Module Introduction
组成部分介绍
Prototype Build
样件制造
1-38
F:/ Summary
Process Flow
过程流程
Feedback Assessment & Corrective Action
反馈、评估和纠正措施
Product & Process Validation
产品与过程确认
Process Design & Devel opment
过程设计和开发
Product Design & Development
产品设计和开发
Prototype Build
样件制造
Plan & Define
计划与定义
1-39
Prototype Build Overview
样件制造概述
APQP Prototype Build elements support the
successful planning and construction of Prototype
Build units, which provide an understanding of the
vehicle's:
APQP 样件制造要素支持样件制造单位的成功的策划和构
造，提供对于车辆的如下理解：
Design
设计
Functionality
功能性
Manufacturability
可制造性
1-40
Prototype Build Elements
样件制造要素
1. The PBCP supports the planning and
construction of prototypes by
documenting the process steps of the
Prototype Build phase.
PBCP 通过将样件制造阶段的过程步骤文
件化支持样件的策划和构造。
1. The Prototype Build ensures that the
customer receives CPs manufactured
and assembled prior to 1PP.
样件制造确保顾客在 1PP 前收到制造和装
配好的 CP。
1-41
PBCP (Prototype Build Control Plan) Definition
PBCP（样件制造控制计划）定义
The PBCP description of the dimensional measurements and
material/functional tests that occur during the CP build.
PBCP 描述了发生在 CP 制造中的尺寸测量和材料/功能试验
It is the first summary document that indicates:
是说明如下事项的摘要文件：
The steps between Prototype Build and Pre-Launch
leading to the Production Control Plan
产生生产控制计划的样件制造和试生产之间的步骤
The process steps to identify and align both the
product's characteristics and its targets
识别和调整产品特性及其指标的过程步骤
1-42
PBCP General Expectations
PBCP 总的期望
Product characteristics are reviewed
评审产品特性
Those characteristics required for PBCPs
are identified.
确定 PBCP 所要求的特性。
All potential significant and critical characteristics from the
DFMEA's must be included.
必须包括 DFMEA 输出的所有潜在重要和关键特性。
The process parameter conditions must be documented.
过程参数条件必须被文件化。
This includes all special tooling, manufacturing, and
assembly conditions.
包括所有特殊工具、制造和装配条件。
1-43
PBCP Checklist
PBCP 检查清单
1-44
Prototype Build
样件制造
Defines the manufacture and assembly of
components, subsystems, systems, and vehicles
supplied to the customer for builds occurring
prior to the 1PP trial run
定义在 1PP 试运行前的样件制造，以提供给零部件、
子系统、系统和车辆的制造和装配。
Includes not only the actual build process, but
the preparation for the build so that CPs are
supplied to the customer prior to 1PP
不仅包括实际的制造过程，而且包括为了在 1PP 前将
CP 提交给顾客而进行的制造准备
1-45
Prototype Build Expectations
样件制造期望
PBCPs are followed.
按照 PBCP 进行
Suppliers receive all necessary information and
participate according to the program's schedule and
timing.
供方收到所有必要的信息并按照项目时间安排定时参与
The timing for changes will be in line with the next build
phase.
更改的时间选择应该符合下一个制造阶段。
All prototype materials must meet 100 percent of the
dimensional specifications and functional requirements at
delivery to meet the CP In-Plant Date.
交付时所有样件材料必须 100% 满足尺寸规范和功能要求以满
足 CP 进厂日期。
1-46
Prototype Build Expectations (Continued)
样件制造期望（续）
Quality levels are checked against the PBCP.
按照 PBCP 检查质量等级。
Dimensional and functional data is available for review by the
customer on each part.
顾客可以获得每个零件的尺寸和功能数据以进行评审。
Suppliers provide customers with any testing and checking
requirements for prove-out of their part design.
供方向顾客提供所有试验和检查要求以证明零件设计是适当的。
An "Action Matrix" is developed to capture and resolve all
concerns found during build and any subsequent lab, plant,
and/or road testing, and all concerns are reviewed with the
program team and appropriate management.
开发“措施矩阵”以获得和解决在制造和所有试验室、工厂和/或道
路试验中并发的问题，和所有项目小组及适当的管理层评审的问题。
1-47
Prototype Build Checklist
样件制造检查清单
1-48
Module Introduction
组成部分介绍
Process Design and
Development
过程设计和开发
1-49
F:/ Question 3
Process Flow
过程流程
Feedback Assessment & Corrective Action
反馈、评估和纠正措施
Product & Process Validation
产品与过程确认
Process Design & Development
过程设计和开发
Product Design & Development
产品设计和开发
Prototype Build
样件制造
Plan & Define
计划与定义
1-50
Elements
要素
1. Facilities, Tools, and Gauges
1. 设施、工具和量具
2. Manufacturing Process Flow
2. 制造过程流程
3. Process FMEA
3. 过程 FMEA
4. Measurement System Evaluation
4. 测量系统评价
5. Pre-Launch Control Plan
5. 试生产控制计划
6. Operator Process Instructions
6. 操作工过程指导书
7. Packaging Specifications
7. 包装规范
1-51
Facilities, Tools, and Gauges (8)
设施、工具和量具(8)
This element identifies the new, additional,
refurbished, and relocated facilities and
resources necessary to manufacture the
customer-specified product at designated
quantity and quality levels.
本要素确定了以规定的数量和质量等级制造顾客指定
的产品所需的新的、额外的、更新的和重新部署的设
施和资源。
The element also identifies the tools and gauges
used in process machinery to transform raw
material into finished parts or assemblies.
本要素还确定了用于将原材料转换为完成的零件或组
装件的机械加工过程的工具和量具。
1-52
Expectations
期望
The planning and execution of this element must align with:
<SI> to <LR> milestones
PQOS Deliverables
本要素的计划和执行必须配合
里程碑 <SI> 到 <LR>
PQOS 需交付的事务
Facility permits, planning approval, drawings, and utilities
must be included on the Manufacturing Timing Plan. In
addition, funding approvals must be completed.
制造时间计划中必须包括设施许可、计划批准、图样和效用。另
外，必须完成资金批准。
The program team must approve statistical requirements
and acceptance criteria before sourcing of tools or gauges
can be made.
在可以进行工具和量具的外包之前，项目小组必须批准统计要求
和接收准则。
1-53
Expectations (Continued)
期望（续）
All tools and gauges must comply with Tooling and
Equipment Supplement requirements.
所有工具和量具必须符合工装和设备补充要求。
Trial runs should occur at the machine builder's location to
qualify all tools.
应该在机械制造者的现场进行试运行，以验证所有工具合格。
All corrective actions for facilities, tools, and gauges not
meeting customer requirements must be completed before
the Production Trial Run.
必须在产品试生产前完成针对不满足顾客要求的设施、工具和量
具的所有纠正措施。
Tools and gauges must be delivered, set up, and approved
in their specified facilities before the Production Trial Run.
产品试生产前工具和量具必须以制定的设施交付、安装和批准。
1-54
Facilities, Tools, and Gauging Checklist
设施、工具和量具检查清单
1-55
Manufacturing Process Flow (13)
制造过程流程（13）
This element is a graphic
representation of the current or
proposed sequence of the
manufacturing process to ensure that
the process definition, PFMEA, and
Control Plans can be created and
analyzed in the appropriate sequence.
本要素制造过程的当前的或建议的次序的图
解表示，以确保以适当的次序建立和分析过
程定义、PFMEA 和控制计划。
1-56
Manufacturing Process Flow Expectations
制造过程流程期望
Manufacturing Process Flow general expectations are that:
制造过程流程总的期望是：
A cross-functional team led by VO Engineering develops a
Manufacturing Process flowchart to serve as an input to
PFMEAs.
由 VO 工程领导的横向职能小组开发制造过程流程图作为 PFMEA
的输入。
The process flowcharts are developed using PFMEAs and
surrogate processes to serve as input for new processes and
technologies.
使用 PFMEA 和替代的过程开发过程流程图，作为新过程和技术的
输入。
The current production flowcharts may be modified to show
revisions to the process flow.
可以修改当前的生产流程图，以显示对过程流程的修改。
1-57
Manufacturing Process Flow Checklist
制造过程流程检查清单
1-58
Process FMEA (14)
过程 FMEA (14)
The PFMEA is a systematic approach
used by a manufacturing-responsible
team to ensure that potential process-
related failure modes and their
associated causes have been
considered and resolved.
PFMEA 是制造职责小组使用的确保已经考
虑并解决了潜在的与过程相关的失效模式及
其相关原因的系统化的方法。
1-59
Expectations
期望
All Process FMEAs are prepared by a cross-functional team led
by Manufacturing Engineering following the steps defined in the
FMEA guideline.
所有过程 FMEA 以制造工程为领导的横向职能小组按照 FMEA 指南
中定义的步骤进行准备。
Process FMEAs must be established any time that:
当存在如下事项时，必须建立过程 FMEA：
New processes, technologies, products, or product
features are introduced.
引入新的过程、技术、产品或产品特征。
Quality risks are identified that cannot be resolved through
design changes.
确定质量风险不能通过设计变更加以解决。
Major quality concerns have not been resolved during the
current production model year.
在当前的生产模型年中，没有解决重大的涉及质量的问题。
1-60
Expectations (Continued)
期望（续）
List of "recommended actions" and lessons
learned is incorporated in the process
(continuous improvement).
将列出的“建议措施”和学到的经验和并在过程
（持续改进）中。
Poke-a-Yoke has been used in addressing
corrective actions.
制定纠正措施中使用防错方法（Poke-a-Yoke）。
1-61
Process FMEA Checklist
过程 FMEA 检查清单
Process FMEA
1-62
Measurement System Evaluation (15)
测量系统评价（15）
This element assesses the
variation of the measurement
system, and determines whether it
is acceptable for monitoring the
production process.
本要素评估测量系统的变差，确定是否
可以接受测量系统监控生产过程。
1-63
Expectations
期望
Correlation standards are reached and agreed to
with the customer for duplicate gauges or test
equipment.
已达到相同的测量或试验设备的相关标准和顾客的批准。
Gauge instructions and visual aids to ensure
appropriate use of gauge and test equipment in
production.
测量指导书和目视辅具确保在生产中适当的使用测量和试
验设备。
All measurement systems (gauges and test
equipment) must be modified to reflect the latest
engineering part level before the Production Trial
Run.
在产品试生产前必须修改所有测量系统（测量和试验设
备）以反映最新工程零件等级。
1-64
Expectations (Continued)
期望（续）
The user/customer must be given the opportunity to review and
concur with the gauges and test equipment study results before
the Production Trial Run.
产品试生产前使用者/顾客,必须有机会评审和批准测量和试验设备研究
结果。
The Measurement System Evaluation must be repeated and
approved following all gauge and test equipment modifications.
所有测量和试验设备更改后,必须重新进行测量系统评价并获得批准。
The Production Control Plan must align with the Measurement
Systems Development plan.
生产控制计划必须配合测量系统开发计划。
Gauge Repeatability and Reproducibility studies must be
conducted on all measurement systems.
所有测量系统必须进行量具重复性和再现性研究。
1-65
Measurement System Evaluation Checklist
测量系统评价检查清单
1-66
Pre-Launch Control Plan (16)
试生产控制计划（16）
This is a description of the dimensional
measurements and material/functional
in-process tests or checks that occur
after prototype builds, but before full
production
对发生在样件制造后，全面生产前的尺寸测
量、过程中材料/功能试验或检查的描述。
1-67
Expectations
期望
Legitimate/appropriate inspection sample sizes, frequencies, control
method, etc. inclusive to
pre-launch phase of production are included.
在生产的试生产阶段包含合理/适当的检验样本容量、频率、控制方法等。
All product & process characteristics for
pre-launch control plans are identified and reviewed.
确定和评审试生产控制计划的所有产品和过程特性。
Results from the PBCP and DFMEA provide the outline for the Pre-Launch
Control Plan.
PBCP 和 DFMEA 的结果提供了试生产控制计划的概要。
The Production Control Plan for the current production model is used to
assist in the development of the
Pre-Launch Control Plan if APQP Elements 8 and 13 have not been
initiated.
如果 APQP 要素 8 和 13 还未启动，使用当前生产模式的生产控制计划协助开发
试生产控制计划。
1-68
Pre-Launch Control Plan Checklist
试生产控制计划检查清单
1-69
Operator Process Instructions (17)
操作工过程指导书（17）
This element describes the details of the
controls and actions that operating personnel
must perform to produce quality products.
本要素描述操作人员为生产质量合格的产品所必须执
行的控制和措施的详细情况。
These instructions are divided into two major
components:
这些指导书分为两个主要部分：
Description of the process
过程描述
Operator instructions
操作供指导书
1-70
Expectations
期望
A completed Operator Process Instructions package.
完成的整套操作工过程指导书。
Instructions developed to be used during a production trial run
to ensure the process performs as intended.
在产品试生产中使用开发的指导书以确保过程按预期执行。
Operator Process Instructions describe all process steps
necessary to produce a quality product. The training
instructions must include:
操作工过程指导书描述了生产质量合格的产品所需的所有过程步骤。
培训指导书必须包括：
Detailed instructions
详细的指导书
Visual aids
目视辅具
Any other quality materials necessary to support the
production operator
支持生产操作工所需的任何质量材料
1-71
Operator Process Instructions Checklist
操作工过程指导书检查清单
1-72
Packaging Specifications (18)
包装规范（18）
This element describes the design
and development of the end-item
shipment packaging, including
interior partitions.
本要素描述产品最后出货包装的设计与
开发，包括包装内部的分隔配置。
1-73
Expectations
期望
Past issues on similar or surrogate packaging are discussed
and resolved by the team.
小组讨论和解决相似或替代的包装中过去发生的问题。
Corrective actions exist for any packaging issues identified that
affect product performance and characteristics.
确定对于任何影响产品性能和特性的包装问题的现存纠正措施。
Supplier and the receiving plant agree upon packaging
requirements.
供方和接收工厂就包装要求达成一致。
Packaging evaluation must test the packaging under the
expected conditions of transport and material handling.
包装评价必须在运输和材料处理期望的条件下测试包装
Packaging design must ensure that the product performance
and characteristics will remain unchanged during packing,
shipping, and unpacking.
包装设计必须确保在包装、运输和打开包装过程中，产品性能和特性
保持不变。
1-74
Packaging Specifications Checklist
包装规范检查清单
1-75
Module Introduction
组成部分介绍
Product and Process
Validation
产品和过程确认
1-76
F:/APQP_Mod08_ProcessD& Summary
Process Flow
过程流程
Feedback Assessment & Corrective Action
反馈、评估和纠正措施
Product & Process Validation
产品与过程确认
Process Design & Devel opment
过程设计和开发
Product Design & Development
产品设计和开发
Prototype Build
样件制造
Plan & Define
计划与定义
1-77
Elements
要素
1. Production Trial Run
产品试生产
2. Production Control Plan
生产控制计划
3. Preliminary Process Capability
初始过程能力
4. Production Validation Testing
生产确认试验
5. Part Submission Warrant
零件提交保证书
1-78
Production Trial Run (19)
产品试生产（19）
The Production Trial Run is a validation
of the effectiveness of the
manufacturing and assembly process,
using production tooling, equipment,
environment (including production
operators), facilities, and cycle times.
产品试生产是对制造和装配过程、使用的生
产工具、设备、环境（包括生产操作工）、
设施和生产周期时间的有效性的确认。
1-79
Expectations
期望
Production facility, tooling, equipment, personnel, packaging, operators, PSW-1
parts, and Pre-Launch Control Plans are used on trial run.
在试生产中使用生产设施、工具、设备、人员、包装、操作工、PSW-1 零件和试生产控制
计划。
Concerns from the trial run that could prevent Run-at-Rate and capacity by date
required are listed.
列出在生产试运行中可能影响到“节拍生产”与“产能”的关注点。
Corrective design and process actions are established.
建立设计和过程纠正措施。
The Pre-Launch Control Plan is followed during the 1PP Production Trial Run.
1PP 产品试生产中按照试生产控制计划进行。
The Production Trial Run is used to confirm or add alignment between product and
process characteristics.
产品试生产用来在产品和过程特性之间进行确认或加强调整。
Operator Process Instructions are followed during the Production Trial Run.
在产品试生产中按照操作工过程指导书执行。
1-80
Element Checklist
要素检查清单
1-81
Production Control Plan (20)
生产控制计划（20）
The Production Control Plan is a written plan of
the systems for controlling parts and processes
during full production.
生产控制计划是在全面生产中控制零件和过程的系统
的书面计划。
This document is based on the Pre-Launch
Control Plan and is a living document that must
be updated to reflect the additions and deletions
of controls, based on experience gained in the
process of producing parts.
本文件基于试生产控制计划，是一份动态文件，必须
基于从零件生产过程中获得经验，加以更新以反映对
控制的增加和删减。
1-82
Expectations
期望
Reaction Plans specify corrective and containment actions necessary to
avoid operating out-of-control or producing nonconforming products.
反应计划明确规定纠正和限制措施，以避免操作失去控制或生产不合格产品。
The Production Control Plan is developed by a cross-functional team led
by Manufacturing Engineering.
由以制造工程为领导的横向职能小组开发生产控制计划。
The Production Control Plan follows the methodology documented in the
AIAG/APQP and Control Plan Reference manual.
生产控制计划遵循 AIAG/APQP 和控制计划参考手册中提供的方法。
The outcomes of the final PBCP provide the basis for the Pre-Launch
Control Plan that in turn becomes the source for the Production Control
Plan.
最终 PBCP 的输出给试生产控制计划提供了基础，然后顺次成为生产控制计划的
资源。
1-83
Element Checklist
要素检查清单
1-84
Preliminary Process Capability (21)
初始过程能力 (21)
The Preliminary Process Capability is
a statistical study and assessment of
the ability to produce product within
specifications.
初始过程能力是对按照规范生产产品的
能力的统计研究和评估。
1-85
Expectations
期望
Results are analyzed to verify statistical stability as well as
capability.
分析结果以验证统计稳定性和能力。
The statistical and analytical techniques used to determine
capability must be acceptable to the customer.
顾客必须接受用来确定能力的统计和分析工具。
Preliminary Process Capability studies must be performed in a
way that aligns with the development of the Pre-Launch Control
Plan.
初始过程能力研究必须以配合试生产控制计划的开发的方式进行。
Preliminary Process Capability studies must be completed:
初始过程能力研究必须完成：
The customer must have the opportunity to review the studies
before Production Part Approval.
在生产件批准前，顾客必须有机会对研究进行评审。
1-86
Element Checklist
要素检查清单
1-87
Production Validation Testing (22)
生产确认试验（22）
Engineering tests validate that the
products made from the production tools
and processes meet engineering
specifications
工程试验确认生产工具和过程制造的产品满足
工程规范。
Internal and external suppliers to Ford
Motor Company must complete
Production Validation Testing as a
requirement of a PSW for 1PP
作为 1PP 的 PSW 要求，福特汽车公司的内、
外部供方必须完成生产确认试验。
1-88
Expectations
期望
A PV Test Plan, including progress achieved, is established.
建立 PV 试验计划，包括取得的改进。
Concerns identified during PV Testing are assigned, resolutions are
implemented, and solutions are tracked through closure of the concern.
指出在 PV 试验阶段识别的关注事项，解决方案被实施，而且跟踪解决方案，彻
底解决了关注事项。
All parts, end-items or components, subsystems, and systems for PV
Testing must be completed before the FEU Build according to the
engineering specifications in the Pre-Launch Control Plan.
必须在根据工程规范建立PEU前，在试生产控制计划中完成所有零件，产品最终
阶段基组成部分，子系统和系统的PV试验。
All customer-specified dimensional, material, functional, and reliability
tests must be completed before Production Part Approval.
生产件批准前必须完成所有顾客规定的尺寸、材料、功能和可靠性试验。
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Element Checklist
要素检查清单
1-90
Part Submission Warrant (23)
零件提交保证书（23）
The PSW ensures that engineering
design requirements are met by the
supplier, and that the process used is
capable of producing parts that meet
these requirements.
PSW 确保供方满足工程设计要求，使用的过
程有能力生产满足这些要求的零件。
The PSW is the final sign-off verifying
that the Production Part Approval
Process (PPAP) has been followed.
PSW 是按照生产件批准过程进行的最终批准
验证。
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Expectations
期望
Concerns identified during PPAP and PSW have been
resolved.
在 PPAP 和 PSW 中确定的关注事项已经被解决。
The customer's material IPD must be included in the
supplier's timing plan.
顾客材料 IPD 必须包含在供方时间计划中。
Production Part Approval requirements must be
completed prior to the IPD of the user plant.
在使用者工厂 IPD 前，必须完成生产件批准要求。
All items of the AIAG/PPAP manual must be completed
and the required documentation provided to the customer
with PSW.
AIAG/PPAP 手册中的所有条款必须完成，并随 PSW 将要求的
文件提交给顾客。
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Element Checklist
要素检查清单
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Module Introduction
组成部分介绍
Status Reporting
状态报告
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F:/ Review Question 2
Design and Manufacturing Reviews (5)
设计和制造评审（5）
This element describes the activities that are necessary to
make the review meetings effective and:
本要素描述了使评审会议更加有效和达到一下目的所需的活动：
Prevent problems and misunderstandings
防止问题和误会发生
Provide a mechanism to monitor the program's
progress and resolutions
提供监控项目进展和结果的机制
Review the product and manufacturing process
detail (., part drawings)
评审产品和制造过程详细情况（例如：零件图样）
Provide data-driven verification of designs and
processes
提供针对设计和过程的以数据驱动的验证
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Expectations
期望
Review APQP Status Reports during the Design Reviews and
discuss relevant issues.
在进行设计评审和讨论相关问题时评审 APQP 状态报告。
Resolve Design Feasibility concerns in time to support each
build's IPD/MRD.
及时解决涉及设计可行性的问题，以支持每个 IPD/MRD。
Appraise the progress of the Design Verification Plan
(unanticipated failure modes encountered during design
verification testing must be addressed in the DFMEA).
评价设计验证计划的进展（必须在 DFMEA 中解决在审计验证试验
中遇到的非预期的失效模式）。
Assess the progress toward achieving reliability, quality,
cost, and timing targets.
根据达到的可靠度、质量、成本和时间目标评估进展。
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Element Checklist
要素检查清单
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