Download xls - APQP PPAP Evidence Workbook

APQP/PPAP External Supplier EvidenceSPECIAL CHARACTERISTICS

Satisfies Schedule A Deliverable #9 / Schedule B Element #4(Special Characteristics Cascaded to Suppliers)

FORD STAForm #:PP-S-F085GIS2 Classification: Proprietary

Page 1 of 35 Date Issued: 14-Jul-2009 Date Revised: 22-Sep-2010

Version 1

###

A. Program Information Date

Model Year 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

Program Code

Engineering Change Level

New TooledEnd Item(Y/N)

Special CharacteristicsPrototype All Measurement Results

Production Process Capability Results

Production Process Control Results

Formatted to Print US (Letter/Legal)

Import Special Characteristics

F9

5 digit GSDB code for Manufacturing Location

K12

(e.g. Print Revision Level)


Satisfies Schedule A Deliverable #9 / Schedule B Element #4(Special Characteristics Cascaded to Suppliers)



Version 1

(PPAP Ppk = 1.67 or Production Ppk = 1.33)B30:

5 digit GSDB code for Manufacturing LocationF9:

(e.g. Red Border Notice)G27:

(PPAP Ppk < 1.67 or Production Ppk < 1.33)G30:

(e.g. Print Revision Level)K12:


Satisfies Schedule A Deliverable #9 / Schedule B Element #4GPDS: Due at <PA>


Page 3 of 35Date Issued: 14-Jul-2009

Date Revised: 22-Sep-2010Version 1

Supplier Code:Part Number:

Approvers Source of Approval Evidence Name email Date

Ford Design & Release Engineer

Ford STA Engineer

Supplier Plant Quality Manager

Key: From DFMEA: From PFMEA:

YC CC

-- OS

YS SC

HI

Special Characteristic Totals: YC YS CC OS SC HINote: Auto calculation of totals 0 0 0 0 0 0

Special Characteristics Communication and Agreement

Num

ber

Characteristic Description Process Control Method1234

Ford Craftsmanship / Systems Engineering

Sev 9,10. Potential Critical Characteristic (YC)

Sev 9,10 (Part). Critical Characteristic (CC)

Sev 9,10 (Process). Operator Safety (OS)

Sev 5-8 Potential Special Characteristic (YS)

Sev 5-8 AND Occ 4-10 (or Ford D&R approval) Significant Characteristic (SC)

Sev 5-8 AND Occ 4-10. High Impact Characteristic (HI)

Specification & Tolerance

DFMEA Class

(YC, YS)

PFMEA Class

(CC, OS, SC, HI)

Pass through Characteristic?

(Y/N)

Supplier's Production

Manufacturing Operation Step

Identifier

For Special Characteristic definitions refer to Ford FMEA Handbook.

C4

Ford Corporate Procedure FAP 03-111 requires that special characteristics approval be recorded on from FAF 03-111-2 for external manufactured parts.

A5

Ford D&R Engineer approval mandatory

A6

Ford STA Engineer approval of Process Control Methods is mandatory for external supplier manufactured parts when requested by the Ford D&R Engineer

A7

Ford Craftsmanship / Systems Engineering approval is mandatory when requested by the Ford D&R Engineer

A8

External Supplier Plant Quality Manager approval mandatory for external supplier manufactured parts

B19

This column is required. A blank value in this column indicates the end of the list.


Instructions

FORD PRODUCT DEVELOPMENTGIS1 Item Number: N/AGIS2 Classification: Proprietary



ROLES AND RESPONSIBILITIESWhat Who When

Ford Product Development (PD) GPDS: 1 month before<FDJ>

Ford PD GPDS: <PA>

Supplier GPDS: <PA>

Supplier / Ford STA / Ford PD GPDS: <PA>

PROGRAM, SUPPLIER, PRODUCT, AND MANUFACTURING INFORMATIONTERMS AND DEFINITIONS

TERMS DEFINITIONS

A. Program Information

Model Year The model year the vehicle is releasedProgram Code

Product Name Product name is for the 'Vehicle' or 'PTO' name


Tier 1 Supplier Name Tier 1 Supplier responsible for the end item

Mfg. Site Code

Tier 1 Supplier Location Production manufacturing location of the Tier 1 Supplier

Part Name General name given to the end itemFord Part Number Ford designated component, sub-assembly or assembly number

New Tooled End Item (Y/N)

Drawing and Specification released to supplier (Deliverable #25)

Failure Mode Avoidance - Special Characteristics cascaded to suppliers (Deliverable #9) through the Special Characteristics Agreement Procedure (FAP 03-111)

Complete - Special Characteristics worksheet as evidence of special characteristics cascaded to suppliers (Deliverable #9)

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

The program code represents the Ford designation for the Vehicle or PTO program

Mfg. Site code is the Global Supplier Data Base (GSDB) Site Code containing 5-digits identifying the supplier manufacturing site

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:Example: WPTSE12178961024a) WPTS = Powertrain Systems Engine Mountsb) E = engineering releasec) 12178961 = WERS noticed) 024 = 24 WERS notices attached to this concern

Example: Engine NE01-E-10243645-011a) NE01 = Engineb) E = engineering releasec) 10243645 = WERS noticed) 011 = 11 Wers notices / releases attached to this concern.

Engineering Change Level - For Engineering Prototype Releases (X0, XM, M1)

Example: Engineering Prototype ReleasesGPIRS prototype release - AVTPROTO20100827- Engineering (engineering samples, xe parts ect … )CMMS prototype release - B2010EF16A252001- Material Control (components in support of engine builds prior to WERS )Is a component, sub-assembly or assembly with a new design for the given Program Code


Instructions




SPECIAL CHARACTERISTICS LISTSPECIAL NOTES

This information satisfies External Supplier APQP/PPAP Readiness Assessment - Schedule A Deliverable #9 / Schedule B Element #4

TERMS AND DEFINITIONSTERMS DEFINITIONS

Approvers

Ford Design & Release Engineer Ford D&R Engineer approval is mandatory per FAP 03-111

Ford STA Engineer


Supplier Plant Quality Manager

Source of Approval Evidence

Characteristic Description Print specification item to be measured


DFMEA Classification (YS, YC)

PFMEA Classification (CC, SC, HI)

Process Control Method

Pass Through Characteristic (PTC)? (Y/N)

Supplier's Manufacturing Operation Identifier

Include all special characteristics

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 approval is mandatory when requested by the Ford D&R Engineer per FAP 03-111

External Supplier Plant Quality Manager approval mandatory for external supplier manufactured parts per FAP 03-111

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.

Specification for the characteristic defined on the design record (print or E.S.) including the tolerance requirement

Classification as identified on the DFMEA as "Potential Critical Characteristic" (YC) or "Potential Signficant Characteristic" (YS).

Classification as identified by the PFMEA. Other characteristics are print requirements that are not identified as Special Characteristics

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.

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). PTC are generally finished characteristics with part print 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

APQP/PPAP External Supplier EvidenceSpecial Characteristics

Process Flow



Version 1

Lead for activity When (VO/PTO) Input Process Output

Ford PD System design requirements

Ford PD GPDS: <PA>

Design Record

DFMEA/ PFMEA

Engineering SpecificationsFAP 03-111

Supplier GPDS: <PA>FAF 03-111-2

Priority Supplier ListProgram STA New Tooled End Item Priority Supplier

Site Readiness or Non-priority Supplier

Part Criticality

Program Induced Risk

GPDS: VP

Ongoing

GPDS: 1 month before FDJ

Drawing and Engineering Specifications

Special Char Agreement Form or FAF 03-111-2

Utilize import function macro or manual data entry

EXTERNAL SUPPLIER SPECIAL CHARACTERISTICS worksheet

Initial selection of Priority sites will

occur by Unit <PTC> /

<PTCC>+90 Days (unless otherwise

identified)

Ford PD / Site STA / Supplier

EXTERNAL SUPPLIER SPECIAL CHARACTERISTICS worksheet

Ford PD / STA / Supplier


Falure Mode Avoidance - Special Characteristics cascaded to suppliers (Deliverable #9) through the Special Characteristics Agreement procedure

FAP 03-111

Priority Supplier

Results maintained with APQP records

and next deliverable evidence form

Review the results of the Special Charcteristics list

during GPDS on-site visit #1

Special Charactreistics

Modified

Update External Supplier Characteristics worksheet

Yes

No

Yes

No

SPECIAL CHARACTERISTICS

DATA STORAGE AND MANAGEMENT REVIEW

Complete - Special Characteristics worksheet with special characteristics cascaded to suppliers (Deliverable #9)

APQP/PPAP External Supplier EvidenceSpecial Characteristics

Process Flow



Version 1

Supplier Ongoing EXTERNAL SUPPLIER SPECIAL CHARACTERISTICS worksheet

Update External Supplier Characteristics worksheet


Satisfies Schedule A Deliverable #9 / Schedule B Element #4GPDS: Due at <PA>




Approvers Source of Approval Evidence Name email Date

Ford Design & Release Engineer FAF 03-111-2 John Young 1-Jun-09

Ford STA Engineer FAF 03-111-2 Ben Anderson 2-Jun-09

FAF 03-111-2 Michelle Darwin 1-Jun-09

Supplier Plant Quality Manager FAF 03-111-2 Sam Miller 15-Jun-09

Key: From DFMEA: From PFMEA:

YC CC

-- OS

YS SC

HI

Special Characteristic Totals: YC YS CC OS SC HINote: Auto calculation of totals 4 6 4 0 6 0

Special Characteristics Communication and Agreement

Num

ber

Characteristic Description Process Control Method

1 Hole size YC CC Air Gage No 10

2 Hardness 80 - 120 BHN YS SC Equotip Yes 503 Material Yield Strength 207 Mpa min YC CC tensile bars Yes 50

4 276 Mpa min YC CC tensile bars Yes 50

5 Material Elongation 7% min YC CC tensile bars Yes 506 Press - in load UCA min 29 KN YS SC Load cell Yes 407 UCA Bore diameter 10 ± 0.5 mm YS SC CMM No 308 UCA Position 0.5 mm max YS SC CMM No 309 UCA Roundness max 0.5 YS SC tallyrand No 30

10 Bushing span 7.36-7.49 mm YS SC optical comparator No 30

[email protected]

[email protected]


[email protected]

[email protected]

Sev 9,10. Potential Critical Characteristic (YC)

Sev 9,10 (Part). Critical Characteristic (CC)

Sev 9,10 (Process). Operator Safety (OS)

Sev 5-8 Potential Special Characteristic (YS)

Sev 5-8 AND Occ 4-10 (or Ford D&R approval) Significant Characteristic (SC)

Sev 5-8 AND Occ 4-10. High Impact Characteristic (HI)


DFMEA Class

PFMEA Class

Pass through Characteristic?

(Y/N)

Supplier's Production

Manufacturing Operation Step

Identifier

10.5 +/- 0.5mm

Material Ultimate Tensile Strength

For Special Characteristic definitions refer to Ford FMEA Handbook.

mailto:[email protected]




A2

Ford D&R Engineer approval mandatory

A3

Ford STA Engineer approval of Process Control Methods is mandatory for external supplier manufactured parts when requested by the Ford D&R Engineer

A4

Ford Craftsmanship / Systems Engineering approval is mandatory when requested by the Ford D&R Engineer

A5

External Supplier Plant Quality Manager approval mandatory for external supplier manufactured parts

B16

This column is required. A blank value in this column indicates the end of the list.

APQP/PPAP External Supplier EvidencePROTOTYPE / ALL MEASUREMENT RESULTS

Satisfies Schedule A Deliverable #23 / Schedule B Element #17GPDS: Due at <VP>

FORD PROUCT DEVELOPMENTGIS1 Item Number: N/AGIS2 Classification: Proprietary


Version 1

Supplier Code:Part Number:

Summary Results 1 2 3

Nu

mb

er

Characteristic Specification X-Bar Range Comments / Actions Taken

1234

DFMEA Classification

(YC, YS)

PFMEA Classification (CC, SC, HI,

Other)

On Prototype Control Plan (Y/N)


Inspection Frequency

Quantity Inspected

(pcs.)

All PartsMeet

Specification(Y/N)

ActualResults

ActualResults

ActualResults

Print Cover Page &

Executive Summary

Evidence Form

N4

This field may be updated to reflect the actual individual part identification used (e.g. individual serial numbers for each part)

O4


P4



Satisfies Schedule A Deliverable #23 / Schedule B Element #17GPDS: Due at <VP>

FORD PROUCT DEVELOPMENTGIS1 Item Number: N/AGIS2 Classification: Proprietary


Version 1

4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

ActualResults

ActualResults

ActualResults

ActualResults

ActualResults

ActualResults

ActualResults

ActualResults

ActualResults

ActualResults

ActualResults

ActualResults

ActualResults

ActualResults

ActualResults

ActualResults

ActualResults

ActualResults

ActualResults

ActualResults

ActualResults

ActualResults

ActualResults

Q4


R4


S4


T4


U4


V4


W4


X4


Y4


Z4


AA4


AB4


AC4


AD4


AE4


AF4


AG4


AH4


AI4


AJ4


AK4


AL4


AM4


APQP/PPAP External Supplier EvidencePRODUCTION PROCESS CAPABILITY RESULTS

Satisfies Schedule A Deliverable #38 / Schedule B Element #35GPDS: Due at <TT>

FORD STA Form #: PP-S-F085GIS2 Classification: Proprietary



Supplier Code:

Part Number:

Characteristic Gauge R&R Process Control Distribution Analysis Capability Results

Num

ber

Characteristic Specification Actions Taken

Study Parameters


(YC, YS)


Other)

On Production

Control Plan (Y/N)

Manufacturing Operation Identifier

Pass Through Characteristic

(PTC) (Y/N)

Error Proofed

(Y/N)


Characteristic dependent on sub-supplier

(Include PTC)(Y/N)

Population Size

Sample Size

% Study

Variation(Target ≤ 10%)

% Tolerance(Target ≤ 10%)

Demonstrated Method of

Stability and Control

Evidence: Number of

Points Not in Control

Distribution Type

Resultant P-value or

Best Fit Coefficient

PPAP PpkValues

Production PpkValues

Meets Capability Requirement

PPAP Ppk ≥ 1.67Production Ppk ≥ 1.33

(Y/N)

Print Cover Page &

Executive Summary Evidence

Form


Instructions



Version 1

ROLES AND RESPONSIBILITIESWhat Who When (Vehicle Operations) When (VP Powertrain) When (X0, XM, M1 - Powertrain Only)

GPDS: 1 month before<FDJ>

Prototype Inspection Requirements Identified Ford PD N/A

Ford PD GPDS: <PA>

Ford PD GPDS: <FDJ>

Ford PD GPDS: <FDJ>

Prototype Control Plan Completed (Deliverable #20) Supplier / Ford PD GPDS: <FDJ> uDC N/A

Produce Prototype Parts Supplier GPDS: In support of <VP> Build

Supplier GPDS: In support of <VP> Build GPDS: In support of uVP IPD

Supplier

Review the results of the Prototype Parts produced

Ford PD

Ford PD

Supplier GPDS: <VP> IDP Promise Date


Ford Product Development (PD)

<uPA> to 1 month after <FDJ> based on the Plan for Every Part

Within 2 weeks after Build Phase DJ eventPO-S-25 for X0PO-T-55 for XMPO-T-70 for M1

<uPA> to <uDC>PP-U-50 for VP

<uPA> to 1 month after <FDJ> based on the Plan for Every PartPP-S-05 for X0PP-T-20 for XMPP-T-35 for M1

Failure Mode Avoidance - Special Characteristics cascaded to suppliers (Deliverable #9) through the Special Characteristics Agreement (FAP 03-111)

uM1DJ to uDC based on the Plan for Every Part

see terms and Definitions below for applicability per Powertrain Unit build phase

Prototype Tool Orders release to suppliers in support of Prototype Build Phase (Deliverable #21)

<uPA> to uDC based on the Plan for Every Part

Per Powertrain Unit Build phase based on the Plan for Every Part

Prototype Parts order with quantity and timing to suppliers in support of Prototype Build Phase (Deliverable #22)

<uPA> to uDC based on the Plan for Every Part

<uPA> to uDC based on the Plan for Every PartPP-S-05 for X0PP-T-20 for XMPP-T-35 for M1

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

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

GPDS: Prior to shipment of <VP> 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)




Prototype Parts achieved 100% of the required print specifications identified for each build phase




Any exception to the design specification requires an approved part design deviation notice (Must use e-Warrant for Powertrain. Other (e.g. WERS Alert for vehicle) prior to shipment.




Supplier Ships part to meet in plant date (IPD) commitment for the Prototype Build Phase

GPDS: Supplier Promise Date must support uVP IPD

GPDS: Supplier Promise Date must support rough or finished Powertrain Unit build phase IPD(s)

Print Instructio

ns, Process

Flow, and

Examples


Instructions



Version 1

PROGRAM, SUPPLIER, PRODUCT, AND PROTOTYPE MANUFACTURING INFORMATION

TERMS AND DEFINITIONSTERMS DEFINITIONS


Model Year The model year the vehicle is releasedProgram Code The program code represents the Ford designation for the Vehicle or PTO programProduct Name Product name is for the 'Vehicle' or 'PTO' nameBuild Event The build event for the GPDS program milestone under reviewRequired In-Plant Date

Required Ford determined number of vehicles/powertrains to be built per GPDS build eventProduced Supplier number of vehicle/powertrain sets built per ford the GPDS build event


Tier 1 Supplier Name Tier 1 Supplier responsible for the end itemMfg. Site CodeTier 1 Supplier Location Production manufacturing location of the Tier 1 SupplierSupplier Delivery Promise DatePart Name General name given to the end itemFord Part Number Ford designated component, sub-assembly or assembly number

New Tooled End Item (Y/N) Is a component, sub-assembly or assembly with a new design for the given Program CodeC. Prototype Manufacturing Information

Manufacturing Site Location where the end item were manufactured for the build eventCarry-over production site Same location as previous model year or common platformNew Production site New facility designated as production intent to produced the end item Prototype site

Manufacturing ProcessCarry-over process Same manufacturing process as previous model year or common platformNew production processPrototype process

Tooling TypeCarry-over production tooling Same manufacturing tooling as previous model year or common platformNew Production ToolingPrototype/ soft tooling

D. Deviations

Prototype Parts achieved 100% of the required print specifications and delivery timing

Part Deviation Notice (e.g. Red Border Notice)Quality or Timing Categorize the reason why the Ford order requirements cannot be met Engineering Notification

EXTERNAL SUPPLIER PROTOTYPE / ALL MEASUREMENTS RESULTS PAGESPECIAL NOTES

Provide the print specifications data item by item

TERMS AND DEFINITIONS

TERMS DEFINITIONS

Characteristic (For VP Builds and beyond)Characteristic (X0, XM and M1)Specification Specification for the inspection item defined on the design record (print or E.S.)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-barResults: Range Calculates of the difference between the largest and smallest data valuesAll Parts Meet Specification (Y/N)Comments / Actions TakenData Reporting

information for the build event

The required date Ford designates all components received in-plant at the Ford designated Build Event Quantity

Planned quantity of vehicles or powertrain quantity for the Build Event. Powertrain should include internal Powertrain Dyno requirements which are not covered in vehicle build.

Mfg. Site code is the Global Supplier Data Base (GSDB) Site Code containing 5-digits

The date entered into GPIRS or VPP by the supplier when the end item will be received In-


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 authorityEngineering Change Level - For Engineering Prototype

Releases (X0, XM, M1)CMMS manual powertrain prototype release (used by PPM) Example: B2010EF16A252001

Facility responsible for producing the end item for the specific build events (i.e. not Manufacturing process for the end item producing for the build event. The scope of information is the end item manufacturing process(es) only

At least one operation contains new manufacturing process(es) to produced the end item At least one operation contains a prototype process(es) to produced the end item for the Manufacturing tooling for the end item producing for the specified build event. The scope of information is the end item manufacturing process(es) only

At least one operation contains new manufacturing tooling to produced the end item or the 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)

None required, all delivered parts meet 100% of the requirements in time to support the build

A Supplier notification that they cannot meet the Ford order requirements for either quality

Provide the Deviation Notification: approved Alert number for the specification deviations. Note: North American Powertrain deviations for prototype builds prior VP are identified on the e-Warrant.

This information satisfies External Supplier APQP/PPAP Readiness Assessment - Schedule A Deliverable #23 / Shedule B Element#17Report data for all required print specifications, engineering requirements and/or process characteristics. Supplier must have all information available for review. For presentations and the executive print summary to Ford management sort to put the 20 most important characteristics at the top of the completed template. Early Powertrain prototype builds (X0 - M1): Suppliers will report the results of the prototype measurements using this format to demonstrate compliance of 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.

All required print specification, engineering requirements and/or process characteristics All required print specification, engineering requirements and/or process characteristics as agreed upon by the Product Engineer and the Supplier are to be measured and reported on

Classification as identified on the DFMEA as "Potential Critical Characteristic" (YC) or Classification as identified by the PFMEA. Other characteristics are print requirements that How are the parts inspected or measured as defined in the Prototype Control Plan? If the How are the parts inspected or measured as agreed upon with the Product Engineer for Is the characteristic contained on the prototype control plan of the reporting supplier for the How many pieces are contained in the inspection results data set? Prototype part quantity Calculated average (mean) from inspection results data set. The mean (arithmetic average)

All parts measured meet the characteristic specificationMake comments specific to the inspection item and include the action plan if the inspection The supplier must complete the measurements and report for all characteristics.


Instructions

FORD STAForm #: PP-S-F085GIS2 Classification: Proprietary


Version 1



Ford PD GPDS: <PA>

Supplier / Ford STA / Ford PD GPDS: <TT>

Supplier / Ford STA GPDS: <TT>

Supplier

Perform inspection method and collect data for analysis Supplier

Supplier

Supplier

Perform capability calculation using Ppk Formula Supplier

Supplier

Supplier / Ford STA

Supplier / Ford STA On-going



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)

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.

GPDS: <TT> andGPDS: <PP>


Analyze data set for statistical process control of the specified special characteristics


Analyze the data set for normality (normal distribution) of the specified special characteristics



Completes the EXTERNAL SUPPLIER PRODUCTION PROCESS CAPABILITY RESULTS proforma

GPDS: <TT> andGPDS: <PP> and as requested

Initial process capability results (Ppk) have achieved results ≥1.67


Production process capability results (Ppk) have achieved results ≥ 1.33


Instructions



Version 1


TERMS DEFINITIONS


Model Year The model year the vehicle is released

Program Code


Build Event The build event for the GPDS program milestone under review



Mfg. Site Code

Tier 1 Supplier Location Production manufacturing location of the Tier 1 SupplierPhase PPAP Status:

Promise Date

PPAP Approval Date Completed PPAP approval for the Phase PPAP DeliverablesPart Name General name given to the end item

Ford Part Number Ford designated component, sub-assembly or assembly number


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

Manufacturing Process

Carry-over process Same manufacturing process as previous model year or common platform

New process



The Phase PPAP Status: date entered into VPP or MPP by the supplier for PPAP commits for the Phase PPAP deliverables

Promise date entered into VPP or MPP by the supplier for PPAP commits for the Phase PPAP deliverables


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 authorityb) 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 the part)Engineering Change Level is also reported on the PSW.

Example: WPTSE12178961024a) WPTS = Powertrain Systems Engine Mountsb) E = engineering releasec) 12178961 = WERS noticed) 024 = 24 WERS notices attached to this concern

Is the component, sub-assembly or assembly a new design for the given Program Code?

Facility responsible for producing the end item for the specific build events (i.e. not production intent)

Manufacturing process for the end item producing for the build event. The scope of information is the end item manufacturing process(es) only

At least one operation contains new manufacturing process(es) to produced the end item for the specific build event (i.e. production intent process)


Instructions



Version 1

Prototype process

Tooling Type

Carry-over tooling Same manufacturing tooling as previous model year or common platform

New Production Tooling

Prototype/ soft tooling

Process Capability Data Represent

One Production Stream

All Production Streams

D. Deviations

Engineering notification

At least one operation contains a prototype process(es) to produced the end item for the specific build event

Manufacturing tooling for the end item producing for the specified build event. The scope of information is the end item manufacturing process(es) only

At least one operation contains new manufacturing tooling to produced the end item or the specific build event (i.e. production intent process)

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)

Demonstrate that Initial Process Capability studies have been completed using Run-at-Rate parts from the same production stream

Demonstrate that separate Initial Process Capability studies have been completed using Run-at-Rate parts from each production stream.

None required, production process is capable (PPAP Ppk ≥ 1.67 or Production Ppk ≥ 1.33)

Parts achieved PPAP Ppk ≥ 1.67 or Production Ppk ≥ 1.33 from the production streams studied

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.

Provide the Deviation Notification. Example: approved WERS Alert number for the specification deviations with the interim PPAP submission.


Instructions



Version 1

EXTERNAL SUPPLIER PRODUCTION PROCESS CAPABILITY RESULTS PAGESPECIAL NOTES

This information satisfies External Supplier APQP/PPAP Readiness Assessment - Schedule A Deliverable #38 / Schedule B Element #35

When specified by Ford, submit completed process control capability evidence at a weekly frequency from MP1 to MP1 + 90 days TERMS AND DEFINITIONS

TERMS DEFINITIONS

Characteristic Print specification item to be measured

Specification Specification for the characteristic defined on the design record (print or E.S.)


PFMEA Classification (CC, SC, HI, Other)

On Production Control Plan (Y/N)


Pass Through Characteristic (PTC) (Y/N)

Error Proofed (Y/N)


Study Parameters

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?

Gauge R&R Repeatability and reproducibility of the measuring system

% Study Variation

% Tolerance Measurement Error as a percentage of Tolerance

Demonstrated Method of Stability and Control




Is the characteristic contained on the production control plan of the reporting supplier?

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

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). PTC are generally finished characteristics with part print tolerances or specifications that are not verified in house or at the supplier, and where defective parts can be passed on to the customer (defined as Vehicle Operations or the buying public).Examples may include:Engine ThermostatsTorque Converter studsCylinder Head – FEAD mounting holesTransmission Case – Starter mounting holesThreaded hole supplied by an external supplier, not used in Powertrain Plant

Does the characteristic have an error proof method? This is required for CCs and Ford identified PTCs.


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 refers to the sample size and population where the capability study data is collected

Measurement System Standard Deviation as a percentage of Total Observed Process Standard Deviation (using Standard Deviation)

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


Instructions



Version 1

Evidence: Number of Points Not in Control

Distribution Analysis

Distribution Type

Resultant P-value or Best Fit Coefficient

Results: PPAP Ppk or Production Ppk

Where standard deviation is defined as:

Comments / Action TakenData Reporting

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.

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

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.

Report the distribution fit statistical hypothesis p-value or the best fit coefficient from the distribution identification fit technique as appropriate

Process Capability Formula: Ppk Example below is a calculation for a normal distribution(Other capability distribution calculations may be applied where appropriate per ISO 21747)

Meets Capability RequirementPPAP Ppk ≥ 1.67Production Ppk ≥ 1.33 (Y/N)

Conditional formatting will automatically populate the cell based on the process capability results meeting the PPAP Ppk requirement or the Production Ppk requirements. PPAP Ppk ≥ 1.67Production Ppk ≥ 1.33 Note: Capability can NOT be determined until tConditional formatting will identify through field transition to clear when comments for action taken is needed based on meeting the capability The supplier must complete the measurements and report for all special characteristics. The first 20 characteristics are selected for report out to Ford management

Ppk=min(USL−X )

3 σ̂ S or

( X−LSL )3 σ̂ S

Ppk: { σ̂ S=√∑i=1

n (X i−X )2

n−1¿


Process Flow



Version 1

Lead for activity When (VO/PTO) Input Process Output

Ford PD System design requirements

Ford PD GPDS: <PA>

Design Record

DFMEA

Engineering SpecificationsFAP 03-111

Ford PD GPDS: FDJ Program requirements Prototype Tool Order

Ford PD GPDS: FDJ Program requirements

Supplier / Ford PD GPDS: FDJ

Prototype Control Plan

Supplier

Supplier

Supplier X-Bar

Range

GPDS: 1 month before FDJ

Drawing and Engineering Specifications

Special Char Agreement Form or FAF 03-111-2

Prototype Parts Order: quantity and timing

Prototype Parts Order: quantity and timing

Including process parameter, gauges, inspection methods, tolerances, reaction plan(s) in the Control Plan.

Special Char Agreement (FAF 03-111-2)

GPDS: In support of VP Build


Verify that gauges and test equipment are accurate, repeatable, and reproducible with adequate discrimination

Prototype part inspection and measurement data





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)

Quantity Inspected (pcs)Corrective action for non-conformancing

product

PROTOTYPE CONTROL PLAN

X-Bar

Range

RESULTS

PRODUCE PROTOYPE PARTS


Process Flow



Version 1

Supplier



Part Criticality


Ford PD

Supplier

GPDS: Prior to shipment of parts

for VP MRD


EXTERNAL SUPPLIER PROTOTYPE INSPECTION RESULTS proforma

Include COMMENTS / ACTIONS TAKEN when all parts do not meet specification for the given characteristic


occurPTO - 2months before Unit PTC

UN - PTCCUP - PTC/M-1DJ (unless otherwise

identified)

Ford PD /Supplier Technical Assistance


for VP MRD

EXTERNAL SUPPLIER PROTOTYPE / ALL MEASUREMENT RESULTS

EXTERNAL SUPPLIER PROTOTYPE INSPECTION RESULTS with team input


for VP MRD


Agreement to ship the prototype parts

Any exception to the design specification requires an approved part design deviation notice (e.g. WERS Alert) prior to shipment.


for VP MRD


Completed EXTERNAL SUPPLIER PROTOTYPE / ALL MEASUREMENT RESULTS

Prototype Parts achieved 100% of the required print specifications.

Review the results of the Prototype Parts produced during GPDS on-

site visit #2

YesYes

Update evidence form updated with Alert Number

No Ford PD Approves part deviation notice

No

PROTOTYPE DATA REVIEW

Range

Priority Supplier

Yes

No

Completes the EXTERNAL SUPPLIER PROTOTYPE / ALL MEASUREMENT RESULTS proforma as evidence of Deliverable #23


Process Flow



Version 1

Supplier GPDS: VP MRD



Part Criticality


Ford PD / Site STAGPDS: VP

Program STAGPDS: VP

Site STA GPDS: VP

Site STAGPDS: VP

Ford ManagementGPDS: VP

Agreement to ship the prototype parts


occur by Unit <PTC> /

<PTCC>+90 Days (unless otherwise

identified)

EXTERNAL SUPPLIER PROTOTYPE INSPECTION RESULTS

Sort data into top 20 most important characteristics(e.g. importance to part functionality)

EXTERNAL SUPPLIER PROTOTYPE / ALL MEASUREMENT RESULTS (Top 20 Characteristics)

Functional area requested supplier proformas

Functional area EXTERNAL SUPPLIER PROTOTYPE / ALL MEASUREMENT RESULTS

All functional area requested supplier proformas All functional area EXTERNAL

SUPPLIER PROTOTYPE / ALL MEASUREMENT RESULTS

Suppler Ships part to meet in plant date (IDP) commitment for VP Build

Priority Supplier

Results maintained with APQP records

Review the results of the Prototype Parts produced

during GPDS on-site visit #2

Program ReviewRequested

Select 'Print Cover Page & Executive Summary Evidence

Form' button to print top 20 characteristics

Send file to STA Program team

Yes

No

Ford Management review of data & feed back actions to STA

Engineer

Yes

No



Satisfies Schedule A Deliverable #23 / Schedule B Element #17(Prototype parts Achieved 100% of Required Print Specifications)

FORD PRODUCT DEVELOPMENTForm #:PP-S-F085GIS2 Classification: Proprietary

Date Issued: 14-Jul-2009 Date Revised: 22-Sep-2010

Version 1

###A. Program Information Date 13-Jul-09

Model Year Product Name Build Event2011 U502 Explorer VP 17-Jul-09 17-Aug-09 Required 94

Produced 150


Tier 1 Supplier Name Site Code Tier 1 Supplier LocationCMI - Muskegon U044M Muskegon, MI USA

City / Region / Country


REAR KNUCKLE ASSEMBLY BB53-5B758(9)-AC WPTSE12178961024 Y


Manufacturing Site Manufacturing Process Tooling Type

Carry-over production site CMI - Muskegon Carry-over production process Carry-over production tooling

New production site New production process New production tooling

Prototype site Prototype process Prototype / soft tooling

D. Deviations

Prototype / All Measurement Results Reason Alert #

Timing

Quality or Timing

Program Code

Required In-Plant

Date

Supplier Delivery Promise

DateBuild Event

Quantity


New TooledEnd Item (Y/N)

Check One

Check One

Check One

None required, all delivered parts meet 100% of the requirements in time to support the build

Part Deviation Notice

Engineering Notification

F9


K12


G27

(e.g. Red Border Notice)


Satisfies Schedule A Deliverable #23 / Schedule B Element #17(Prototype parts Achieved 100% of Required Print Specifications)

FORD PRODUCT DEVELOPMENTForm #:PP-S-F085GIS2 Classification: Proprietary


Version 1







Satisfies Schedule A Deliverable #23 / Schedule B Element #17 GPDS: Due at <VP>



Version 1

Num

ber

Characteristic Specification

Results

Comments / Action PlanX-Bar Range

1 Material Yield Strength YC CC 207 Mpa min tensile bars Y 4 218 3 Y none required

2 YC CC 276 Mpa min tensile bars Y 4 290 10 Y none required

3 Material Elongation YC CC 7% min tensile bars Y 4 11 2 Y none required

4 Press - in load UCA YS SC min 29 KN Load cell Y 150 35 KN 5 KN Y none required

5 UCA Bore diameter YS SC 10 ± 0.5 mm CMM Y 150 10.2 0.2 Y none required

6 UCA Position YS SC 0.5 mm max CMM Y 150 0.75 0.25 Y none required

7 UCA Roundness YS SC max 0.5 tallyrand Y 150 0.22 0.4 Y none required

8 Bushing span YS SC 7.36-7.49 mm optical comparator Y 150 7.44 0.04 Y none required

9 Shield diameter other 19.0 +0.2 / -0.1 CMM Y 150 18.99 0.14 Y none required

10 other 9.2 +0.1/-0.2 Caliper Y 150 9.17 0.24 Y none required

11 other 14.6 ± .1 CMM Y 150 14.61 0.03 Y none required

12 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


(YC, YS)

PFMEA Characteristic Classification (CC, SC, HI,

Other)

Inspection Method

On Prototype

Control Plan (Y/N)

Quantity Inspected

(pcs.)

All PartsMeet Specification

(Y/N)


Inside side support dimensionBearing bolt hole diameter

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


Process Flow



Version 1

When (VO/PTO) Input Process Output

Characteristics isted

Specificaiton limits

Ford PD GPDS: <PA>DFMEA Characteristic Classification

DFMEA PFMEA Characteristic Classification

PFMEA

Ford PD Production Control Plan Linkage


Pass through characteristics identified Error Proof methods

Inspection methods and gauges

Run-at-rate

Parts available for measurement

Capacity Analysis Report (CAR)

Lead for activity

Ford Product Development

GPDS: 1 month before FDJ Drawing and Specification released to

supplier (Deliverable #25)

Failure Mode Avoidance - Special Characteristics cascaded to suppliers (Deliverable #9) through the Special Characteristics Agreement within this workbook or FAF 03-111-2

GPDS: TT / Unit <TT>


Supplier / Ford STA


Supplier / Ford STA / Ford PD


Inspection methods, gauges, and test equipment

Supplier / Ford STA / Ford PD


Sub-supplier process flow / PFMEA / control plan

Sub-supplier control plan contains process control methods

Supplier / Ford STA

Phase 0: Prior to TT MRD/Unit <TT> MRD (VO/PTO) and Phase II: PP MRD/Unit <PP> MRD (VO/PTO)

Conduct a valid production trial run(s) per the Phase PPAP requirements. (i.e. Run-at-Rate completed on production homeline equipment, process, and tooling)

Phase 0 (Deliverable #36) and Phase II (Deliverable #42) for GPDS.

Supplier / Ford STA

GPDS: TT / Unit <TT> and

GPDS: PP MRD / Unit <PP> MRD

Measurement System Analysis - Gauge R&R Measurement System Analysis

Gauge R&R results ≤ 10% per PPAP Ford customer specifics (Deliverable #30)

Characteristic and Specification

DFMEA and PFMEA Characteristic Classification

(CC, SC, HI, Other)

%Study Variation

Pass Through Characteristic (PTC) and Error Proofed

Remove special causes and

implement corrective actions

On Production Control Plan (Y/N) and Manufacturing Operation Identifier

Process control method

Population Size

CHARACTERISTICS

GAUGE R&R

Sample Size

%Tolerance

Characteristic dependent on sub-supplier (Include PTC)

STUDY PARAMETERS


Process Flow



Version 1

Supplier

SupplierStatistical software (e.g. MINITAB)

Normality tests

Distribution TypeResultant P-Value

Distribution ID fit statistical analysis

Known Distribution List


Ppk calculation


Ppk calculation Meets PPAP Ppk of 1.67

Or Action Taken

Meets Production Ppk of 1.33Or Action Taken

SupplierStatistical software (e.g. MINITAB)Ppk calculation

(Post PPAP)

Supplier

Stable and in-control statistical process control tools (Xbar and R or Xbar and S, or IM-R or other method)



Statistical process control tools (Xbar and R or Xbar and S, or IM-R or other method)



Data transformation method (Box-Cox or Johnson Transformations) as needed

Best Fit Coefficient for alternative distributions



PPAP Ppk requirement OR Production Ppk requirementPending PPAP or PPAP previously

achieved



On going production



EXTERNAL SUPPLIER PRODUCTION PROCESS CAPABILITY RESULTS

Completed EXTERNAL SUPPLIER PRODUCTION PROCESS CAPABILITY RESULTS

Include ACTIONS TAKEN when capability requirements for the given characteristic are not met

Yes

Evidence demonstrates stability & control

Data is normally distributed

DISTRIBUTION ANALYSIS

Known Distribution ID

Fit

No

Perform capability calculationusing Ppk Formula

PPAP Ppk process capability meets 1.67 Requirement

Production Ppk process capability meets 1.33 Requirement

Mistake-proof modified control method is in place if the process capability does not

meet the requirements

Identified special cause remove from data set

PROCESS CONTROL

No

Yes

Yes

No

Yes

No

CAPABILITY RESULTS

YesNo

No

Yes

No

Yes

Non-normal data is

transformed

No

Yes

Capability Study is evidence for PPAP

Report results on EXTERNAL SUPPLIER PRODUCTION PROCESS CAPABILITY RESULTS proforma


Process Flow



Version 1

Priority Supplier ListNew Tooled End Item Priority Supplier Site Readiness Non-priority SupplierPart Criticality

Program STA Program Induced Risk

Site STA

Ford PD

Program STA Programs request supplier proformas

SupplierPrograms request supplier proformas

Site STA

MP1 + 90 DAYS As requested by Ford Program


occurPTO - 2months before Unit PTC

UN - PTCCUP - PTC/M-1DJ (unless otherwise

identified)



Conduct a valid production trial run(s) per the Phase PPAP requirements. (i.e. Run-at-Rate completed on production homeline equipment, process, and tooling)









Sort data into top 20 most important characteristics(e.g. importance to part functionality)

Functional area EXTERNAL SUPPLIER PRODUCTION PROCESS CAPABILITY RESULTS (sort Top 20)

Ford Management



All functional area requested supplier proformas All functional areas\ EXTERNAL

SUPPLIER PRODUCTION PROCESS CAPABILITY RESULTS

Supplier / Site STA


Priority Supplier

File results in support of PPAP

Results review during GPDS on-site Visit #3 and Visit #4

Program Review

Requested

Send file to STA Program team as requested

Select 'Print Cover Page & Executive Summary Evidence Form' button to

print top 20 characteristics

Yes

No

Ford Management review of data & feed back actions to STA Engineer

Yes

No


When specified by Ford, submit completed process control capability evidence

ONGOING PRODUCTION CONTROL VERIFICATION


Satisfies Schedule A Deliverable #38 / Schedule B Element #35(Initial Process Capability Results (Ppk) >= 1.67)



Version 1

###A. Program Information Date 5-Aug-09

Model Year Product Name Build Event2010 B299N Fiesta TT

Phase PPAP Status

B. Production Supplier / Product Information Phase 1 Phase 2 Phase 3

Tier 1 Supplier Name Site Code Tier 1 Supplier Location Promise Date 10-Aug-10 1-Oct-10 20-Dec-09

CMI - Muskegon U044M Muskegon, MI USA PPAP Approved Date 4-Aug-09City / Region / Country


REAR KNUCKLE ASSEMBLY BB53-5B758(9)-AC WPTSE12178961024 Y


Manufacturing Site Manufacturing Process Tooling Type

Carry-over production site CMI - Muskegon Carry-over production process Carry-over production tooling

New production site New production process New production tooling

Prototype site Prototype process Prototype / soft tooling

One production stream

All production streams

D. Deviations

Process Capability Results Alert #

Actions taken for non-capable process(See page 2 for Actions Taken)

Program Code


New TooledEnd Item (Y/N)

Check One

Check One

Check One

Process Capability Data Represent:

None required, production process is capable

Engineering notification

F9


K12


B30

(PPAP Ppk = 1.67 or Production Ppk = 1.33)

G30

(PPAP Ppk < 1.67 or Production Ppk < 1.33)


Satisfies Schedule A Deliverable #38 / Schedule B Element #35(Initial Process Capability Results (Ppk) >= 1.67)



Version 1







Satisfies Schedule A Deliverable #38 / Schedule B Element #35GPDS: Due at <TT>



Version 1

Characteristic Gauge R&R Process Control Capability Results

Num

ber


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 N 100% in-line air gage

2 Hardness 80 - 120 BHN YS SC Y Subsupplier Y N Equotip Y 300 30 18.66% 3.33% I-MR 0 Normal 0.06 1.68 Y

3 207 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

4 276 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

5 Material Elongation 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

6 Press - in load UCA min 29 KN YS SC Y OP40 N Y Load cell N 300 125 2.55% 5.99% X-bar and R 2 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 0.002 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 0.001 1.34 N 100% in-line air gage

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

Study Parameters

Distribution Analysis


(YC, YS)


Other)

On Production

Control Plan (Y/N)



(PTC) (Y/N)

Error Proofed

(Y/N)



(Include PTC)(Y/N)

Population Size

Sample Size

% Study


% Tolerance(Target ≤ 10%)



Evidence: Number of


Distribution Type

Resultant P-value or

Best Fit Coefficient

PPAP PpkValues

Production PpkValues

Meets Capability Requirement

PPAP Ppk ≥ 1.67Production Ppk ≥ 1.33

(Y/N)

Material Yield Strength


100% press force monitoring

Box-Cox Transformed

Johnson Transformed

APQP/PPAP External Supplier EvidencePRODUCTION PROCESS CONTROL RESULTS

Required When Specified by Ford Motor Company (MP1 to MP1 + 90 Days)GPDS: MP1 to MP1 + 90 Days



Version 1

Supplier Code:

Part Number:

Characteristic Gauge R&R Process Control

Num

ber


1

2

3

4

Study Parameters


(YC, YS)


Other)

On Production

Control Plan (Y/N)



(PTC) (Y/N)

Error Proofed

(Y/N)



(Include PTC)(Y/N)

Population Size

Sample Size

% Study


% Tolerance (Target ≤ 10%)



Evidence: Number of


Print Cover Page & Executive Summary

Evidence Form


Instructions



Version 1



Ford PD GPDS: <PA>

Supplier / Ford STA / Ford PD GPDS: <TT>

Supplier / Ford STA GPDS: <TT>

Supplier On-going

Supplier Weekly from MP1 to MP1 + 90 days

Supplier / Ford STA On-going


TERMS DEFINITIONS


Model Year The model year the vehicle is released

Program Code


Build Event The build event for the GPDS program milestone under review



Mfg. Site Code

Tier 1 Supplier Location Production manufacturing location of the Tier 1 SupplierPhase PPAP Status:

Promise Date

PPAP Approval Date Completed PPAP approval for the Phase PPAP DeliverablesPart Name General name given to the end item

Ford Part Number Ford designated component, sub-assembly or assembly number



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




Measurement System Analysis Gauge R&R results ≤ 10% per PPAP Ford customer specifics (Deliverable #30)

Execute control plan and monitor process for statistical process control

Report process control results on the EXTERNAL SUPPLIER PRODUCTION PROCESS CONTROL RESULTS proforma

All production processes are stable and in-control; actions taken for out of control processes



The Phase PPAP Status: date entered into VPP or MPP by the supplier for PPAP commits for the Phase PPAP deliverables

Promise date entered into VPP or MPP by the supplier for PPAP commits for the Phase PPAP deliverables


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:Example: WPTSE12178961024a) WPTS = Powertrain Systems Engine Mountsb) E = engineering releasec) 12178961 = WERS noticed) 024 = 24 WERS notices attached to this concern

Is the component, sub-assembly or assembly a new design for the given Program Code?


Instructions



Version 1

New Production site New facility designated as production intent to produce the end item

Prototype site

Manufacturing Process

Carry-over process Same manufacturing process as previous model year or common platform

New process

Prototype process

Tooling Type

Carry-over tooling Same manufacturing tooling as previous model year or common platform

New Production Tooling

Prototype/ soft tooling

Process Capability Data Represent

One Production Stream

All Production Streams

D. Deviations

Actions taken for out of control processes

EXTERNAL SUPPLIER PRODUCTION PROCESS CAPABILITY RESULTS PAGESPECIAL NOTES

This information satisfies External Supplier APQP/PPAP Readiness Assessment - Schedule A Deliverable #38 / Schedule B Row #35

When specified by Ford, submit completed process control capability evidence at a weekly frequency from MP1 to MP1 + 90 days TERMS AND DEFINITIONS

TERMS DEFINITIONS

Characteristic Print specification item to be measured

Specification Specification for the characteristic defined on the design record (print or E.S.)

Facility responsible for producing the end item for the specific build events (i.e. not production intent)

Manufacturing process for the end item producing for the build event. The scope of information is the end item manufacturing process(es) only

At least one operation contains new manufacturing process(es) to produced the end item for the specific build event (i.e. production intent process)

At least one operation contains a prototype process(es) to produced the end item for the specific build event

Manufacturing tooling for the end item producing for the specified build event. The scope of information is the end item manufacturing process(es) only

At least one operation contains new manufacturing tooling to produced the end item or the specific build event (i.e. production intent process)

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)

Demonstrate that Initial Process Capability studies have been completed using Run-at-Rate parts from the same production stream

Demonstrate that separate Initial Process Capability studies have been completed using Run-at-Rate parts from each production stream.

All production processes are stable and in-control Demonstrated method of stability and control evidence indicates all points are in control

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.

FTTPlannedDemonstrated

Report the manufacturing process First Time Through (FTT) as a planned (target) and demonstrated (actual) result. FTT is the percentage of units processed at the Evaluation Point (EP) that meet Quality Guidelines the first time without being repaired, retested, returned from within the plant, or scrapped.


Total Units Processed - Units Not OKTotal Units Processed

FTT @ an EP = X 100 %


Instructions



Version 1


PFMEA Classification (CC, SC, HI, Other)

On Production Control Plan (Y/N)


Pass Through Characteristic (PTC) (Y/N)

Error Proofed (Y/N)


Study Parameters

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?

Gauge R&R Repeatability and reproducibility of the measuring system

% Study Variation

% Tolerance Measurement Error as a percentage of Tolerance

Demonstrated Method of Stability and Control

Evidence: Number of Points Not in Control

Comments / Action Taken

Data Reporting



Is the characteristic contained on the production control plan of the reporting supplier?

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

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)

Does the characteristic have an error proof method? This is required for CCs and Ford identified PTCs.


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 refers to the sample size and population where the capability study data is collected

Measurement System Standard Deviation as a percentage of Total Observed Process Standard Deviation (using Standard Deviation)

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

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.

Conditional formatting will identify through field transition to clear when comments for action taken is needed based on demonstration of process control. Make comments specific to the special characteristic and include actions taken for out of control process.

The supplier must complete the measurements and report for all special characteristics.


Required When Specified by Ford Motor Company (MP1 to MP1 + 90 Days)GPDS: MP1 to MP1 + 90 Days




Characteristic Gauge R&R Process Control

Num

ber


1 Hole size 10.5 +/- 0.5mm YC CC Y 10 Y Y Air Gage N 300 125 10.54% 9.55% X-bar and R 1

2 Hardness 80 - 120 BHN YS SC Y 50 Y N Equotip Y 300 30 18.66% 3.33% I-MR 0

3 207 Mpa min YC CC Y 50 Y N tensile bars Y 300 30 2.09% 2.22% X-bar and R 0

4 276 Mpa min YC CC Y 50 Y N tensile bars Y 300 30 3.45% 2.77% Other 0

5 Material Elongation 7% min YC CC Y 50 Y N tensile bars Y 300 30 9.09% 4.67% I-MR 0

6 Press - in load UCA min 29 KN YS SC Y 40 Y Y Load cell Y 300 125 2.55% 5.99% X-bar and R 2

7 UCA Bore diameter 10 ± 0.5 mm YS SC Y 30 N N CMM N 300 125 12.45% 11.11% X-bar and R 0

8 UCA Position 0.5 mm max YS SC Y 30 N N CMM N 300 125 18.56% 15.88% 3

9 UCA Roundness max 0.5 YS SC Y 30 N N tallyrand N 300 125 21.50% 17.76% 4

10 Bushing span 7.36-7.49 mm YS SC Y 30 N N optical comparator N 300 125 4.65% 7.88% X-bar and S 0

Study Parameters


(YC, YS)


Other)

On Production

Control Plan (Y/N)



(PTC) (Y/N)

Error Proofed

(Y/N)



(Include PTC)(Y/N)

Population Size

Sample Size

% Study


% Tolerance (Target ≤ 10%)



Evidence: Number of


Air gage is 100% inspection frequency

Material Yield Strength


Load cell is 100% inspection frequency

End Point Control

Containment of suspect lot 100% re-inspected

Modified Control Chart

for Non Random Variation

Air gage is 100% inspection frequency