phased ppap requirements handbook - elsmar cove and other manuals/phased ppap...phased production...

Phased PPAP Requirements Handbook Ford

GLOBAL PURCHASING

Supplier Technical Assistance

Phased PPAP Requirements Handbook

u00drd2

XOFRD004 - Rev. Date 12/04 - Eff. 5/5/2005

u00drd2

Rev. No. 12/2004

Phased Production Part Approval Process

Phased PPAP Requirements Handbook

Ford Motor Company Supplier Technical Assistance

December 2004

Acknowledgements: The Phased PPAP development represents the efforts of Ford and its suppliers. Acknowledgement should be made to the core team which comprised of: Erin Bates, Chris Burford, Volker Domdei, Matthias Duex, Timo Golzio, Brian Grandstaff, Russ Hopkins, Tim Jolly, Debra Keller, Tom Miller, Jim Polman, Ranga Rajan, Aricka Long, Hans Pettersson, Julian Taylor and Steve Walsh. This core team gratefully acknowledges the contributions made by employees at Ford and its suppliers who have developed and continue to support effective implementation of Phased PPAP.

u00drd2



Table of Contents

Page

Phased PPAP Introduction 3

Phased PPAP Overview 4

Process Flow Overview 5

Phased PPAP Key Definitions 6

Phase 0 PPAP – Run–at-Rate 7

Phase 1 PPAP – Quality Verification 8

Phase 2 PPAP – Production Verification 9

Phase 3 PPAP – Capacity Verification 10

Customer Approval of Phased PPAP 11

Expectations 12

Appendix A - STA Roles & Responsibilities 13

Appendix B – Exception Management Process 14 – 17

Appendix C – Phased PPAP Submission Warrant 18

Appendix D – PPAP Requirements Listing 19

Appendix E - Acronym List 20

u00drd2



Phased PPAP Introduction In order to improve launch performance, Ford has structured the Production Part Approval Process (PPAP) into a phased approach that will require an organization to demonstrate manufacturing capability, product quality and production capacity prior to Job #1. Phased PPAP will provide Ford and the supplier with an improved understanding of supplier manufacturing process and part readiness.

Phased PPAP organizes the Production Part Approval Process into four phases: Phase 0: 'Run-at-Rate' Phase 1: 'Quality Verification' Phase 2: ‘Production Verification' Phase 3: ‘Capacity Verification’.

Benefits of Phased PPAP Phased PPAP will benefit Ford and its Suppliers by:

• Dividing PPAP activities into more manageable segments • Providing a structured approach aligned with manufacturing process development • Providing a program team with earlier and additional measures to forecast

program/product readiness • Providing a consistent mechanism for a supplier to demonstrate their ability to

support Ford production volume requirements/capacity Teamwork Ford Motor Company and its Suppliers must work together to deliver a quality part, produced on-time, that meets all Ford engineering requirements. To drive flawless execution in launching and delivering products that surpass customer expectations, Ford and its suppliers must place trust, integrity and accuracy above all else in the Production Part Approval Process.

What Phased PPAP Means to Ford Motor Company Successful completion of Phased PPAP:

• Confirms that all customer engineering design record and specification requirements are properly understood by the supplier, and that ALL production streams have the potential to produce product consistently meeting these requirements during an actual production run at the quoted production rate.

AND

• Verifies that the supplier's production system can support the Daily Production Volume declared by the customer.

3

u00drd2



Phased PPAP Overview Scope

• Phased PPAP must be completed for any of the situations already specified by the current edition AIAG PPAP Manual. In addition, any increase in the Daily Production Volume declared by the customer above the verified declared DVP will require the supplier to re-complete any affected Phased PPAP phases.

Summary Phase 0: Run-at-Rate Objectives: To confirm that all production input requirements are available and understood, and can support a limited production run.

To provide an early indicator that the design of the process/tool/facility has the potential to produce at rate the required number of acceptable parts as determined by the pre-launch control plan.

Phase 1: Quality Verification Utilizes parts produced during Phase 0. Objectives: To confirm all customer design record and specification requirements are properly understood by the supplier.

To provide an early indicator that the design of the process/tool/facility has the potential to produce product consistently meeting these requirements during an actual production run at the quoted production rate by operating a minimum of one selected production stream. Phase 2: Production Verification Objectives: To confirm all customer engineering design record and specification requirements are properly understood by the supplier, and that ALL production streams have the potential to produce product consistently meeting these requirements during an actual production run at the quoted production rate. Phase 3: Capacity Verification Objective: Verify the supplier's production system can support customer declared DPV while meeting Phase 2 requirements.

4

u00drd2


Pha

sed

PP

AP

Req

uire

men

ts H

andb

ook

F

ord

Proc

ess O

verv

iew

This

pro

cess

flow

(an

extra

ct fr

om F

ord

Inte

rnal

Pro

cedu

re P

SP

-011

) is

inte

nded

to li

nk th

e ac

tiviti

es in

Pha

sed

PPA

P to

incl

ude

4-P

anel

Pro

cess

Fl

ow, R

oles

& R

espo

nsib

ilitie

s M

atric

es &

Exc

eptio

n M

anag

emen

t Pro

cess

with

the

AIA

G P

PA

P R

efer

ence

Man

ual a

nd a

ny re

late

d Fo

rd In

tern

al

proc

edur

es.

F

PD

S

Tim

elin

e

La

unc

h

Te

am

c)

Sup

plie

r d)

,e)

ST

A S

ite

Eng

ine

er

a),

d),

e

)

ST

A P

rog

ram

E

ng

ine

er

Bu

yer

Pha

se 0

ST

AR

T

Co

mp

lete

s so

urc

ing

of s

up

plie

r si

te p

er

Pu

rch

asin

g P

roce

du

re 2

.1 o

r lo

cal p

ract

ice

<

Job

#1

>

Ph

ase

3

No

te: I

n s

om

e r

eg

ion

s th

e P

rogr

am

me

En

gin

eer

m

ay b

e r

esp

ons

ible

for

ass

ign

ing

site

PP

AP

su

bm

issi

on

leve

l and

m

ay

be

the

re

spon

sibl

e

Par

t Ap

pro

val A

ctiv

ity.

Are

all

Ph

ase

s c

om

ple

te?

EN

D

Ye

s

Th

e p

roce

ss b

elo

w is

no

t to

sca

le b

etw

een

tim

ing

po

ints

<P

lea

se r

efe

r to

Ph

ase

d P

PA

P H

and

boo

k fo

r T

imin

g E

xpe

cta

tion

s b

y P

ha

se>

Ass

ign

s P

PA

P

leve

l to

Su

ppl

ier

Site

(p

er P

SP

-01

1:

Ta

ble

1).

Agr

ee

s w

ith P

rog

ram

e

ngin

ee

r o

n H

igh

-Im

pac

t Pa

rts

Ha

vin

g c

om

ple

ted

PS

W-

009

, agr

ees

Hig

h Im

pa

ct

Pa

rts

de

sig

nat

ion

with

S

ite E

ngi

nee

r. I

nfo

rms

affe

cte

d s

up

plie

rs o

f HI

pa

rt s

tatu

s an

d

de

sign

atio

n o

f PP

AP

S

ubm

issi

on

Le

vel 5

Inpu

ts P

hase

d P

PA

P

Pro

mis

e d

ate

s in

to

VP

P p

er P

has

ed

PP

AP

Ha

ndb

ook

En

ters

"R

" (R

eje

cted

) in

V

PP

with

in

24

hou

rsE

nte

rs "

A"

(Ap

pro

ved

) in

V

PP

with

in

24

ho

urs

Re

fer

to th

e P

ha

sed

PP

AP

Exc

eptio

n

Ma

na

gem

en

t Pro

cess

, el

em

ent

4.2

.3 in

the

Pha

sed

PP

AP

H

and

boo

k b

)

No

tes

a)

Ref

er

to R

ole

s a

nd R

espo

nsi

bilit

ies

Mat

rice

s to

det

erm

ine

min

imu

m e

xpe

cta

tions

by

sub

mis

sio

n le

vel a

nd p

has

e.b)

P

rod

uct

Dev

elo

pmen

t (C

rea

tion

) h

ave

the

au

tho

rity

to a

uth

ori

se a

n A

lert

(o

r re

gio

na

l eq

uiva

len

t) w

he

re a

de

viat

ion

to s

pe

cific

atio

n e

xist

s, a

nd

Inte

rim

App

rova

l is

req

uire

d.

c)

Lau

nch

team

typ

ica

lly c

on

sist

s o

f ST

A,

Pu

rch

asi

ng

, Pro

du

ct D

eve

lop

me

nt (

Cre

atio

n), N

ew

Mo

del

La

un

ch a

nd

Ma

teria

l Pla

nn

ing

& L

ogis

tics

(M

P&

L).

d)

Dat

a in

pu

t in

to V

PP

may

be

co

ndu

cte

d b

y an

adm

inis

tra

tion

tea

m c

onsi

ste

nt a

s d

efin

ed

by

loca

l pro

cedu

re. I

f ST

A d

ecis

ion

on

Ph

ased

PP

AP

Wa

rra

nt i

s e

nte

red

by

the

sup

plie

r, S

TA

ma

y o

verr

ide

su

ppl

ier

VP

P e

ntr

y a

t an

y tim

e.

Th

is a

lso

ap

plie

s in

the

ca

ses

of P

PA

P S

ub

mis

sio

n L

evel

1 (

"Sup

plie

r S

elf

Ce

rtifi

catio

n")

, whe

re A

pp

rova

l is

reg

iste

red

in V

PP

au

tom

atic

ally

whe

n th

e su

pp

lier

ente

rs "

Y"

cod

e

e)

Doc

umen

tatio

n is

no

t lim

ited

to th

at d

efin

ed

in th

is P

roce

ss F

low

char

t. T

he F

ord

Ph

ase

d P

PA

P 4

-Pa

ne

l Pro

cess

Ma

p (

see

Ph

ased

PP

AP

Han

dbo

ok)

de

fine

s th

e d

ocu

me

nta

tion

tha

t is

req

uire

d to

be

co

mp

lete

d

at e

ach

Ph

ase

. S

ubm

issi

on

to th

e C

usto

mer

Ap

prov

al A

uth

ority

(S

TA

) is

de

fine

d in

the

AIA

G P

PA

P M

anu

al.

En

ter

"Y"

cod

e in

V

PP

for

Pha

se &

su

bmit

do

cum

en

tatio

n

de

fine

d fo

r P

ha

se to

ST

A

Do

cum

en

tatio

n

de

fine

d fo

r P

ha

se

Re

view

&

Sig

n D

ocu

me

nta

tion

d

efin

ed

for

Pha

se

Wer

e al

l req

uire

men

ts

of t

he

Ph

ase

me

t?

No

Ye

s

Ph

ase

0 -

Ca

pa

city

A

nal

ysis

Re

po

rtP

has

e 1

- W

arra

nt

Ph

ase

2 -

War

rant

Ph

ase

3 -

War

rant

&

Ca

paci

ty A

naly

sis

Re

port

Com

ple

tes

Ph

ased

P

PA

P R

equ

ire

me

nts

(Ph

ase

0, 1

, 2 o

r 3)

&

Do

cum

en

tatio

n d

efin

ed

for

Ph

ase

be

low

No

Ph

ase

1

<1

PP

>

Pha

se 2

<F

EU

>

Tim

ing

of P

has

e 0

is d

ete

rmin

ed b

y lo

ng

est l

ea

d a

ctiv

ity th

at m

ust

be

com

ple

ted

to m

ee

t Ph

ase

1

Req

uire

men

ts

Was

the

D

ocu

me

nta

tion

A

pp

rove

d?

No

Sig

ned

-off

Do

cum

ent

atio

n

as d

efin

ed

by

Pha

se

Th

e p

roce

ss b

elo

w is

no

t to

sca

le b

etw

een

tim

ing

po

ints

<P

lea

se r

efe

r to

Pha

sed

PP

AP

Ha

ndb

oo

k fo

r T

imin

g E

xpe

ctat

ions

by

Ph

ase>

Re

cord

s S

TA

De

cisi

on

in

VP

P

Rej

ect

App

rove

Ye

s

5


6

Definitions: Production Stream A single production stream is a sequence of a minimum of one line, machine, tool, cavity, facility, equipment, gage, operator and other required items at the intended location and with the intended layout that will be used to produce parts that meet Ford specifications.

All production streams must include any additional items not included in the single production stream that are required to meet the Ford Capacity Planning Volume (CPV) requirements of the intended program being launched (e.g. additional tools, cavities, lines, conveyors, machines)

Conveyor EOL Tester

Others Stream

Operators

Gages

Facilities

Cavity

Tool

Line

CPV (Capacity Planning Volumes) Capacity Planning Volumes are the volumes for which Ford requires suppliers to facilitize and tool-up for. CPV's are approximately 10 percent higher than "production planning volumes," in order to cover spares (service requirements) and volume spikes. The CPV is communicated to Suppliers on a part level basis through the Ford Purchasing “Request for Quotation” (RfQ).

CPV's are typically expressed as weekly volumes. Suppliers are expected to satisfy the production weekly demand based on a maximum 5 days/3 shifts manufacturing operating pattern.

DPV (Daily Planning Volume) DPV's are the maximum planned requirement for this part per day and are broken down by plant and Brand (e.g. Volvo).

Acceptable Parts (referenced in Phase 0 objectives) Acceptable Parts are defined as parts produced using the required PPAP inputs for Phase 0 as identified on the Process Map and manufactured in conformance with the relevant control plan, either Pre-Launch or Production.

Interim Accepted Part meets customer specifications and includes valid Temporary Engineering Specification for temporary exception.

Temporary Engineering Specification Temporary specification provided by the customer engineering release organization. The Ford Brand specific method for communicating these specifications is as follows:

• WERS Alert (Ford/Jaguar); • Temporary Part Change Management (Land Rover); • Temporary Part Deviation (Volvo).

u00drd2



7

Process Map Phase 0 Run-at-Rate Objectives: To confirm that all production input requirements are available and understood, and can support a limited production run. To provide an early indicator that the design of the process/tool/facility has the potential to produce at rate the required number of acceptable parts as determined by the Pre-Launch control plan.

Refer to web link https://web.qpr.ford.com/sta/Capacity_Analysis_Report.xls for Capacity Analysis Report and supporting documentation.

INPUTSReleased

design[#1,2,3 & 4]

Trained supplier

production operators

Sub-supplier(s) material status

from Tier-x Run-at-Rate

Job 1 Location (final site &

line)

Quantity of parts required as defined by

customer (default 300 consecutive

parts)

Production process including

control plan, flow diagram instructions &

Process parameters [#5,6 & 7]

Production Tools, Facilities

& Gauging[#8,16 & 17]

EVENT:Conduct Run-

at-Rate

Planned production cycle times required to

support Daily Production

Volume

Outputs from the event STATUS:

Phase 0 Completed

Implement Corrective

Action on Input

Was the Pre-Launch Control Plan

followed?

Were the prescribed number of acceptable parts

produced?

Were the parts produced in the defined

period?

Did all operations

meet their planned cycle time

?

Yes

Yes

Yes

Yes

No

No

No

No

Are the Run-at-Rate input

requirements in place for the production

stream?

Yes

START

No

Capacity Analysis Report

Status Tracking Database

1

4

Phase 0Run-at-Rate

Proc

eed

to n

ext p

age

Req

uire

d In

puts

Submit to Customer

Sup

plie

r

Note: refer to Appendix D which lists the PPAP requirements number (#x) noted in the 4-Panel Process Map

u00drd2



Process Map Phase 1 Quality Verification Objectives: To determine if all customer engineering design record and specification requirements are properly understood by the supplier. To provide an early indicator that the design of the process/tool/facility has the potential to produce product consistently meeting these requirements during an actual production run at the quoted production rate by operating a minimum of one selected production stream.

STATUS: Phase 1

Completed

Continue Production Part Approval Process (PPAP) using parts from Phase 0

- Dimensional measurements [#9]- Material Tests [#10]- Statistical process package [#11]- Performance Tests [#12]- Appearance criteria [#13]- Sample parts [#14]- Master samples [#15]- Customer Specific Requirements[#17]- as defined by PPAP

Have the PPAP requirements

been satisfied?

Yes


1

4

2

4

Phase 1 Quality Verification

Important notes: For suppliers with only one production stream completion of Phase 1 & 2 occur at the same time utilizing the Production Control Plan.It is required that prior to Phase 1 submission that sub-supplier(s) material status from Tier-x has also achieved Phase 1.

Proc

eed

to n

ext p

age

Return to Phase 0 for corrective

action

No

Submit to Customer

Phase 1 Warrant

[#18]

8

u00drd2



Process Map Phase 2 Production Verification Objectives: To determine if all customer engineering design record and specification requirements are properly understood by the supplier, and that ALL production streams have the potential to produce product consistently meeting these requirements during an actual production run at the quoted production rate. Note: The approach adopted for PPAP of multiple production streams is scenario-specific and must be agreed between the Supplier and STA. In general terms each production stream should be assessed for Run-at-Rate and Quality Verification separately. Consideration should also be given to the risk that the introduction of further production streams may impact the validity of the Phase 1 approval. (e.g. Phase 1 achieved on cavity #1 of a four cavity tool - the introduction of cavity #2, 3 & may impact the cavity #1 part and it may no longer be to specification). 4

STATUS:Phase 2

Completed

Phase 2 W arrant

[#18]

Have Run-at-Rates (Phase 0) been conducted

and Q uality Verifications (Phase 1) been satisfied for

ALL production streams ?

Y es


2 3

4

Phase 2 Production Verification

Proc

eed

to n

ext p

age

Submit to Customer

Im portant note:Phase 2 and Phase 3 can happen concurrently if all Inputs and Outputs are satisfied.Expectation that the Production Control Plan is follow ed during this Phase.

No

9

u00drd2



Process Map Phase 3 Capacity Verification Objective: Verify the supplier's production system can support customer declared DPV while meeting Phase 2 requirements. Update process flow with latest version to include nomenclature 'Capacity Analysis Report'

Refer to web link https://web.qpr.ford.com/sta/Capacity_Analysis_Report.xls for Capacity Analysis eport and supporting documentation. R

P has e 2 W arrant

S cheduled down t im e

defined (TP M , c hange over, B reak s etc .)

S ub s upplier m aterial s tatus

from Tier-x P has e 3

E V E NT: Conduc t Capac ity

V erific ation Run S TA TUS :P hase 3

Com pleted

Quantity required is

c us tom er DP V for one full day

A ll pers onnel for all s hifts ,

trained

A re the CV input

requirem ents in plac e for all produc tion

s tream s ?

Y es

E ND

S tatus Trac k ing Database

Return to affec ted phas e

and s tart correc tive ac tion

P hase 3 W arrant

[#18]& Capac ity A nalys is

Report

Determ ine Root Caus e & P lan Correc tive

A c tion

W as the P roduc tion c ontrol

plan followed & acc eptable parts

produced?

D id th e vo lu m e o f a cce p ta b le

p a rts p ro d u ce d m e e t o r e xce e d th e re q u ire d

D P V?

No

Y es

No

3

Phase 3C apacity Verification

Req

uire

d In

puts

P hase 0 P has e 1 P has e 2 P has e 3

S ubm it to C ustom er

Com plete Capac ity A naly s is

W ork s heet

Y es

10

https://web.qpr.ford.com/sta/Capacity_Analysis_Report.xls

u00drd2



Customer Approval of Phased PPAP

Phased PPAP Approval Phase 0 does not require a Phased PPAP Submission Warrant, however a Capacity Analysis Report (Refer to web link https://web.qpr.ford.com/sta/Capacity_Analysis_Report.xls for Capacity Analysis Report and supporting documentation) must be submitted with the Run-at-Rate box ticked indicating Phase 0. In addition, the supplier should have results from Run-at-Rate readily available for STA Engineer review and approval where required (see roles & responsibilities section, appendix A).

Phase 1, 2 and 3 each require a Phased PPAP Submission Warrant and customer approval in line with the AIAG PPAP submission level requirements or as otherwise specified by STA (see roles & responsibilities section, appendix A).

Phase 3 requires Suppliers to complete the Capacity Analysis Report in addition to the Phased PPAP Submission Warrant.

Suppliers to Ford and its affiliates will utilize the Phased PPAP warrant (Appendix C). For suppliers designated as non-Q1 and suppliers/parts identified as High-Impact, STA will review and either approve or reject the PPAP submission warrant within 48 hours of the supplier indicating the PPAP is "Ready-for-STA-Inspection" in the Vehicle Parts Progress (VPP) database. Once STA has determined the PPAP status and signed the Warrant (Phase 1, 2 and 3) and Capacity Analysis Report (Phase 0 and 3), the supplier or STA's designate will enter the PPAP decision status in the Vehicle Parts Progress (VPP) database within 24 hours of receiving a STA's signed copy of the warrant.

Any temporary exception due to non-compliance with a PPAP element or build timing requirement is handled in line with the Exception Management Process (refer to Appendix B).

Transition: Phase 1 Approval to Phase 2 Approval - Status and Part Supply In cases where more than two production streams are to be used to support Ford's capacity requirements, the degree of complexity regarding the declaration of Phased PPAP Status and the ability to supply parts during the transition from Phase 1 to Phase 2 inevitably increases. In order to illustrate how this should be managed please consider the following example:

• A supplier will be introducing a total of four production streams. In line with Phased PPAP methodology, the supplier will only be ready to submit the Phase 2 Warrant when they are able to prove that the PPAP requirements have been met for all 4 production streams.

• 3 months prior to 1PP the supplier has achieved Phase 1 Warrant approval for one production stream.

• As 1PP approaches the PPAP requirements for the second and third production streams have been satisfied, and the supplier wants to supply parts for 1PP from the three streams.

• In order to supply these parts the supplier must have an approved, updated, Phase 1 Warrant, that declares that the PPAP requirements for the 3 production streams have been met (plus supporting data as per submission level requirements). The date for which Phase 1 requirements were achieved is not affected in reporting metrics.

11

https://web.qpr.ford.com/sta/Capacity_Analysis_Report.xls

u00drd2



Expectations

Phased PPAP Achievement by Build Milestone

1PP (PV1) Phase 1 100% Completed FEU (PV2) Phase 2 100% Completed Job #1 Phase 3 100% Completed

The decision to progress through the FPDS Milestones is determined by the Global Launch QOS; refer to New Model Launch Team for latest version. Note: Phased PPAP achievement by Volvo build event is Phase 1: Tryout, Phase 2 and Phase 3: Job 1. Phased PPAP Reporting Expectations The preferred system to track and report Phased PPAP is VPP (Vehicle Parts Progress in CMMS3).

Phased PPAP now requires suppliers to track and report on multiple promise dates. Suppliers operating in VPP must enter any remaining open Phased PPAP promise dates (Phase 0 – 3) within one full working day of the part appearing in the supplier work queue. Supplier's Approval submission via VPP is the electronic equivalent to a signed PPAP Warrant.

Tier 1 Suppliers shipping to Ford must use a production part approval process for their sub-suppliers. Additionally, suppliers are required to verify their sub-supplier can meet required volumes at the required time; suppliers and/or sub-suppliers may use the Ford Capacity Analysis Report and documentation.

12

u00drd2



Appendix A

STA Phased PPAP Roles & Responsibilities

Minimum STA Review Requirements a, b)

Site Status Part Status

PPAP Submisssion

Level c)

Phase 0 Run-At-Rate

Phase 1 Quality

Verification

Phase 2 Production Verification

Phase 3 Capacity

Verification

Regardless of Site Status d)

High-Impact 5

Review must be

on site At least a desktop review

Review must be

on site

Non-Q1 Site

Non High-Impact

3 Phase 0, 1, 2 and 3 must be at least a desktop review

Q1 Site f) Non High-Impact

1 None

Documentation

Capacity Analysis Report

PPAP submission Warrant (Phase 1), Supporting Documentation and Sample Parts

PPAP submission Warrant (Phase 2), Supporting Documentation and Sample Parts

Capacity Analysis Report and PPAP Submisssion Warrant (Phase 3)

PPAP Outcome d, e)

Approve or Reject

Warrant requiring an Temporary Engineering Specification

No change to the assessment requirements as defined in table above.

a) For Programs utilizing Supply Base launch Teams (SBLT's) 100% of STA Tier 1 reviews will be conducted On Site for a minimum of 3 of 4 Phases. Any deviation from the minimum requirements listed above must receive STA management authorization. b) For ongoing running changes, MCR, or resourcing action: Phase 0 (Run-at-Rate), Phase 1 (Quality Verification),

Phase 2 (Production Verification) and Phase 3 (Capacity Verification) will follow the minimum STA review requirements stated in the table. c) PPAP submission level is assigned per STA procedure PSP-011.

d) Site may be designated Q1 or Non-Q1.

e) Input into VPP is executed by the Supplier, or their Ford internal administrator, upon receipt of a signed warrant. f) Submission Level 1 suppliers self approve submission

13

u00drd2



Appendix B

Exception Process Purpose The purpose of this instruction is to identify the supplier and customer responsibilities when PPAP is not complete and approved material is required to support customer manufacturing. Also, this instruction defines the process steps for achieving Interim Accepted of a part with a valid Temporary

ngineering Specification. E

Team Supplier Product Development New Model Launch /Manuf. Plant STA

* Notes: Temporary EngineeringSpecification: Ford = WERS AlertLand Rover = Temporary PCMVolvo = Temporary Part Deviation

**Notes: If Phased PPAP timing has not been achieved as per customer requirements (normally specified in the Launch QOS) refer to NML Team for clarification on requirement for Temporary Engineering Specification.

***Notes: For programs following FPDS this refers to IB build and after.

Process Flow -- Deviations to PPAP Element(s) or Timing

Deviation to PPAP Element(s) or PPAP Timing requirements

Correctable prior to Build

need?

Develop, Agree and Implement Corrective action Plan

Raise Temporary Engineering Specification*

Update control plan & implement process control

changes accordingly

Submit Warrant to the Temporary Engineering

Specification with Documentation

Approve or Reject

TemporaryEngrg. Spec.?

No

Yes

Complete PPAP process and address Temporary

Engineering Specification

Does this Temporary Engrg.

Spec. apply to parts required for Integrated Build

***?No

Yes

Consider risks that affect successful completion

and monitor accordinglyNo

Is there a deviation to

PPAP Elements?

Does Local Practice require Temporary Engrg. Spec. for

part status that fails to support customer

Timing requirements?**

No

No

No

Supplier develops Support/Containment Plan and

submits to NML

Approve Support Plan in 'Open-to-Go'? NML & Chief

Engineer

Yes

Permission to Ship for Build

Supplier inputs plan information into VPP

Yes

Yes

Approve Warrant

per PPAP Submission

Level?

Yes

No

No

Consider risks that affect successful completion and

monitor accordinglyImplement Corrective Action Plan

Refer to web-link: https://web.qpr.ford.com/sta/Exception_Management.pdf

14

https://web.qpr.ford.com/sta/Exception_Management.pdf

u00drd2



Appendix B

Definitions "Approved Material" – parts with Warrant declaring "Approved" in the customer use block of the PPAP Warrant.

"Temporary Engineering Specification" – temporary specification provided by the customer engineering release organization. The Ford Brand specific method for communicating these specifications is as follows:

• WERS Alert (Ford/Jaguar); • Temporary Part Change Management (Land Rover); • Temporary Part Deviation (Volvo).

"Full Approval" – part meets all customer specifications and requirements.

"Interim Accepted" – part meets customer specifications and includes valid Temporary Engineering Specification for deviation.

"Process Flow Diagram" – Deviation to PPAP Element(s) or Timing

Process Flow Description Deviation to PPAP Requirements: It is the responsibility of the supplier to complete the 19 requirements of PPAP prior to the date when the customer requires approved material. Typically, there are four situations that prohibit PPAP completion:

• Incomplete PPAP Element – e.g. PV testing not complete; • Deviation to requirement – e.g. dimension out of tolerance; • Parts not produced using intended production flow – e.g. rework due to urgent change,

use of temporary tooling/facility, not all equipment on home-line. • Deviation to required cycle time.

The team should develop, agree and implement a corrective action plan. If this plan is not complete prior to the build requirements then a Temporary Engineering Specification is needed.

Deviation from PPAP Timing: It is the responsibility of the supplier to complete the appropriate Phase by the required timing as determined by the customer. If this timing is not achieved then the team should develop, agree and implement a Corrective action plan. If this plan is not complete prior to the build requirement then a support plan should be developed. Local practice determines whether a Temporary Engineering Specification is required for Deviations to PPAP Timing.

Corrective Action Plan: It is the responsibility of the supplier to develop a corrective action plan that achieves Approved Material status by the required part submission date. The supplier should seek input from the customer's product development, manufacturing, and launch management to assure their concurrence with the planned corrective actions.

Support Plan: If the PPAP is not complete on time a Support Plan must be developed that identifies how the supplier will support the build volume requirements, as well as, the activities to support Full Approval

15

u00drd2



Appendix B

Temporary Engineering Specification: Shipment of production level parts with an incomplete PPAP requires a supplier's PPAP Warrant consistent with the requirements stated in a Temporary Engineering Specification. The Temporary Engineering Specification must describe the specific PPAP Element(s) (or timing deviations per local practice) that are not completed, the modified specification(s) that the part satisfies and the justification why the modified specification is acceptable.

Additionally, the Temporary Engineering Specification shall describe how the supplier will assure quality of parts (e.g. extra ordinary controls/inspection process and robust measurement system) to the modified specification. The Temporary Engineering Specification is effective for a limited period of time, typically reflected in terms of days, quantity, or specific launch build event.

Examples of Temporary Engineering Specifications: • Geometry – expanded tolerance or mean shift • PV Testing – partial completion • Functional Testing - Use of surrogate test results

The Temporary Engineering Specification processes and originators differ by brand as follows:

Brand Process Originator Ford Worldwide Engineering

Release System (WERS) Alert

Ford Product Development or Supplier with WERS access

Jaguar Worldwide Engineering Release System (WERS) Alert

Ford Product Development or Supplier with WERS access

Land Rover Temporary Product Change Management (Temporary PCM)

Land Rover Product Development

Volvo Temporary Part Deviation (TPD)

Volvo Research & Development, Purchasing, or Manufacturing

Approve/Release Temporary Engineering Specification: The customer is responsible to approve and release engineering deviations. Typically, the customer's Product Development, Launch Management, and Manufacturing will (electronically) sign-off on the deviation, and it will be approved by the releasing activity. This approval is authorization to the supplier to proceed with the corrective actions necessary to achieve Approved Material status on a time-limited basis.

Update quality control documents: Upon receiving the approved Temporary Engineering Specification from the customer, the supplier is responsible to update all affected quality control documents. The PFMEA shall be updated to determine if there are any new or changed failure modes. Additionally, items such as Gage R&R, Controls Plans, Operator Instructions and Visual Aids shall be reviewed.

16

u00drd2



Appendix B

Provide PPAP Warrant: It is the responsibility of the supplier to complete a PPAP Warrant per the specifications provided in the Temporary Engineering Specification. The purpose of this Warrant is for the supplier to declare that inspections and tests on production parts show conformance to customer specifications including the Temporary Engineering Specification.

The supplier must indicate the following on the PPAP Warrant section addressing Interim Status: • In the Interim Status section, check the box indicating Interim Submission • Enter the Temporary Engineering Specification number against Engineering Authorization • Provide a brief description of the reason(s) for the Temporary Engineering Specification

Approve or Reject Warrant: If the Temporary Engineering Specification applies to parts to parts required for Integrated Build and subsequent builds (or Brand equivalent Build Phase) then the customer approval authority is required to either Approve or Reject the submission. Prior to this build phase the customer approval authority may choose to review the documentation at their discretion. Approval of the Warrant is the supplier's permission to ship products for a specified time period or quantity. Rejection of the Warrant means customer requirements were not fulfilled and requires the supplier to make corrections and submit a new warrant.

Upon review of the Warrant and supporting evidence, the Customer Part Approval Activity completes the Customer Use section of the Warrant.

• If Interim Accepted, check Interim Accepted against Phased Part Warrant Status • If Reject, check Reject against Part Warrant Disposition

Warrant disposition is communicated by local practice.

If a submission at any phase is due to be, or has been, rejected the STA Program Manager should be notified. The STA Program Manager may choose to utilize this Exception Management process to gain approval for the submission

Actions to achieve Full Approval: The supplier is responsible to implement the corrective actions necessary to achieve a Full Approval. If Full Approval is not complete by the next launch build event, the customer should process a new or updated Temporary Engineering Specification. If the conditions within the Temporary Engineering Specification are changed, a new Warrant is required from the supplier.

Timing Approved material requirements vary based upon customer as follows:

• Ford, Jaguar, and Land Rover vehicle programs by the 1PP build event. • Ford, Jaguar, and Land Rover Powertrain programs by the PV (or "Powertrain 1PP") build

event. • Volvo Vehicle and Powertrain programs by Try-out.

17

u00drd2



Appendix C Phased PPAP Submission Warrant 1/

PPAP Submission Warrant StatusPART INFORMATION

Part Name

Shown on Drawing Number Organization Part Number

Engineering Change Level Date

Additional Engineering Changes Date

Optional Tracking Number

Safety and/or Government Regulation Purchase Order No. Weight (kg)

Checking Aid Number Checking Aid Change Level Dated

ORGANIZATION MANUFACTURING INFORMATION

Organization Name and Supplier Code Customer Name/Division

Street Address Buyer/Buyer Code

City Zip Country Application

REASON FOR SUBMISSION

Initial submission Change to Optional Construction or Material

Engineering Change(s) Sub-Supplier or Material Source Change

Tooling: Transfer, Replacement, Refurbishment, or additional Change in Part Processing

Correction of Discrepancy Parts produced at Additional Location

Tooling Inactive > than 1 year Other - please specify below

REQUESTED SUBMISSION LEVEL (Check one)

Level 1 - Warrant only (and for designated appearance items, an Appearance Approval Report) submitted to customer.

Level 2 - Warrant with product samples and limited supporting data submitted to customer.

Level 3 - Warrant with product samples and complete supporting data submitted to customer.

Level 4 - Warrant and other requirements as defined by customer.

Level 5 - Warrant with product samples and complete supporting data reviewed at supplier's manufacturing location.

DECLARATION and SUBMISSION RESULTSI affirm that the samples represented by this warrant are representative of our parts which were made by a process which meets all

current edition Production Part Approval Process Manual requirements including all Ford-specific requirements. I further affirm that these samples were produced at the production rate of ________ / hours using production streams. I also certify that

documented evidence of such compliance is on file and is available for review. I have noted any exceptions from this declaration below.

EXPLANATION/COMMENTS

List Molds / Cavities / Production Processes: (Attach a separate page if additional space is necessary)

Supplier Authorized Signature Date

Print Name Phone No. Fax

Title Email

FOR FORD USE ONLY PPAP . Non-PPAP a/ .

Authorization: Alert, Temp. PCM, TPD Number

Print Name

Customer Signature . Date

Interim Accepted

Customer Part Number

.

State/County/Province

Interim Status (to be completed by Supplier)

Interim Submission:

. Description: (Open Issues) .

Engineering .

a/ Non-PPAP indicates the part does not satisfy one or more PPAP requirements and is considered incomplete until all PPAP requirements are satisfied.

Phased PPAP Warrant Status: Rejected

.

Yes No

Approved

Phase 1 Phase 2 Phase 3

1/ Refer to web-link: https://web.qpr.ford.com/sta/Phased_PPAP_Warrant.xls

18

https://web.qpr.ford.com/sta/Phased_PPAP_Warrant.xls

u00drd2



19

Appendix D

PPAP Requirements as Noted in the Phased PPAP Process Map 1/

# Requirement

1 Design Records

2 Engineering Change Documents

3 Customer engineering Approval

4 Design FMEA

5 Process Flow Diagrams

6 Process FMEA

7 Control Plans

8 Measurement System Analysis Studies

9 Dimensional Results

10 Records of Material/Performance Test Results

11 Initial Process Studies

12 Qualified Laboratory Documentation

13 Appearance Approval Reports

14 Sample Production Parts

15 Master Sample

16 Checking Aids

17 Customer-Specific Requirements

18 PPAP Warrant

1/ Bulk Material expectations are not addressed within Global Phased PPAP requirements.

u00drd2



20

Appendix E

Acronym List

STA - Supplier Technical Assistance

PPAP - Production Part Approval Process

PSW - PPAP Submission Warrant

TACT - Total Actual Cycle Time

EOL - End of Line

DPV - Daily Production Volume

CPV - Capacity Planning Volume

IPD - In Plant Date (to a program build event)

1PP - 1st Production Prove-Out Units (at customer plant)

FEU - Field Evaluation Units (at customer plant)

VPP - Vehicle Parts Progress

AIAG - Automotive Industry Action Group

FPDS - Ford Product Development System

WERS - Worldwide Engineering Release System

PM Parts - Part Process Modification

TIKO - TidsInformationKöpOrder (Part Information and Order System)

PTIS - Part Tracking Information System

u00drd2


u00drd2
