Course IntroductionAPQP Status Reporting Process APQP 状态报告程序状态报告程序Participant IntroductionslWrite your name and division on a name tent card with the markers provided. 在纸上写下你的姓名部门在纸上写下你的姓名部门. lPrepare to introduce yourself to the class by sharing: 向课堂上的所有人介绍向课堂上的所有人介绍:qYour name 你的名字你的名字qYour title 你的职称你的职称qWhy you are interested in the APQP course 你为什对你为什对APQP课程感兴趣课程感兴趣qYour interest 你的日常兴趣爱好你的日常兴趣爱好Course GoalsUpon completion this course, Participants willbe able to:完成本课程培训，参加人员可完成本课程培训，参加人员可:1.Describe the relationship between FPDS and APQP.2.理解理解FPDS和和APQP的关系的关系.3.Describe the importance of cross-functional team communication. 跨功能小组合作沟通的重要性跨功能小组合作沟通的重要性.3. Explain the APQP elements required in product/process design. 解释在产品解释在产品/过程设计中过程设计中 APQP 各要素的要求各要素的要求.4. Explain the APQP elements required in preparation for manufacturing. 解释在准备生产过程中解释在准备生产过程中APQP各要素的要求各要素的要求.5. Explain the APQP Status Reporting Process. 理解理解APQP 状态报告过程状态报告过程.FPDSMonths before Job 1 for S1 to S6 programsS1-S6项目在项目在Job 1之前的时间节点之前的时间节点FPDS Online Resources. Module Introduction组成部分介绍组成部分介绍Introduction to the APQP ProcessAPQP过程介绍过程介绍1-1Ford InitiativesDefinitionAPQP (Advanced Product Quality Planning) is a structured method for defining and executing the actions necessary to ensure that a product satisfies the customer. APQP是一种结构化的方法，用来确是一种结构化的方法，用来确定和制定确保某产品使顾客满意所需定和制定确保某产品使顾客满意所需的步骤的步骤GoalThe goal of the APQP process 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.APQP的目的是使所有参加该项目的人员的目的是使所有参加该项目的人员和行为便于沟通，确保所有开发阶段按时和行为便于沟通，确保所有开发阶段按时，以可接受的成本和质量水准完成以可接受的成本和质量水准完成.APQP PurposeThe purpose if the APQP process is to establish:APQP的目的是建立的目的是建立:lCommon expectations for internal and external suppliers 对内外部供应商共同的要求对内外部供应商共同的要求lCommon process metrics 通用的过程表格通用的过程表格lA common program status reporting format 共同的状态报告格式共同的状态报告格式lRoles and responsibilities for the APQP elements APQP各要素的职责和角色各要素的职责和角色lA better understanding of how the APQP elements relate to FPDS 更好理解更好理解APQP各要素和各要素和 FPDS的联系的联系APQP BenefitsAPQP aids the program team by:APQP帮助项目小组帮助项目小组:lAdding discipline 增加纪律增加纪律 lFacilitating early identification of required changes 早期确定可能的更改早期确定可能的更改lAvoiding late changes 避免晚期更改避免晚期更改 lProviding a quality product on time, at acceptable cost, to satisfy customers 用可接受的价格，准时提供优质的产品，满足客户用可接受的价格，准时提供优质的产品，满足客户lFacilitating continuous improvement 使持续改进更方便使持续改进更方便APQP Benefits (Contd)Elements要素要素lTeamwork 小组工作小组工作lCommunication 沟通沟通lTiming/Planning 时间时间/计划计划lIdentify Activities 定义行动定义行动Roles角色角色lProgram Management 项目管理项目管理lQuality and Reliability 质量和可靠性质量和可靠性lTeam Leaders 小组领导小组领导lEngineers 工程师工程师lSuppliers 供应商供应商lProgram Team 项目小组项目小组APQP 23个要素 1 选点决定 2 顾客输入要求 3 精致工艺技术 4 设计失效模式后果分析 5 设计评审 6 设计验证计划 7 分承包方 APQP 状态 8 设施、工具和量具 9 样件制造计划 10 样件制造 11 图纸和规范 12 小组可行性承诺 13 制造过程流程图 14 过程失效模式后果分析 15 测量系统评价 16 试生产控制计划 17 操作工过程指导书 18 包装规范 19 产品试生产 20 生产控制计划 21 初始过程能力研究 22 生产确认试验 23 生产件批准 (PSW)福特四项特殊要素1. Sourcing Decision 选点决定 ；2. Customer Input Requirements 顾客输入要求 ;3. Craftsmanship 精致工艺；4. Subcontractor APQP Status 分承包方APQP状态 ;检查清单中的重要要素Design FMEA 设计设计FMEADesign Verification Plan & Report 设计验证计划和报告设计验证计划和报告Prototype Build Control Plan 样件制造控制计划Manufacturing Process Flowchart 制造过程流程图Process FMEA 过程FMEAPre-Launch Control Plan 试生产控制计划Operator Process Instructions 作业指导书Production Control Plan 生产控制计划16Feedback Assessment & Corrective Action反馈、评估和纠正措施反馈、评估和纠正措施Product & Process Validation产品与过程确认产品与过程确认Process Design & Development过程设计和开发过程设计和开发Product Design & Development产品设计和开发产品设计和开发Prototype Build样件制造样件制造Plan & Define计划与定义计划与定义1-2APQP 指南目的指南目的lIncludes best practice APQP evaluation process, process metrics, and status reporting lLinks the APQP process to Product Development and manufacturing processes l把把APQP过程与产品开发和制造过程相联系。过程与产品开发和制造过程相联系。lDefines roles and responsibilities for the APQP process l定义定义APQP过程的角色和职责过程的角色和职责lDevelops a common APQP process for both internal and external manufacturing and assembly suppliersl为内部制造和外部供应商提供一个通用的开发过程为内部制造和外部供应商提供一个通用的开发过程Accessing the APQP Guidelines访问访问 APQP 指南指南Both the Guideline and the forms are available.指南和表格均可由此获得。指南和表格均可由此获得。1-4Module IntroductionFPDS Timing Relationship and ResponsibilitiesFPDS 时间进度时间进度关系和职责关系和职责ScaleabilityVehicle ScaleabilityManufacturing ScaleabilityPowertrain ScaleabilityS1 - Modifications to trim, e.g., new seat sew style modifications only for seats or insert material changes for interior appliqus. M1 - Carry-over engine/transmission with minor calibration revisions to, i.e., no machining changes, very minor assembly revisions, and no plant facilities/infrastructure revisions.P1 - No base engine/transmission/catalyst changes, e.g., wire routing, dipsticks.S2 - Minor freshening, e.g., new seat pads, lamp decoration with carryover tooling, optics.M2 - Carry-over engine/transmission with moderate calibration revisions, i.e., no machining changes, minor assembly revisions, and no plant facilities/infrastructure revisions.P2 - Very minor package-driven changes, e.g., engine actions (such as corrosion upgrades and oil coolers).S3 - Moderate freshening, e.g., carry-over inner panels, new outers.M3 - Minor engine/transmission upgrade, i.e., minor machining/assembly changes (retool existing equipment in place), minor CNC programming changes, and very minor plant facilities/infrastructure revisions.P3 - Minor package-driven changes, e.g., revised exhaust manifolds, non-structural oil pan.S4 - Carry-over platforms, i.e., all new to the customer.M4 - Moderate engine/transmission upgrade, i.e., retool existing machining/assembly lines (minimal number of new or reworked machines), CNC programming changes, and minor plant facilities/infrastructure revisions.P4 - New use of P/T for non-structural engine actions, e.g., new exhaust manifolds, new catalysts.S5 - Modified platforms, i.e., carry-over platforms with structural changes.M5 - Major engine/transmission upgrade, i.e., significant portion of machining (assembly lines are new, reworked, or retooled), and major plant facilities/infrastructure revisions.P5 - P/T design actions are within correlation of analytical tools, e.g., major engine/transmission upgrade.S6 - New platforms, i.e., all new platform and structure. M6 - All new engine/transmission, i.e., nearly all machining (assembly lines are new, reworked, or retooled), and major plant facilities/infrastructure revisions.P6 - Analytical tools are not sufficiently developed, e.g., new engine/combustion. APQP Generic Program Gantt ChartRelationship TableVO NMPLaunch EngineerMatrix for Quality Planning质量策划矩阵质量策划矩阵1-6Module IntroductionAPQP Risk Assessment and Kick-offAPQP 风险评审风险评审和起动和起动APQP Systemic FlowAPQP 系统流程系统流程APQP过程流程精致工艺精致工艺资源决定资源决定顾客输入要求顾客输入要求小组可行性承诺小组可行性承诺图纸图纸/规范规范P-图失效模式和后果分析规范和目标（VDS/SDS/CDS）车辆/系统/子系统/部件的设计设计失效模式后果分设计失效模式后果分析析（DFMEADFMEA）图纸图纸/规范规范（文件（文件/电子档）电子档）设计验证计划设计验证计划（DVPDVP）样件制造样件制造控制计划控制计划样件制造样件制造测量系统评价测量系统评价（尺寸控制）（尺寸控制）设施设施/工具工具/量具量具制造过程流程制造过程流程操作工过程指导书操作工过程指导书（过程定义）（过程定义）试生产控制计划试生产控制计划过程失效模式后果过程失效模式后果分析分析（PFMEAPFMEA）操作工过程指导书操作工过程指导书（验证和培训）（验证和培训）生产控制计划生产控制计划产品试生产产品试生产初始过程能力初始过程能力生产确认试验生产确认试验零件提交保证书零件提交保证书（PSWPSW）向前的信息流向后的信息流设计设计/制造评审制造评审（在所有（在所有APQPAPQP要素后）要素后）1-3-CAPQP 起动会议起动会议Step 1. Initiate the APQP process第一步第一步. 开始开始APQP过程过程Step 2. Educate the attendees 第二步第二步. 培训参加人员培训参加人员Step 3. Finalize roles and responsibilities 第三步第三步. 定义角色和职责定义角色和职责Step 4. Discuss and finalize work plans第四步第四步. 讨论和决定工作计划讨论和决定工作计划风险评估的目的风险评估的目的The purpose is to help determine the extent to which the APQP status reporting process needs to be performed by the supplier:目的是为了决定各个供应商在目的是为了决定各个供应商在APQP状态报告的状态报告的范围：范围：lAt the beginning of a new model program 在每一个新项目开始的时候在每一个新项目开始的时候lAny time a PSW is completed PSW 完成的时间完成的时间 风险评估检查清单风险评估检查清单lIs used as a thought starter to assist in assessing potential risk in a supplier 用作开始支持对潜在的风险供应商的评用作开始支持对潜在的风险供应商的评估方法估方法lRequires subjective experience to be used most effectively 利用个人经验使评审效果最佳利用个人经验使评审效果最佳Parts/Systems PriorityParts/Systems Priority零件零件零件零件/ /系统优先级系统优先级系统优先级系统优先级High Impact parts/systems are those that require special attention.高影响度零件高影响度零件/系统需要特别关注。系统需要特别关注。Prioritized parts/systems maximize the use of Suppler Technical Assistance (STA) and team resources.优先的零件优先的零件/系统使供方技术支持（系统使供方技术支持（STA）和小组资源的使用最大化。和小组资源的使用最大化。Medium and Low Impact parts/systems are monitored, but do not get the high level of attention.中等和低影响度零件中等和低影响度零件/系统被监视，但不会引起高度关注。系统被监视，但不会引起高度关注。Priority Selection Criteria优先选择准则优先选择准则Program Team categorizes parts/systems using four major areas of risk:项目小组依据风险的四个要素把零件项目小组依据风险的四个要素把零件/系统分类：系统分类：#1 Quality History#1 质量历史质量历史#2 Supplier Profile#2 供方大纲供方大纲#3 Engineering Profile#3 工程大纲工程大纲#4 Performance v/s target#4 与目标相对的绩效与目标相对的绩效Priority Selection Criteria优先选择准则优先选择准则#1 Quality History#1 质量历史质量历史High warranty or Things Gone Wrong.高的保修记录或运行状况不良高的保修记录或运行状况不良Frequent Quality Rejects and/or campaigns.频繁的质量拒收和频繁的质量拒收和/或冲突。或冲突。Similar component/system was the cause of a recall action.相似的部件相似的部件/系统导致一次召回行动。系统导致一次召回行动。Priority Selection Criteria优先选择准则优先选择准则#2 Supplier Profile #2 供方大纲供方大纲New supplier.新供方。新供方。New manufacturing location.新制造场所。新制造场所。Product or manufacturing technology is new.产品或制造技术是全新的。产品或制造技术是全新的。Supplier does not meet Ford Quality供方不满足福特的质量要求供方不满足福特的质量要求 Standards (Q1) or is under Q1 probation（Q1）标准或低于标准或低于Q1证明。证明。Priority Selection Criteria优先选择准则优先选择准则#3 Engineering Profile #3 工程大纲工程大纲Design is new.新设计。新设计。Manufacturing techniques are new.制造技术是新的。制造技术是新的。Similar products are subject to numerous design changes that threaten program timing.相似的产品是导致大量设计变更而威胁项目事件进度原因相似的产品是导致大量设计变更而威胁项目事件进度原因 。High product or process complexity.高的产品或过程复杂性。高的产品或过程复杂性。Product is strategically important due to high visibility or functional performance.由于高的可见度或功能性，产品处于战略重要地位由于高的可见度或功能性，产品处于战略重要地位 。Priority Selection Criteria优先选择准则优先选择准则#4 Performance vs. Targets#4 与目标相对的绩效与目标相对的绩效Design goals will be difficult to achieve.设计目标将难以完成。设计目标将难以完成。Reliability goals will be difficult to achieve.可靠性目标将难以完成。可靠性目标将难以完成。Quality goals will be difficult to achieve.质量目标将难以完成。质量目标将难以完成。Program timing is compressed.项目时间进度被压缩。项目时间进度被压缩。Cost targets are aggressive.成本目标过高。成本目标过高。Example Risk Assessment ChecklistExample Risk Assessment Checklist AnswersModule IntroductionAPQP Reporting FormsAPQP报告格式报告格式计划和定义计划和定义成立小组预算批准初始材料清单产品保证计划项目追踪表资源决定问题日志管理者支持顾客输入要求项目进度设计目标可靠和质量目标可承受的成本目标计划产量关键联系人产品质量进度计划产品设计和开发产品设计和开发DFMEA初始CC/SC清单设计评审设计验证计划设计验证分供方APQP状态设备、工装和量具样件制作控制计划制造系统分析计划MSA计划小组可行性承诺样件制作包装规范图纸和规范PFMEA特殊产品/过程特性初始过程能力研究计划MSA试生产控制计划过程与产品特性联结平面布景图特性矩阵表包装标准产品/过程质量系统评审管理层评审产品和过程验证产品和过程验证作业指导书试生产生产控制计划质量计划批准和管理层支持生产件批准(PSW)在物料需求日提交PSW零件功能检查报告初始过程能力研究生产验证包装评估信息反馈和纠正措施经验学习交货和服务过程设计和开发过程设计和开发SIPTPDPITDTCPCPRSOLRJIPS客户满意减少偏差设计验证和批准报告Accessing Forms1.Select “APQP Guideline” or “APQP Quality-of-Event Checklists” Information WorksheetThe Information Worksheet summarizes program information on one form. 在一张信息工作单在一张信息工作单上总结了项目上总结了项目的所有信息的所有信息Element Rating ChecklistStatus ReportGYR StatusRisk (color)风险（颜色）Definition定义High (Red)高（红）Target dates and/or deliverables are at risk. A recovery work plan is not available and/or implemented, or the work plan does not achieve program targets. 目标日期和/或可交付性是有风险的。恢复工作计划是不可获得的和/或不可实施的，或工作计划没有完成项目目标。 Moderate (Yellow)中（黄） Target dates and/or deliverables are at risk, but a resourced recovery work plan has been developed to achieve program targets and has been approved by the management team.目标日期和/或可交付性有风险，但恢复工作计划已经被开发以完成项目目标，并且已经过管理小组的适当的批准。 None (Green) 低（绿）Target dates and/or deliverables are on track and meeting objectives.目标日期和可交付性被跟踪并满足目标。 Forms LinkageInformation Worksheet FieldsElement Rating ChecklistChecklist FieldsStatus ReportStatus Report (Continued)Checklist GuidelineslMost planning for the APQP elements occurs from (KO) to . APQP要素中大部分计划发生在要素中大部分计划发生在(KO)到到阶段阶段.lProgram team reporting for most APQP elements begins at . APQP要素中大部分项目小组报告发生要素中大部分项目小组报告发生阶段阶段.lBoth the APQP checklist and Status Report have common fields that are not linked between the forms. lThe APQP checklist and Status Report must be updated for each milestone/team event as required by the program team or customer. 根据客户或项目小组要求根据客户或项目小组要求APQP检查清单和状态报告在每一个检查清单和状态报告在每一个时间节点时间节点/小组事件时必须更新小组事件时必须更新Module Introduction组成部分介绍组成部分介绍Plan and Define计划与定义计划与定义1-7Process Flow过程流程过程流程Feedback Assessment & Corrective Action反馈、评估和纠正措施反馈、评估和纠正措施Product & Process Validation产品与过程确认产品与过程确认Process Design & Devel opment过程设计和开发过程设计和开发Product Design & Development产品设计和开发产品设计和开发Prototype Build样件制造样件制造Plan & Define计划与定义计划与定义1-8Sourcing Decision选点决定选点决定lIt is a document that advises internal and external suppliers of key contact personnel within Ford (STA, purchasing, engineers, etc.).是内、外部供方与是内、外部供方与 Ford （STA、采购、工程等）采购、工程等）协商关键联络人的文件。协商关键联络人的文件。 lIt serves as a formal customer commitment to work with all internal and external part suppliers, tooling suppliers, and facility suppliers on a program. 作为与项目中的内、外部零件供方、工装供方和设作为与项目中的内、外部零件供方、工装供方和设施供方共同工作的正式对顾客的承诺。施供方共同工作的正式对顾客的承诺。1-9Sourcing Decision Expectations选点决定的期望选点决定的期望lAll internal and external suppliers for a program are identified 项目所有的内、外部供方已经确定项目所有的内、外部供方已经确定lEarly sourcing target agreements are established and signed by appropriate areas由适当的区域建立并签署早期资源指标协议由适当的区域建立并签署早期资源指标协议lAll non-Q1 suppliers are identified所有非所有非 Q1 供方已经确定供方已经确定lSpecial arrangements for non-Q1 suppliers are identified非非 Q1 供方的特殊安排已经确定供方的特殊安排已经确定lA program timeline, aligned to FPDS, is established from to 已经建立了从已经建立了从 到到 的、与的、与 FPDS 一致的项目时间安排一致的项目时间安排1-10Sourcing Decision Checklist选点决定检查清单选点决定检查清单1-11Customer Input Requirements顾客输入要求顾客输入要求lThe Customer Input Requirements element ensures that the program team appropriately assesses the potential manufacturing, process, and design issues early in the product development phase.顾客输入要求要素为了要让项目小组，在产品开发阶段顾客输入要求要素为了要让项目小组，在产品开发阶段适当的评估潜在的制造、过程和设计问题。适当的评估潜在的制造、过程和设计问题。 lCustomer Input Requirements are the design criteria and the program requirements necessary to initiate the APQP process. 顾客输入要求是启动顾客输入要求是启动 APQP 过程的必要的设计准则和过程的必要的设计准则和项目要求。项目要求。1-12Customer Input Requirements Expectations顾客输入要求期望顾客输入要求期望lIssues from surrogate components or plants are identified and addressed with product and manufacturing.已经识别了暂时代替的零部件或工厂的问题，并解决了生产已经识别了暂时代替的零部件或工厂的问题，并解决了生产和制造问题和制造问题lComponent targets and product assumptions are defined.已经定义了零部件指标和产品假设已经定义了零部件指标和产品假设lTargets for TGW, TGR, Warranty, Useful Life Reliability, and Incoming Quality are established.已经建立已经建立 TGW、TGR、保证、使用寿命可靠性和进货质量指保证、使用寿命可靠性和进货质量指标标lCapacity planning volumes are defined.生产量策划值已定义生产量策划值已定义1-13Customer Input Expectations (Continued)顾客输入要求期望（续）顾客输入要求期望（续）System component designs and specifications should include:系统部件设计和规范应该包括：系统部件设计和规范应该包括： lProduct assumptions 产品假设产品假设lFunctional performance性能表现性能表现lDimensions几何尺寸几何尺寸 lWeight重量重量 lMaterial材料材料 lReliability and quality goals可靠性和质量目标可靠性和质量目标1-14Customer Input Checklist顾客输入检查清单顾客输入检查清单1-15Craftsmanship is an assessment of what the customer sees, touches, uses, hears, and smells. It affects design and manufacturing, and it improves the overall perception of value.精致工艺是对顾客看到的、感觉到的、使精致工艺是对顾客看到的、感觉到的、使用的、听到的和闻到的评估。影响设计和用的、听到的和闻到的评估。影响设计和生产，并改进全面感官的价值。生产，并改进全面感官的价值。 Craftsmanship精致工艺精致工艺1-16Craftsmanship Expectations精致工艺期望精致工艺期望lObtain Craftsmanship targets and objectives to develop Craftsmanship plans获得精致工艺获得精致工艺 指标和目标以开发精致工艺计划指标和目标以开发精致工艺计划lDevelop the Craftsmanship strategy开发精致工艺战略开发精致工艺战略lImplement a plan to achieve Craftsmanship targets实施计划以达到精致工艺指标实施计划以达到精致工艺指标 lIntegrate plans to support the final Craftsmanship theme 整合各项计划以支持最终精致工艺计划整合各项计划以支持最终精致工艺计划lEnsure that the design and manufacturing processes comply with Craftsmanship strategy and plans 确保设计和制造过程符合精致工艺战略和计划确保设计和制造过程符合精致工艺战略和计划lIdentify and resolve Craftsmanship issues that arise识别并解决发生的精致工艺问题识别并解决发生的精致工艺问题1-17Craftsmanship Checklist精致工艺检查清单精致工艺检查清单1-18Team Feasibility Commitment小组可行性承诺小组可行性承诺The Team Feasibility Commitment element determines whether the proposed design can be manufactured within the programs guidelines and specifications.小组可行性承诺要素确定了建议的设计是否能根据项目指南和规范进行小组可行性承诺要素确定了建议的设计是否能根据项目指南和规范进行制造制造 The goals of this element are to verify that all of the:本要素的目的是验证所有：本要素的目的是验证所有：lActivities agree that they can produce the product within specifications.活动可以生产符合规范的产品活动可以生产符合规范的产品lFeasibility concerns are resolved and necessary product and process changes are completed before first production prove-outs (1PP).在第一预生产单元建立（在第一预生产单元建立（1PP）前解决可行性问题和必要的产品和前解决可行性问题和必要的产品和过程更改过程更改.1-19Team Feasibility Commitment Expectations小组可行性承诺期望小组可行性承诺期望 lThe program team must establish a formal feasibility process and document.项目小组必须建立正式的可行性过程和文件。项目小组必须建立正式的可行性过程和文件。lFeasibilities are tracked and major feasibility concerns can be resolved before Production Trial Run.在产品试生产前追踪可行性，并解决可行性涉及的重要问题。在产品试生产前追踪可行性，并解决可行性涉及的重要问题。lWERS and AIMS concerns are resolved, and the product can be manufactured to meet Cp/Cpk and tolerance requirements.解决了解决了WERS 和和 AIMS 设计的问题，可以在满足设计的问题，可以在满足Cp/Cpk 和公差要和公差要求的情况下制造产品。求的情况下制造产品。lSuppliers and subsuppliers were part of the feasibility process.供方和分承包方式可行性过程的一部分。供方和分承包方式可行性过程的一部分。1-20Team Feasibility Commitment Checklist小组可行性承诺检查清单小组可行性承诺检查清单1-21Module Introduction组成部分介绍组成部分介绍Product Design and Development产品设计和开发产品设计和开发1-22Product Design and Development产品设计和开发产品设计和开发Feedback Assessment & Corrective Action反馈、评估和纠正措施反馈、评估和纠正措施Product & Process Validation产品与过程确认产品与过程确认Process Design & Devel opment过程设计和开发过程设计和开发Product Design & Development产品设计和开发产品设计和开发Prototype Build样件制造样件制造Plan & Define计划与定义计划与定义1-23Elements要素要素lDesign FMEA设计设计 FMEAlDVP&R设计验证计划和报告设计验证计划和报告 lSubcontractor/Subsupplier APQP Status分承包方分承包方/分供方分供方 APQP 状态状态lDrawings and Specifications图样和规范图样和规范1-24Design FMEA设计设计 FMEAA group of activities intended to:一组活动，用于一组活动，用于:lIdentify potential: 识别潜在的识别潜在的:qProduct failure modes early in the product development phase产品开发阶段的早期产品失效模式产品开发阶段的早期产品失效模式 qProduct design safety concerns产品设计安全涉及的问题产品设计安全涉及的问题 qSignificant/critical/special characteristics重要重要/关键关键/特殊特性特殊特性lEstablish a priority for design improvement actions 为设计改进活动建立优先顺序为设计改进活动建立优先顺序lDocument the rationale behind product design changes to the development of future product designs将产品设计变更中的思路文件化，作为未来产品设计的开发的输入将产品设计变更中的思路文件化，作为未来产品设计的开发的输入1-25DFMEA ExpectationsDFMEA 期望期望lCompleting DFMEAs that focus on what has changed in the design and its effect on the entire system完成关注设计中进行的更改及其对整个系统的影响的完成关注设计中进行的更改及其对整个系统的影响的 DFMEAlCreating a list of potential Special Characteristics (YC, YS) resulting from DFMEAs or equivalent analysis建立建立 DFMEA 或类似的分析输出的潜在特殊特性或类似的分析输出的潜在特殊特性 (YC, YS) 清清单单lAddressing lessons learned and quality issues found in element 2, Customer Input Requirement解决在要素解决在要素 2，顾客输入要求中发现的质量问题和学到的经验，顾客输入要求中发现的质量问题和学到的经验lEnsuring that the DFMEA info is sent to PFMEA teams, including the special characteristics list确保将确保将 DFMEA 信息，包括特殊特性清单传递给信息，包括特殊特性清单传递给 PFMEA 小小组组1-26Design FMEA Checklist设计设计 FMEA 检查清单检查清单1-27DVP&R设计验证计划和报告设计验证计划和报告 lLists the engineering evaluations and tests required to establish that a design is fit for use in the intended environment列出建立适于在预期的环境中使用的设计所要求的工程评价和试验列出建立适于在预期的环境中使用的设计所要求的工程评价和试验lAssists Product Development (PD) in verifying and documenting the functionality, reliability, and durability of the vehicles design through planned tests and evaluations协助产品开发（协助产品开发（PD）按计划的试验和评价，验证和文件化车辆设计按计划的试验和评价，验证和文件化车辆设计的功能性、可靠性和耐久性的功能性、可靠性和耐久性lDocuments the plans and reports for Design Verification of a given design将对给定设计进行设计验证的策划和报告文件化将对给定设计进行设计验证的策划和报告文件化lIdentifies tests, acceptance criteria, sample sizes, and completion dates in a standard format以标准的形式确定试验、接受准则、样本容量和完成日期以标准的形式确定试验、接受准则、样本容量和完成日期1-28DVP&R Expectations设计验证计划和报告期望设计验证计划和报告期望lCorrective action plans must be completed for any test result that does not meet design spec and reliability goals必须针对任何没有满足设计期望和可靠性目标的试验结果完必须针对任何没有满足设计期望和可靠性目标的试验结果完成纠正措施计划成纠正措施计划lThe DVP&R must:DVP&R 必须：必须： qAlign with PQOS deliverables配合配合 PQOS 可交付性可交付性 qProvide inputs to complete reports and proformas向完成报告和形式提供输入向完成报告和形式提供输入qIdentify any specific tests, methods, equipment, acceptance criteria, sample sizes, design level, and timing确定任何特殊的试验、方法、设备、接收准则、样本容量、确定任何特殊的试验、方法、设备、接收准则、样本容量、设计等级和时间安排设计等级和时间安排1-29DVP&R Checklist设计验证计划和报告检查清单设计验证计划和报告检查清单1-30Subcontractor APQP Status分承包方分承包方 APQP 状态状态lThe Subcontractor APQP Status element identifies and reports on the condition of external contractors (i.e., suppliers) and subcontractors APQP process. 分承包方分承包方 APQP 状态要素确定和报告外部承包方状态要素确定和报告外部承包方（例如供方）和分承包方（例如供方）和分承包方 APQP 过程的状况过程的状况lInternal and external suppliers identify APQP requirements by cascading program targets APQP requirements to their subcontractors, and by conducting APQP reviews, as appropriate.内部和外部供方通过向分承包方逐级传递项目指标内部和外部供方通过向分承包方逐级传递项目指标 APQP 要求和适当时进行要求和适当时进行 APQP 评审确定评审确定 APQP 要求要求1-31Subcontractor Expectations分承包方期望分承包方期望Subcontractor APQP Status general expectations are that all internal and external suppliers must: 分承包方分承包方 APQP 状态的总的期望是所有内部和外部供方必须：状态的总的期望是所有内部和外部供方必须：lAssess the risk and specify the level of their subcontractors APQP participation评估风险和确定它们的分承包方参与评估风险和确定它们的分承包方参与 APQP 的等级的等级 lCascade APQP requirements to their subcontractors向它们的分承包方逐级传递向它们的分承包方逐级传递 APQP 要求要求 lHold regularly scheduled APQP review meetings with their subcontractors有规律的与分承包方会议，进行安排好的有规律的与分承包方会议，进行安排好的 APQP 评审评审 1-32Subcontractor APQP Checklist分承包方分承包方 APQP 检查清单检查清单1-33Drawing and Specifications图样和规范图样和规范This element provides an evaluation of the development of targets and specifications to be input to the design process and drawings.本要素提供对输入到设计过程和图样的指标和规本要素提供对输入到设计过程和图样的指标和规范的开发的评价。范的开发的评价。These drawings include all engineering drawings, CAD data, material specifications, and engineering specifications.这些图样包括所有工程图样、这些图样包括所有工程图样、CAD 数据、材料数据、材料规范和工程规范。规范和工程规范。1-34Drawing and Specifications Expectations图样和规范期望图样和规范期望lProgram Need Dates are communicated and agreed to by effected areas.项目所需数据由受到影响的区域进行沟通和批准。项目所需数据由受到影响的区域进行沟通和批准。lSCs and CCs are identified on the drawings or attached documents.在图样和附带文件中确定在图样和附带文件中确定 SC 和和 CC。lTolerances and part specs are compatible with accepted manufacturing standards for gauges and equipment.公差和零件规格与量具和设备的可接受的制造标准一致。公差和零件规格与量具和设备的可接受的制造标准一致。lDrawings and specifications must include:图样和规范必须包括：图样和规范必须包括： qEngineering specification tests工程规范试验工程规范试验 qProduct validation test requirements产品确认试验要求产品确认试验要求 qDocumentation to support prototype build and pre-launch control plan development文件化以支持样件制造和试生产控制计划的开发文件化以支持样件制造和试生产控制计划的开发 1-35Drawing and Specifications Expectations (Continued)图样和规范期望（续）图样和规范期望（续）lThe drawing information and engineering specifications will be used as a prerequisite to the PBCP. 图样信息和工程规范将作为样件制造控制计划（图样信息和工程规范将作为样件制造控制计划（ PBCP） 的先决条件。的先决条件。lMaterial used by the suppliers or the subcontractors must be approved and included in the Ford Approved Source list.供方或分承包方使用的材料，必须被批准并包含在福特供方或分承包方使用的材料，必须被批准并包含在福特批准资源清单内。批准资源清单内。lPD and ME personnel will assess drawings and specifications to ensure they meet the programs ABS and quality requirements.PD 和和 ME 人员将评估图样和规范，以确保满足项目人员将评估图样和规范，以确保满足项目 ABS 和质量要求。和质量要求。1-36Drawings and Specifications Checklist图样和规范检查清单图样和规范检查清单1-37Module Introduction组成部分介绍组成部分介绍Prototype Build样件制造样件制造1-38Process Flow过程流程过程流程Feedback Assessment & Corrective Action反馈、评估和纠正措施反馈、评估和纠正措施Product & Process Validation产品与过程确认产品与过程确认Process Design & Devel opment过程设计和开发过程设计和开发Product Design & Development产品设计和开发产品设计和开发Prototype Build样件制造样件制造Plan & Define计划与定义计划与定义1-39Prototype Build Overview样件制造概述样件制造概述APQP Prototype Build elements support the successful planning and construction of Prototype Build units, which provide an understanding of the vehicles:APQP 样件制造要素支持样件制造单位的成功的策划和样件制造要素支持样件制造单位的成功的策划和构造，提供对于车辆的如下理解：构造，提供对于车辆的如下理解：lDesign设计设计lFunctionality功能性功能性lManufacturability可制造性可制造性1-40Prototype Build Elements样件制造要素样件制造要素1.The PBCP supports the planning and construction of prototypes by documenting the process steps of the Prototype Build phase.PBCP 通过将样件制造阶段的过程步骤文通过将样件制造阶段的过程步骤文件化支持样件的策划和构造。件化支持样件的策划和构造。1.The Prototype Build ensures that the customer receives CPs manufactured and assembled prior to 1PP.样件制造确保顾客在样件制造确保顾客在 1PP 前收到制造和前收到制造和装配好的装配好的 CP。1-41PBCP (Prototype Build Control Plan) DefinitionPBCP（样件制造控制计划）定义样件制造控制计划）定义lThe PBCP description of the dimensional measurements and material/functional tests that occur during the CP build.PBCP 描述了发生在描述了发生在 CP 制造中的尺寸测量和材料制造中的尺寸测量和材料/功能试验功能试验lIt is the first summary document that indicates:是说明如下事项的摘要文件：是说明如下事项的摘要文件：qThe steps between Prototype Build and Pre-Launch leading to the Production Control Plan产生生产控制计划的样件制造和试生产之间的步骤产生生产控制计划的样件制造和试生产之间的步骤qThe process steps to identify and align both the products characteristics and its targets识别和调整产品特性及其指标的过程步骤识别和调整产品特性及其指标的过程步骤1-42PBCP General ExpectationsPBCP 总的期望总的期望lProduct characteristics are reviewed评审产品特性评审产品特性qThose characteristics required for PBCPs are identified.确定确定 PBCP 所要求的特性。所要求的特性。qAll potential significant and critical characteristics from the DFMEAs must be included.必须包括必须包括 DFMEA 输出的所有潜在重要和关键特性。输出的所有潜在重要和关键特性。lThe process parameter conditions must be documented.过程参数条件必须被文件化。过程参数条件必须被文件化。qThis includes all special tooling, manufacturing, and assembly conditions.包括所有特殊工具、制造和装配条件。包括所有特殊工具、制造和装配条件。1-43PBCP ChecklistPBCP 检查清单检查清单1-44Prototype Build样件制造样件制造lDefines the manufacture and assembly of components, subsystems, systems, and vehicles supplied to the customer for builds occurring prior to the 1PP trial run 定义在定义在 1PP 试运行前的样件制造，以提供给零部件、试运行前的样件制造，以提供给零部件、子系统、系统和车辆的制造和装配。子系统、系统和车辆的制造和装配。lIncludes not only the actual build process, but the preparation for the build so that CPs are supplied to the customer prior to 1PP不仅包括实际的制造过程，而且包括为了在不仅包括实际的制造过程，而且包括为了在 1PP 前前将将 CP 提交给顾客而进行的制造准备提交给顾客而进行的制造准备1-45Prototype Build Expectations样件制造期望样件制造期望lPBCPs are followed.按照按照 PBCP 进行进行lSuppliers receive all necessary information and participate according to the programs schedule and timing.供方收到所有必要的信息并按照项目时间安排定时参与供方收到所有必要的信息并按照项目时间安排定时参与lThe timing for changes will be in line with the next build phase.更改的时间选择应该符合下一个制造阶段。更改的时间选择应该符合下一个制造阶段。lAll prototype materials must meet 100 percent of the dimensional specifications and functional requirements at delivery to meet the CP In-Plant Date.交付时所有样件材料必须交付时所有样件材料必须 100% 满足尺寸规范和功能要求以满足尺寸规范和功能要求以满足满足 CP 进厂日期。进厂日期。1-46Prototype Build Expectations (Continued)样件制造期望（续）样件制造期望（续）lQuality levels are checked against the PBCP.按照按照 PBCP 检查质量等级。检查质量等级。lDimensional and functional data is available for review by the customer on each part.顾客可以获得每个零件的尺寸和功能数据以进行评审。顾客可以获得每个零件的尺寸和功能数据以进行评审。lSuppliers provide customers with any testing and checking requirements for prove-out of their part design.供方向顾客提供所有试验和检查要求以证明零件设计是适当的。供方向顾客提供所有试验和检查要求以证明零件设计是适当的。lAn Action Matrix is developed to capture and resolve all concerns found during build and any subsequent lab, plant, and/or road testing, and all concerns are reviewed with the program team and appropriate management.开发开发“措施矩阵措施矩阵”以获得和解决在制造和所有试验室、工厂和以获得和解决在制造和所有试验室、工厂和/或或道路试验中并发的问题，和所有项目小组及适当的管理层评审的问道路试验中并发的问题，和所有项目小组及适当的管理层评审的问题。题。1-47Prototype Build Checklist样件制造检查清单样件制造检查清单1-48Module Introduction组成部分介绍组成部分介绍Process Design and Development过程设计和开发过程设计和开发1-49Process Flow过程流程过程流程Feedback Assessment & Corrective Action反馈、评估和纠正措施反馈、评估和纠正措施Product & Process Validation产品与过程确认产品与过程确认Process Design & Development过程设计和开发过程设计和开发Product Design & Development产品设计和开发产品设计和开发Prototype Build样件制造样件制造Plan & Define计划与定义计划与定义1-50Elements要素要素1.Facilities, Tools, and Gauges1. 设施、工具和量具设施、工具和量具2. Manufacturing Process Flow2. 制造过程流程制造过程流程3. Process FMEA3. 过程过程 FMEA4. Measurement System Evaluation4. 测量系统评价测量系统评价5. Pre-Launch Control Plan5. 试生产控制计划试生产控制计划6. Operator Process Instructions6. 操作工过程指导书操作工过程指导书7. Packaging Specifications7. 包装规范包装规范1-51Facilities, Tools, and Gauges (8)设施、工具和量具设施、工具和量具(8)lThis element identifies the new, additional, refurbished, and relocated facilities and resources necessary to manufacture the customer-specified product at designated quantity and quality levels. 本要素确定了以规定的数量和质量等级制造顾客指本要素确定了以规定的数量和质量等级制造顾客指定的产品所需的新的、额外的、更新的和重新部署定的产品所需的新的、额外的、更新的和重新部署的设施和资源。的设施和资源。lThe element also identifies the tools and gauges used in process machinery to transform raw material into finished parts or assemblies. 本要素还确定了用于将原材料转换为完成的零件或本要素还确定了用于将原材料转换为完成的零件或组装件的机械加工过程的工具和量具。组装件的机械加工过程的工具和量具。1-52Expectations期望期望lThe planning and execution of this element must align with: q to milestones qPQOS Deliverables 本要素的计划和执行必须配合本要素的计划和执行必须配合 里程碑里程碑 到到 PQOS 需交付的事务需交付的事务lFacility permits, planning approval, drawings, and utilities must be included on the Manufacturing Timing Plan. In addition, funding approvals must be completed.制造时间计划中必须包括设施许可、计划批准、图样和效用。另制造时间计划中必须包括设施许可、计划批准、图样和效用。另外，必须完成资金批准。外，必须完成资金批准。lThe program team must approve statistical requirements and acceptance criteria before sourcing of tools or gauges can be made. 在可以进行工具和量具的外包之前，项目小组必须批准统计要求在可以进行工具和量具的外包之前，项目小组必须批准统计要求和接收准则。和接收准则。1-53Expectations (Continued)期望（续）期望（续）lAll tools and gauges must comply with Tooling and Equipment Supplement requirements.所有工具和量具必须符合工装和设备补充要求。所有工具和量具必须符合工装和设备补充要求。lTrial runs should occur at the machine builders location to qualify all tools.应该在机械制造者的现场进行试运行，以验证所有工具合格。应该在机械制造者的现场进行试运行，以验证所有工具合格。lAll corrective actions for facilities, tools, and gauges not meeting customer requirements must be completed before the Production Trial Run.必须在产品试生产前完成针对不满足顾客要求的设施、工具和必须在产品试生产前完成针对不满足顾客要求的设施、工具和量具的所有纠正措施。量具的所有纠正措施。lTools and gauges must be delivered, set up, and approved in their specified facilities before the Production Trial Run. 产品试生产前工具和量具必须以制定的设施交付、安装和批准。产品试生产前工具和量具必须以制定的设施交付、安装和批准。1-54Facilities, Tools, and Gauging Checklist设施、工具和量具检查清单设施、工具和量具检查清单1-55Manufacturing Process Flow (13)制造过程流程（制造过程流程（13）This element is a graphic representation of the current or proposed sequence of the manufacturing process to ensure that the process definition, PFMEA, and Control Plans can be created and analyzed in the appropriate sequence.本要素制造过程的当前的或建议的次序的本要素制造过程的当前的或建议的次序的图解表示，以确保以适当的次序建立和分图解表示，以确保以适当的次序建立和分析过程定义、析过程定义、PFMEA 和控制计划。和控制计划。1-56Manufacturing Process Flow Expectations制造过程流程期望制造过程流程期望Manufacturing Process Flow general expectations are that:制造过程流程总的期望是：制造过程流程总的期望是：lA cross-functional team led by VO Engineering develops a Manufacturing Process flowchart to serve as an input to PFMEAs.由由 VO 工程领导的横向职能小组开发制造过程流程图作为工程领导的横向职能小组开发制造过程流程图作为 PFMEA 的输入。的输入。lThe process flowcharts are developed using PFMEAs and surrogate processes to serve as input for new processes and technologies.使用使用 PFMEA 和替代的过程开发过程流程图，作为新过程和技术和替代的过程开发过程流程图，作为新过程和技术的输入。的输入。lThe current production flowcharts may be modified to show revisions to the process flow.可以修改当前的生产流程图，以显示对过程流程的修改。可以修改当前的生产流程图，以显示对过程流程的修改。1-57Manufacturing Process Flow Checklist制造过程流程检查清单制造过程流程检查清单1-58Process FMEA (14) 过程过程 FMEA (14)The PFMEA is a systematic approach used by a manufacturing-responsible team to ensure that potential process-related failure modes and their associated causes have been considered and resolved.PFMEA 是制造职责小组使用的确保已经是制造职责小组使用的确保已经考虑并解决了潜在的与过程相关的失效模考虑并解决了潜在的与过程相关的失效模式及其相关原因的系统化的方法。式及其相关原因的系统化的方法。1-59Expectations期望期望lAll Process FMEAs are prepared by a cross-functional team led by Manufacturing Engineering following the steps defined in the FMEA guideline.所有过程所有过程 FMEA 以制造工程为领导的横向职能小组按照以制造工程为领导的横向职能小组按照 FMEA 指南指南中定义的步骤进行准备。中定义的步骤进行准备。lProcess FMEAs must be established any time that: 当存在如下事项时，必须建立过程当存在如下事项时，必须建立过程 FMEA： qNew processes, technologies, products, or product features are introduced. 引入新的过程、技术、产品或产品特征。引入新的过程、技术、产品或产品特征。qQuality risks are identified that cannot be resolved through design changes. 确定质量风险不能通过设计变更加以解决。确定质量风险不能通过设计变更加以解决。qMajor quality concerns have not been resolved during the current production model year.在当前的生产模型年中，没有解决重大的涉及质量的问题。在当前的生产模型年中，没有解决重大的涉及质量的问题。1-60Expectations (Continued)期望（续）期望（续）lList of recommended actions and lessons learned is incorporated in the process (continuous improvement).将列出的将列出的“建议措施建议措施”和学到的经验和并在过和学到的经验和并在过程（持续改进）中。程（持续改进）中。lPoke-a-Yoke has been used in addressing corrective actions.制定纠正措施中使用防错方法（制定纠正措施中使用防错方法（Poke-a-Yoke）。）。1-61Process FMEA Checklist过程过程 FMEA 检查清单检查清单Process FMEA 1-62Measurement System Evaluation (15)测量系统评价（测量系统评价（15）This element assesses the variation of the measurement system, and determines whether it is acceptable for monitoring the production process.本要素评估测量系统的变差，确定是本要素评估测量系统的变差，确定是否可以接受测量系统监控生产过程。否可以接受测量系统监控生产过程。1-63Expectations期望期望lCorrelation standards are reached and agreed to with the customer for duplicate gauges or test equipment.已达到相同的测量或试验设备的相关标准和顾客的批准。已达到相同的测量或试验设备的相关标准和顾客的批准。lGauge instructions and visual aids to ensure appropriate use of gauge and test equipment in production.测量指导书和目视辅具确保在生产中适当的使用测量和测量指导书和目视辅具确保在生产中适当的使用测量和试验设备。试验设备。lAll measurement systems (gauges and test equipment) must be modified to reflect the latest engineering part level before the Production Trial Run. 在产品试生产前必须修改所有测量系统（测量和试验设在产品试生产前必须修改所有测量系统（测量和试验设备）以反映最新工程零件等级。备）以反映最新工程零件等级。 1-64Expectations (Continued)期望（续）期望（续）lThe user/customer must be given the opportunity to review and concur with the gauges and test equipment study results before the Production Trial Run. 产品试生产前使用者产品试生产前使用者/顾客顾客,必须有机会评审和批准测量和试验设备研必须有机会评审和批准测量和试验设备研究结果。究结果。lThe Measurement System Evaluation must be repeated and approved following all gauge and test equipment modifications.所有测量和试验设备更改后所有测量和试验设备更改后,必须重新进行测量系统评价并获得批准。必须重新进行测量系统评价并获得批准。 lThe Production Control Plan must align with the Measurement Systems Development plan.生产控制计划必须配合测量系统开发计划。生产控制计划必须配合测量系统开发计划。 lGauge Repeatability and Reproducibility studies must be conducted on all measurement systems.所有测量系统必须进行量具重复性和再现性研究。所有测量系统必须进行量具重复性和再现性研究。1-65Measurement System Evaluation Checklist测量系统评价检查清单测量系统评价检查清单1-66Pre-Launch Control Plan (16)试生产控制计划（试生产控制计划（16）This is a description of the dimensional measurements and material/functional in-process tests or checks that occur after prototype builds, but before full production 对发生在样件制造后，全面生产前的尺寸对发生在样件制造后，全面生产前的尺寸测量、过程中材料测量、过程中材料/功能试验或检查的描述。功能试验或检查的描述。1-67Expectations期望期望lLegitimate/appropriate inspection sample sizes, frequencies, control method, etc. inclusive to pre-launch phase of production are included.在生产的试生产阶段包含合理在生产的试生产阶段包含合理/适当的检验样本容量、频率、控制方法等。适当的检验样本容量、频率、控制方法等。lAll product & process characteristics for pre-launch control plans are identified and reviewed.确定和评审试生产控制计划的所有产品和过程特性。确定和评审试生产控制计划的所有产品和过程特性。lResults from the PBCP and DFMEA provide the outline for the Pre-Launch Control Plan.PBCP 和和 DFMEA 的结果提供了试生产控制计划的概要。的结果提供了试生产控制计划的概要。lThe Production Control Plan for the current production model is used to assist in the development of the Pre-Launch Control Plan if APQP Elements 8 and 13 have not been initiated.如果如果 APQP 要素要素 8 和和 13 还未启动，使用当前生产模式的生产控制计划协助开还未启动，使用当前生产模式的生产控制计划协助开发试生产控制计划。发试生产控制计划。1-68Pre-Launch Control Plan Checklist试生产控制计划检查清单试生产控制计划检查清单1-69Operator Process Instructions (17)操作工过程指导书（操作工过程指导书（17） lThis element describes the details of the controls and actions that operating personnel must perform to produce quality products.本要素描述操作人员为生产质量合格的产品所必须本要素描述操作人员为生产质量合格的产品所必须执行的控制和措施的详细情况。执行的控制和措施的详细情况。lThese instructions are divided into two major components:这些指导书分为两个主要部分：这些指导书分为两个主要部分：qDescription of the process过程描述过程描述 qOperator instructions操作供指导书操作供指导书1-70Expectations期望期望lA completed Operator Process Instructions package.完成的整套操作工过程指导书。完成的整套操作工过程指导书。lInstructions developed to be used during a production trial run to ensure the process performs as intended. 在产品试生产中使用开发的指导书以确保过程按预期执行。在产品试生产中使用开发的指导书以确保过程按预期执行。lOperator Process Instructions describe all process steps necessary to produce a quality product. The training instructions must include:操作工过程指导书描述了生产质量合格的产品所需的所有过程步骤。操作工过程指导书描述了生产质量合格的产品所需的所有过程步骤。培训指导书必须包括：培训指导书必须包括：qDetailed instructions详细的指导书详细的指导书qVisual aids目视辅具目视辅具qAny other quality materials necessary to support the production operator支持生产操作工所需的任何质量材料支持生产操作工所需的任何质量材料1-71Operator Process Instructions Checklist 操作工过程指导书检查清单操作工过程指导书检查清单1-72Packaging Specifications (18)包装规范（包装规范（18） This element describes the design and development of the end-item shipment packaging, including interior partitions.本要素描述产品最后出货包装的设计本要素描述产品最后出货包装的设计与开发，包括包装内部的分隔配置。与开发，包括包装内部的分隔配置。 1-73Expectations期望期望lPast issues on similar or surrogate packaging are discussed and resolved by the team.小组讨论和解决相似或替代的包装中过去发生的问题。小组讨论和解决相似或替代的包装中过去发生的问题。lCorrective actions exist for any packaging issues identified that affect product performance and characteristics.确定对于任何影响产品性能和特性的包装问题的现存纠正措施。确定对于任何影响产品性能和特性的包装问题的现存纠正措施。lSupplier and the receiving plant agree upon packaging requirements.供方和接收工厂就包装要求达成一致。供方和接收工厂就包装要求达成一致。lPackaging evaluation must test the packaging under the expected conditions of transport and material handling.包装评价必须在运输和材料处理期望的条件下测试包装包装评价必须在运输和材料处理期望的条件下测试包装lPackaging design must ensure that the product performance and characteristics will remain unchanged during packing, shipping, and unpacking.包装设计必须确保在包装、运输和打开包装过程中，产品性能和特包装设计必须确保在包装、运输和打开包装过程中，产品性能和特性保持不变。性保持不变。1-74Packaging Specifications Checklist包装规范检查清单包装规范检查清单1-75Module Introduction组成部分介绍组成部分介绍Product and Process Validation产品和过程确认产品和过程确认1-76Process Flow过程流程过程流程Feedback Assessment & Corrective Action反馈、评估和纠正措施反馈、评估和纠正措施Product & Process Validation产品与过程确认产品与过程确认Process Design & Devel opment过程设计和开发过程设计和开发Product Design & Development产品设计和开发产品设计和开发Prototype Build样件制造样件制造Plan & Define计划与定义计划与定义1-77Elements要素要素1.Production Trial Run产品试生产产品试生产 2. Production Control Plan 生产控制计划生产控制计划3. Preliminary Process Capability 初始过程能力初始过程能力4. Production Validation Testing生产确认试验生产确认试验5. Part Submission Warrant零件提交保证书零件提交保证书1-78Production Trial Run (19) 产品试生产（产品试生产（19）The Production Trial Run is a validation of the effectiveness of the manufacturing and assembly process, using production tooling, equipment, environment (including production operators), facilities, and cycle times.产品试生产是对制造和装配过程、使用的产品试生产是对制造和装配过程、使用的生产工具、设备、环境（包括生产操作工）生产工具、设备、环境（包括生产操作工）、设施和生产周期时间的有效性的确认。、设施和生产周期时间的有效性的确认。1-79Expectations期望期望lProduction facility, tooling, equipment, personnel, packaging, operators, PSW-1 parts, and Pre-Launch Control Plans are used on trial run.在试生产中使用生产设施、工具、设备、人员、包装、操作工、在试生产中使用生产设施、工具、设备、人员、包装、操作工、PSW-1 零件和试生产控零件和试生产控制计划。制计划。 lConcerns from the trial run that could prevent Run-at-Rate and capacity by date required are listed.列出在生产试运行中可能影响到列出在生产试运行中可能影响到“节拍生产节拍生产”与与“产能产能”的关注点。的关注点。lCorrective design and process actions are established.建立设计和过程纠正措施。建立设计和过程纠正措施。lThe Pre-Launch Control Plan is followed during the 1PP Production Trial Run.1PP 产品试生产中按照试生产控制计划进行。产品试生产中按照试生产控制计划进行。lThe Production Trial Run is used to confirm or add alignment between product and process characteristics.产品试生产用来在产品和过程特性之间进行确认或加强调整。产品试生产用来在产品和过程特性之间进行确认或加强调整。lOperator Process Instructions are followed during the Production Trial Run.在产品试生产中按照操作工过程指导书执行。在产品试生产中按照操作工过程指导书执行。1-80Element Checklist要素检查清单要素检查清单1-81Production Control Plan (20)生产控制计划（生产控制计划（20）lThe Production Control Plan is a written plan of the systems for controlling parts and processes during full production. 生产控制计划是在全面生产中控制零件和过程的系生产控制计划是在全面生产中控制零件和过程的系统的书面计划。统的书面计划。lThis document is based on the Pre-Launch Control Plan and is a living document that must be updated to reflect the additions and deletions of controls, based on experience gained in the process of producing parts.本文件基于试生产控制计划，是一份动态文件，必本文件基于试生产控制计划，是一份动态文件，必须基于从零件生产过程中获得经验，加以更新以反须基于从零件生产过程中获得经验，加以更新以反映对控制的增加和删减。映对控制的增加和删减。 1-82Expectations期望期望lReaction Plans specify corrective and containment actions necessary to avoid operating out-of-control or producing nonconforming products.反应计划明确规定纠正和限制措施，以避免操作失去控制或生产不合格产品。反应计划明确规定纠正和限制措施，以避免操作失去控制或生产不合格产品。lThe Production Control Plan is developed by a cross-functional team led by Manufacturing Engineering.由以制造工程为领导的横向职能小组开发生产控制计划。由以制造工程为领导的横向职能小组开发生产控制计划。lThe Production Control Plan follows the methodology documented in the AIAG/APQP and Control Plan Reference manual.生产控制计划遵循生产控制计划遵循 AIAG/APQP 和控制计划参考手册中提供的方法。和控制计划参考手册中提供的方法。lThe outcomes of the final PBCP provide the basis for the Pre-Launch Control Plan that in turn becomes the source for the Production Control Plan.最终最终 PBCP 的输出给试生产控制计划提供了基础，然后顺次成为生产控制计划的输出给试生产控制计划提供了基础，然后顺次成为生产控制计划的资源。的资源。 1-83Element Checklist要素检查清单要素检查清单1-84Preliminary Process Capability (21)初始过程能力初始过程能力 (21)The Preliminary Process Capability is a statistical study and assessment of the ability to produce product within specifications. 初始过程能力是对按照规范生产产品的初始过程能力是对按照规范生产产品的能力的统计研究和评估。能力的统计研究和评估。1-85Expectations期望期望lResults are analyzed to verify statistical stability as well as capability.分析结果以验证统计稳定性和能力。分析结果以验证统计稳定性和能力。lThe statistical and analytical techniques used to determine capability must be acceptable to the customer. 顾客必须接受用来确定能力的统计和分析工具。顾客必须接受用来确定能力的统计和分析工具。lPreliminary Process Capability studies must be performed in a way that aligns with the development of the Pre-Launch Control Plan.初始过程能力研究必须以配合试生产控制计划的开发的方式进行。初始过程能力研究必须以配合试生产控制计划的开发的方式进行。lPreliminary Process Capability studies must be completed:初始过程能力研究必须完成：初始过程能力研究必须完成：qThe customer must have the opportunity to review the studies before Production Part Approval.在生产件批准前，顾客必须有机会对研究进行评审。在生产件批准前，顾客必须有机会对研究进行评审。1-86Element Checklist要素检查清单要素检查清单1-87Production Validation Testing (22)生产确认试验（生产确认试验（22）lEngineering tests validate that the products made from the production tools and processes meet engineering specifications工程试验确认生产工具和过程制造的产品满工程试验确认生产工具和过程制造的产品满足工程规范。足工程规范。lInternal and external suppliers to Ford Motor Company must complete Production Validation Testing as a requirement of a PSW for 1PP 作为作为 1PP 的的 PSW 要求，福特汽车公司的内、要求，福特汽车公司的内、外部供方必须完成生产确认试验。外部供方必须完成生产确认试验。1-88Expectations期望期望lA PV Test Plan, including progress achieved, is established.建立建立 PV 试验计划，包括取得的改进。试验计划，包括取得的改进。lConcerns identified during PV Testing are assigned, resolutions are implemented, and solutions are tracked through closure of the concern.指出在指出在 PV 试验阶段识别的关注事项，解决方案被实施，而且跟踪解决方案，彻试验阶段识别的关注事项，解决方案被实施，而且跟踪解决方案，彻底解决了关注事项。底解决了关注事项。lAll parts, end-items or components, subsystems, and systems for PV Testing must be completed before the FEU Build according to the engineering specifications in the Pre-Launch Control Plan.必须在根据工程规范建立必须在根据工程规范建立PEU前，在试生产控制计划中完成所有零件，产品最前，在试生产控制计划中完成所有零件，产品最终阶段基组成部分，子系统和系统的终阶段基组成部分，子系统和系统的PV试验。试验。lAll customer-specified dimensional, material, functional, and reliability tests must be completed before Production Part Approval. 生产件批准前必须完成所有顾客规定的尺寸、材料、功能和可靠性试验。生产件批准前必须完成所有顾客规定的尺寸、材料、功能和可靠性试验。1-89Element Checklist要素检查清单要素检查清单1-90Part Submission Warrant (23) 零件提交保证书（零件提交保证书（23）lThe PSW ensures that engineering design requirements are met by the supplier, and that the process used is capable of producing parts that meet these requirements.PSW 确保供方满足工程设计要求，使用的确保供方满足工程设计要求，使用的过程有能力生产满足这些要求的零件。过程有能力生产满足这些要求的零件。 lThe PSW is the final sign-off verifying that the Production Part Approval Process (PPAP) has been followed.PSW 是按照生产件批准过程进行的最终批是按照生产件批准过程进行的最终批准验证。准验证。1-91Expectations期望期望lConcerns identified during PPAP and PSW have been resolved. 在在 PPAP 和和 PSW 中确定的关注事项已经被解决。中确定的关注事项已经被解决。lThe customers material IPD must be included in the suppliers timing plan.顾客材料顾客材料 IPD 必须包含在供方时间计划中。必须包含在供方时间计划中。lProduction Part Approval requirements must be completed prior to the IPD of the user plant.在使用者工厂在使用者工厂 IPD 前，必须完成生产件批准要求。前，必须完成生产件批准要求。lAll items of the AIAG/PPAP manual must be completed and the required documentation provided to the customer with PSW. AIAG/PPAP 手册中的所有条款必须完成，并随手册中的所有条款必须完成，并随 PSW 将要求将要求的文件提交给顾客。的文件提交给顾客。1-92Element Checklist要素检查清单要素检查清单1-93Module Introduction组成部分介绍组成部分介绍Status Reporting状态报告状态报告1-94Design and Manufacturing Reviews (5)设计和制造评审（设计和制造评审（5）This element describes the activities that are necessary to make the review meetings effective and:本要素描述了使评审会议更加有效和达到一下目的所需的活动：本要素描述了使评审会议更加有效和达到一下目的所需的活动：lPrevent problems and misunderstandings防止问题和误会发生防止问题和误会发生 lProvide a mechanism to monitor the programs progress and resolutions提供监控项目进展和结果的机制提供监控项目进展和结果的机制 lReview the product and manufacturing process detail (e.g., part drawings)评审产品和制造过程详细情况（例如：零件图样）评审产品和制造过程详细情况（例如：零件图样） lProvide data-driven verification of designs and processes提供针对设计和过程的以数据驱动的验证提供针对设计和过程的以数据驱动的验证1-95Expectations期望期望lReview APQP Status Reports during the Design Reviews and discuss relevant issues.在进行设计评审和讨论相关问题时评审在进行设计评审和讨论相关问题时评审 APQP 状态报告。状态报告。lResolve Design Feasibility concerns in time to support each builds IPD/MRD.及时解决涉及设计可行性的问题，以支持每个及时解决涉及设计可行性的问题，以支持每个 IPD/MRD。lAppraise the progress of the Design Verification Plan (unanticipated failure modes encountered during design verification testing must be addressed in the DFMEA).评价设计验证计划的进展（必须在评价设计验证计划的进展（必须在 DFMEA 中解决在审计验证试中解决在审计验证试验中遇到的非预期的失效模式）。验中遇到的非预期的失效模式）。lAssess the progress toward achieving reliability, quality, cost, and timing targets.根据达到的可靠度、质量、成本和时间目标评估进展。根据达到的可靠度、质量、成本和时间目标评估进展。1-96Element Checklist要素检查清单要素检查清单1-97