality
Priority Supplier No
Priority Supplier
or Non-priority Supplier
Program Induced Risk
GPDS: Prior to EXTERNAL SUPPLIER shipment of parts PROTOTYPE / ALL for VP MRD MEASUREMENT RESULTS
Yes
Review the results of the Prototype Parts produced during GPDS onsite visit #2
EXTERNAL SUPPLIER PROTOTYPE INSPECTION RESULTS with team input
No
Ford PD GPDS: Prior to EXTERNAL SUPPLIER shipment of parts PROTOTYPE / ALL
Prototype Parts achieved 100% of the
No
Ford PD Approves part deviation
Agreement to ship the prototype parts
APQP/PPAP External Supplier Evidence PROTOTYPE / ALL MEASUREMENT RESULTS Process Flow Supplier
GPDS: VP MRD
Agreement to ship the prototype parts
Suppler Ships part to meet in plant date (IDP) commitment for VP Build
DATA STORAGE AND MANAGEMENT REVIEW Program STA
Initial selection of Priority sites will occur by Unit / +90 Days (unless otherwise identified)
Priority Supplier List New Tooled End Item
Priority Supplier
No
Site Readiness Part Criticality
or Non-priority Supplier
Priority Supplier
Program Induced Risk
Yes
Results maintained with APQP records
Ford PD / Site STA
Review the results of the Prototype Parts produced during GPDS on-site visit #2
GPDS: VP
No
Program STA
GPDS: VP
EXTERNAL SUPPLIER PROTOTYPE INSPECTION RESULTS
Program Review Requested
Yes
Site STA
Site STA
GPDS: VP
Sort data into top 20 most important characteristics (e.g. importance to part functionality)
Select 'Print Cover Page & Executive Summary Evidence Form' button to print top 20 characteristics
EXTERNAL SUPPLIER PROTOTYPE / ALL MEASUREMENT RESULTS (Top 20 Characteristics)
GPDS: VP
Functional area requested supplier proformas
Send file to STA Program team
Functional area EXTERNAL SUPPLIER PROTOTYPE / ALL MEASUREMENT RESULTS
APQP/PPAP External Supplier Evidence PROTOTYPE / ALL MEASUREMENT RESULTS Satisfies Schedule A Deliverable #23 / Schedule B Element #17
2 A. Program Information
Date
Model Year
Program Code
Product Name
Build Event
Required In-Plant Date
2011
U502
Explorer
VP
17-Jul-09
Supplier Delivery Promise Date 17-Aug-09
B. Production Supplier / Product Information Tier 1 Supplier Name
Site Code
Tier 1 Supplier Location
CMI - Muskegon
U044M
Muskegon, MI USA City / Region / Country
Part Name
Ford Part Number
REAR KNUCKLE ASSEMBLY
BB53-5B758(9)-AC
Engineering Change Level
New Tooled End Item (Y/N)
WPTSE12178961024
Y
C. Manufacturing Information Check One
Manufacturing Site Carry-over production site New production site Prototype site
CMI - Muskegon
Check One
Manufacturing Process
Check One
Tooling Type
Carry-over production process New production process
Carry-over production tooling New production tooling
Prototype process
Prototype / soft tooling
13-Jul-09
Build Event Quantity 94 Required Produced 150
APQP/PPAP External Supplier Evidence PROTOTYPE / ALL MEASUREMENT RESULTS Satisfies Schedule A Deliverable #23 / Schedule B Element #17 F9:
5 digit GSDB code for Manufacturing Location
K12:
(e.g. Print Revision Level)
G27:
(e.g. Red Border Notice)
B30:
(PPAP Ppk = 1.67 or Production Ppk = 1.33)
G30:
(PPAP Ppk < 1.67 or Production Ppk < 1.33)
APQP/PPAP External Supplier Evidence PROTOTYPE / ALL MEASUREMENT RESULTS
DFMEA Classification (YC, YS)
PFMEA Characteristic Classification (CC, SC, HI, Other)
Specification
Material Yield Strength Material Ultimate Tensile Strength
YC
CC
YC
CC
3
Material Elongation
YC
4
Press - in load UCA
5
r e b m u N
Results
Inspection Method
On Prototype Control Plan (Y/N)
Quantity Inspected (pcs.)
X-Bar
207 Mpa min
tensile bars
Y
4
276 Mpa min
tensile bars
Y
4
CC
7% min
tensile bars
Y
YS
SC
min 29 KN
Load cell
UCA Bore diameter
YS
SC
10 ± 0.5 mm
6
UCA Position
YS
SC
7
UCA Roundness
YS
8
Bushing span
YS
9 11
Shield diameter ns e s e suppor dimension Bearing bolt hole diameter
12
Range
All Parts Meet Specification (Y/N)
Comments / Action Plan
218
3
Y
none required
290
10
Y
none required
4
11
2
Y
none required
Y
150
35 KN
5 KN
Y
none required
CMM
Y
150
10.2
0.2
Y
none required
0.5 mm max
CMM
Y
150
0.75
0.25
Y
none required
SC
max 0.5
tallyrand
Y
150
0.22
0.4
Y
none required
SC
7.36-7.49 mm
optical comparator
Y
150
7.44
0.04
Y
none required
other
19.0 +0.2 / -0.1
CMM
Y
150
18.99
0.14
Y
none required
other
9.2 +0.1/-0.2
Caliper
Y
150
9.17
0.24
Y
none required
other
14.6 ± .1
CMM
Y
150
14.61
0.03
Y
none required
Side support length
other
17.2±0.1
Caliper
Y
150
17.26
0.08
Y
none required
13
Stud torque
other
4.5-6.3 Nm
torque meter
Y
150
5.1
0.2
Y
none required
14
RD Can base
other
166.23±2.5
CMM
Y
150
165.91
2.58
Y
none required
15
Outlet block height
other
49.0±2.5
Caliper
Y
150
47.56
1.27
Y
none required
16
Leak check
other
max 7 ccm
Helium leak detector
Y
150
2.2
1.9
Y
none required
17
Hydralic Pressure
other
1200 -1400 PSI
Dial Gage
Y
150
1300
250
Y
none required
18
Valve torque
other
1-6 lb-in
torque meter
Y
150
3.1
1.5
Y
none required
19
Valve height
other
6.1-7.1mm
Dial Gauge
Y
150
6.5
0.75
Y
none required
20
Cap torque
other
2-12 lb-in
torque meter
Y
150
7.5
2.6
Y
none required
1 2
10
Characteristic
External Supplier Submissions: Report all print requirements. Add rows as necessary. Internal Ford Usage Note: Characteristics #21 and beyond are on file with the supplier
APQP/PPAP External Supplier Evidence PRODUCTION PROCESS CAPABILITY RESULTS Lead for activity
When (VO/PTO)
Input
Process
Output
CHARACTERISTICS Ford Product Development
Ford PD
GPDS: 1 month Drawing and Specification released to before FDJ supplier (Deliverable #25)
GPDS:
Failure Mode Avoidance - Special Characteristics cascaded to suppliers (Deliverable #9) through the Special Characteristics Agreement within this workbook or FAF 03-111-2
Characteristics isted
Characteristic and Specification
Specificaiton limits
DFMEA Characteristic Classification DFMEA and PFMEA Characteristic Classification (CC, SC, HI, Other)
DFMEA
PFMEA Characteristic Classification
PFMEA
Ford PD
Production Control Plan is completed and GPDS: TT / Unit has linkages to DFMEA and PFMEA (Deliverable #37)
Production Control Plan Linkage
On Production Control Plan (Y/N) and Manufacturing Operation Identifier
Manufacturing Operation Identifier Supplier / Ford STA
GPDS: TT / Unit Pass through characteristics identified
Supplier / Ford STA / Ford PD
GPDS: TT / Unit Inspection methods and gauges
Supplier / Ford STA / Ford PD
GPDS: TT / Unit Sub-supplier process flow / PFMEA / control plan
Error Proof methods
Pass Through Characteristic (PTC) and Error Proofed
Process control method
Inspection methods, gauges, and test equipment
Characteristic dependent on subsupplier (Include PTC)
Sub-supplier control plan contains process control methods
STUDY PARAMETERS
Supplier / Ford Phase 0: Prior to TT MRD/Unit STA MRD (VO/PTO) and Phase II: PP MRD/Unit MRD (VO/PTO)
Conduct a valid production trial run(s) per the Phase PPAP requirements. (i.e. Run-atRate completed on production homeline equipment, process, and tooling)
Run-at-rate
Sample Size Phase 0 (Deliverable #36) and Phase II (Deliverable #42) for GPDS. Capacity Analysis Report (CAR)
Supplier / Ford STA
Population Size
Measurement System Analysis - Gauge GPDS: TT / Unit R&R and GPDS: PP MRD / Unit MRD
Parts available for measurement
GAUGE R&R %Study Variation %Tolerance
Remove special causes and implement corrective actions
Measurement System Analysis Gauge R&R results ≤ 10% per PPAP Ford customer specifics (Deliverable #30)
APQP/PPAP External Supplier Evidence PRODUCTION PROCESS CAPABILITY RESULTS PROCESS CONTROL
Supplier
No
GPDS: TT / Unit and Statistical process control tools (Xbar and R GPDS: PP MRD / or Xbar and S, or IM-R or other method) Unit MRD
Identified special cause remove from data set
Evidence demonstrates stability & control
Yes
Supplier
GPDS: TT / Unit Statistical software (e.g. MINITAB) and GPDS: PP MRD / Unit MRD Normality tests Data transformation method (Box-Cox or Johnson Transformations) as needed
No
Stable and in-control statistical process control tools (Xbar and R or Xbar and S, or IM-R or other method)
Yes
DISTRIBUTION ANALYSIS
No
Data is normally distributed
Known Distribution ID Fit
No
Non-normal data is transformed
Distribution ID fit statistical analysis Known Distribution List
Yes
Yes
No Distribution Type Resultant P-Value Best Fit Coefficient for alternative distributions
Yes
CAPABILITY RESULTS
Supplier
GPDS: TT / Unit Statistical software (e.g. MINITAB) and Ppk calculation GPDS: PP MRD / Unit MRD
Mistake-proof modified control method is in place if the process capability does not meet the requirements
Perform capability calculationusing Ppk Formula
Capability Study is evidence for PPAP
Yes Pending PPAP or PPAP previously achieved
Supplier
Statistical software (e.g. MINITAB) GPDS: TT / Unit Ppk calculation and GPDS: PP MRD / Unit MRD
No
PPAP Ppk requirement OR Production Ppk requirement
No
PPAP Ppk process capability meets 1.67 Requirement
Meets PPAP Ppk of 1.67 Or Action Taken
Yes No Supplier
On going production (Post PPAP)
Statistical software (e.g. MINITAB) Ppk calculation
Production Ppk process capability meets 1.33 Requirement
Yes
Meets Production Ppk of 1.33 Or Action Taken
APQP/PPAP External Supplier Evidence PRODUCTION PROCESS CAPABILITY RESULTS DATA STORAGE AND MANAGEMENT REVIEW
Program STA
Site STA Ford PD
Program STA
Initial selection of Priority sites will occur PTO - 2months before Unit PTC UN - PTCC UP - PTC/M-1DJ (unless otherwise identified)
Priority Supplier List New Tooled End Item Site Readiness Part Criticality Program Induced Risk
GPDS: TT / Unit Conduct a valid production trial run(s) per and GPDS: PP MRD / the Phase PPAP requirements. (i.e. Run-atRate completed on production homeline Unit MRD equipment, process, and tooling)
GPDS: TT / Unit and Programs request supplier proformas GPDS: PP MRD / Unit MRD
No
Priority Supplier Non-priority Supplier
Priority Supplier
Yes
File results in support of PPAP
Results review during GPDS on-site Visit #3 and Visit #4
EXTERNAL SUPPLIER PRODUCTION PROCESS CAPABILITY RESULTS
No Program Review Requested
Yes Supplier
Site STA
Ford Management
GPDS: TT / Unit and Programs request supplier proformas GPDS: PP MRD / Unit MRD
GPDS: TT / Unit Sort data into top 20 most important characteristics and GPDS: PP MRD / (e.g. importance to part functionality) Unit MRD
All functional area requested supplier GPDS: TT / Unit proformas and GPDS: PP MRD / Unit MRD
Send file to STA Program team as requested
Select 'Print Cover Page & Executive Summary Evidence Form' button to print top 20 characteristics
Ford Management review of data & feed back actions to STA Engineer
EXTERNAL SUPPLIER PRODUCTION PROCESS CAPABILITY RESULTS
Functional area EXTERNAL SUPPLIER PRODUCTION PROCESS CAPABILITY RESULTS (sort Top 20)
All functional areas\ EXTERNAL SUPPLIER PRODUCTION PROCESS CAPABILITY RESULTS
ONGOING PRODUCTION CONTROL VERIFICATION Supplier / Site STA
MP1 + 90 DAYS As requested by Ford Program
When specified by Ford, submit completed process control capability evidence
EXTERNAL SUPPLIER PRODUCTION PROCESS CAPABILITY RESULTS
3 A. Program Information
Date
Model Year
Program Code
Product Name
Build Event
2010
B299N
Fiesta
TT
Phase PPAP Status Phase 1 Phase 2 Phase 3
B. Production Supplier / Product Information Tier 1 Supplier Name
Site Code
Tier 1 Supplier Location
CMI - Muskegon
U044M
Muskegon, MI USA
Promise Date 1 0- Au g- 10 PPAP Approved Date 4-Aug-09
City / Region / Country
Part Name
Ford Part Number
REAR KNUCKLE ASSEMBLY
BB53-5B758(9)-AC
Engineering Change Level
New Tooled End Item (Y/N)
WPTSE12178961024
Y
C. Manufacturing Information Check One
Manufacturing Site Carry-over production site
Manufacturing Process
Check One
Tooling Type Carry-over production tooling
New production site
New production process
New production tooling
Prototype site
Prototype process
Prototype / soft tooling
All production streams
D. Deviations
CMI - Muskegon
Check One
Carry-over production process
One production stream
5-Aug-09
1 -O ct -1 0
2 0- De c- 09
F9:
5 digit GSDB code for Manufacturing Location
K12:
(e.g. Print Revision Level)
G27:
(e.g. Red Border Notice)
B30:
(PPAP Ppk = 1.67 or Production Ppk = 1.33)
G30:
(PPAP Ppk < 1.67 or Production Ppk < 1.33)
APQP/PPAP External Supplier Evidence Study Parameters
Characteristic r e b m u N
Characteristic
Specification
DFMEA Classification (YC, YS)
PFMEA On Manufacturing Classification Production Operation (CC, SC, HI, Control Identifier Other) Plan (Y/N)
Pass Through Characteristic (PTC) (Y/N)
Error Proofed (Y/N)
Process Control Method
Characteristic dependent on Population Sample sub-supplier Size Size (Include PTC) (Y/N)
Gauge R&R
Process Control
% Study Variation (Target ≤ 10%)
% Tolerance (Target ≤ 10%)
Demonstrated Method of Stability and Control
Evidence: Number of Points Not in Control
Distribution Analysis Distribution Type
Resultant P-value or Best Fit Coefficient
Normal
0.06
Capability Results PPAP Ppk Values Production Ppk Values
Meets Capability Requirement PPAP Ppk ≥ 1.67 Production Ppk ≥ 1.33 (Y/N)
Actions Taken
N
100% in-line air gage
1
Hole size
10.5 +/- 0.5mm
YC
CC
Y
OP10
N
Y
Air Gage
N
300
125
10.54%
9.55%
X-bar and R
1
2
Hardness Material Yield Strength
80 - 120 BHN
YS
SC
Y
Subsupplier
Y
N
Equotip
Y
300
30
18.66%
3.33%
I-MR
0
207 Mpa min
YC
CC
Y
Subsupplier
Y
N
tensile bars
Y
300
30
2.09%
2.22%
I-MR
0
Normal
0.76
2.01
Y
276 Mpa min
YC
CC
Y
Subsupplier
Y
N
tensile bars
Y
300
30
3.45%
2.77%
I-MR
0
Weibull
0.88
1.77
Y
7% min
YC
CC
Y
Subsupplier
Y
N
tensile bars
Y
300
30
9.09%
4.67%
I-MR
0
Weibull
0.06
1.88
Y
min 29 KN
YS
SC
Y
OP40
N
Y
Load cell
N
300
125
2.55%
5.99%
X-bar and R
2
3
5
Material Ultimate Tensile Strength Material Elongation
6
Press - in load UCA
4
1.68
Y
N
7
UCA Bore diameter
10 ± 0.5 mm
YS
SC
Y
OP20
N
Y
CMM
N
300
125
12.45%
11.11%
X-bar and R
0
Box-Cox Transformed
0
1.67
Y
8
UCA Position
0.5 mm max
YS
SC
Y
OP20
N
N
CMM
N
300
125
18.56%
15.88%
X-bar and R
0
Lognormal
0.85
1.81
Y
9
UCA Roundness
max 0.5
YS
SC
Y
OP30
N
Y
tallyrand
N
300
125
21.50%
17.76%
X-bar and R
0
Johnson Transformed
0
1.34
N
10
Bushing span
7.36-7.49 mm
YS
SC
Y
OP20
N
N
optical comparator
Y
300
125
4.65%
7.88%
X-bar and R
0
Normal
0.34
2.33
Y
100% press force monitoring
100% in-line air gage
APQP/PPAP External Supplier Evidence PRODUCTION PROCESS CONTROL RESULTS Required When Specified by Ford Motor Company (MP1 to MP1 + 90 Days) Supplier Code: Part Number:
Page &
Executive Summary Study Parameters
Characteristic r e b m u N
1 2 3 4
Characteristic
Specification
DFMEA Classification (YC, YS)
PFMEA On Manufacturing Classification Production Operation (CC, SC, HI, Control Plan Identifier Other) (Y/N)
Pass Through Characteristic (PTC) (Y/N)
Error Proofed (Y/N)
Process Control Method
Characteristic dependent on sub-supplier (Include PTC) (Y/N)
Population Size
Sample Size
Gauge R&R % Study Variation (Target ≤ 10%)
% Tolerance (Target ≤ 10%)
Process Control Demonstrated Method of Stability and Control
Evidence: Number of Points Not in Control
Actions Taken
APQP/PPAP External Supplier Evidence PRODUCTION PROCESS CONTROL RESULTS ROLES AND RESPONSIBILITIES What
Who
When
Drawing and Specification released to supplier (Deliverable #25)
Ford Product Development (PD)
GPDS: 1 month before
Failure Mode Avoidance - Special Characteristics cascaded to suppliers (Deliverable #9) through the Special Characteristics Agreement (FAP 03-111)
Ford PD
GPDS:
Supplier / Ford STA / Ford PD
GPDS:
Production Control Plan is completed and has linkages to DFMEA and PFMEA (Deliverable #20) Measurement System Analysis Gauge R&R results ≤ 10% per PPAP Ford customer specifics (Deliverable #30)
Supplier / Ford STA
GPDS:
Execute control plan and monitor process for statistical process control
Supplier
On-going
Report process control results on the EXTERNAL SUPPLIER PRODUCTION PROCESS CONTROL RESULTS proforma
Supplier
Weekly from MP1 to MP1 + 90 days
Supplier / Ford STA
On-going
All production processes are stable and in-control; actions taken for out of control processes
PROGRAM, SUPPLIER, PRODUCT, AND MANUFACTURING INFORMATION TERMS AND DEFINITIONS TERMS A. Program Information Model Year
DEFINITIONS The model year the vehicle is released
APQP/PPAP External Supplier Evidence PRODUCTION PROCESS CONTROL RESULTS New Production site
New facility designated as production intent to produce the end item
Prototype site
Facility responsible for producing the end item for the specific build events (i.e. not production intent)
Manufacturing Process
Manufacturing process for the end item producing for the build event. The scope of information is the end item manufacturing process(es) only
Carry-over process
Same manufacturing process as previous model year or common platform
New process
At least one operation contains new manufacturing process(es) to produced the end item for the specific build event (i.e. production intent process)
Prototype process
At least one operation contains a prototype process(es) to produced the end item for the specific build event
Tooling Type
Manufacturing tooling for the end item producing for the specified build event. The scope of information is the end item manufacturing process(es) only
Carry-over tooling
Same manufacturing tooling as previous model year or common platform
New Production Tooling
At least one operation contains new manufacturing tooling to produced the end item or the specific build event (i.e. production intent process)
Prototype/ soft tooling
At least one operation contains prototype tooling in the process utilized to produce the end item for the specific build event (i.e. not production intent)
Process Capability Data Represent One Production Stream
Demonstrate that Initial Process Capability studies have been completed using Run-at-Rate parts from the same production stream
APQP/PPAP External Supplier Evidence PRODUCTION PROCESS CONTROL RESULTS DFMEA Classification (YS, YC)
Classification as identified on the DFMEA as "Potential Critical Characteristic" (YC) or "Potential Signficant Characteristic" (YS).
PFMEA Classification (CC, SC, HI, Other)
Classification as identified by the PFMEA. Other characteristics are print requirements that are not identified as Special Characteristics
On Production Control Plan (Y/N)
Is the characteristic contained on the production control plan of the reporting supplier?
Manufacturing Operation Identifier
Supplier's Production Manufacturing Operation identifier is a code or number unique to the operation identified on the process flow chart and process control plan
Pass Through Characteristic (PTC) (Y/N)
A Pass through Characteristic (PTC) is a product characteristic whose fit or function qualities are not validated, verified or functionally tested within the manufacturing or assembly process in question (external suppliers and internally Ford-made parts)
Error Proofed (Y/N)
Does the characteristic have an error proof method? This is required for CCs and Ford identified PTCs.
Process Control Method
How are the parts inspected or measured? If the control method is different than the method identified on the Special Characteristics Agreement then report the reasons in the Comments / Actions Taken cell.
Characteristic dependent on sub-supplier (Include PTC) (Y/N)
Does the characteristic control require process control at a sub-supplier? This applies to all characteristics classifications and include PTCs.
Study Parameters
Study parameters refers to the sample size and population where the capability study data is collected
Population
What is the population (or estimate) size that contains the samples?
Sample Size
How many pieces are contained in the inspection results data set?
