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Use of Ford APQP Status Report
Tong Lei
Supplier Technical Assistance
Ford Motor Company
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Use of Ford APQP Status Report
APQP Overview
Introduction to Ford APQP Status Reporting System
How to use Ford APQP Status Reporting System
Q&A
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APQP Overview
APQP is a structured method for guiding an
organization to execute the necessary actions
to ensure that the product satisfies the
customers.
APQP is a supplier-led program that is
applicable for all systems, subsystems and
components levels.
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APQP Overview- The Goal of APQP
The goal of APQP is to facilitate
communication between all involved personnel
and disciplines in a program by completing all
required steps on time, at acceptable cost and
quality levels. Flawless product launch will
result.
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Elements of APQP (AIAG)
19 are from the AIAG APQP and Control Plan manual.
Facilities / Tools / Gauges
Prototype Builds
Drawings and Specifications
Team Feasibility Commitment
Measurement Systems
Evaluation
Packaging Specifications
Production Trial Run
Preliminary Process
Capability Study
Production Validation Testing
Production Part Approval
(PSW)
Design FMEA
Design Verification Plan &
Report
Prototype Build Control Plan
Manufacturing Process Flow
Chart
Process FMEA
Pre-Launch Control Plan
Operation Process
Instructions
Production Control Plan
Design & Mfg. Review(s)
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AIAG APQP Timing Chart
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
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Ford APQP Status Reporting System
An improvement of the AIAG APQP system.
Four additional elements
Elements start and finish are tied to program
milestones.
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Purpose of APQP Status Report
Common APQP expectations for internal and
external suppliers to Ford Motor Company
Common APQP process metrics
A common program status reporting format
Roles and responsibilities for those involved in
APQP element implementation.
Establishing:
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Ford APQP Status Reporting System
23 elements.
19 elements from AIAG APQP, plus
4 Ford unique elements. They are:
Sourcing Decision
Customer Input Requirements
Subcontractor APQP Status
Craftsmanship
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Approach of Ford APQP
This status reporting guideline describes 23 key
APQP elements.
Ford Motor Company expectations are defined for
these key elements in definitions, and detailed
checklists.
The status for these elements is summarized using
metrics described in the Reporting section.
This status reporting guideline is written from a
supplier standpoint.
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APQP Process Flow
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The APQP Process includes 5 main
functions:
1. Planning of the APQP elements
2. Execution of the APQP elements
3. Monitoring the "Quality-of-Event" of the
execution of the elements, as well as the
timing, by the team in-between milestones
4. Issues Resolution
5. Status Reporting (minimum at each
milestones)
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Use of Ford APQP Status Report
How to use Ford APQP Status Report for
Emerging Market Re-sourcing Programs.
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Backgrounds of APQP for Emerging Market
Re-sourcing Programs --- Ford APQP
Ford APQP Status Report is one Excel file with 26
work sheets.
2 Summary sheets
1) APQP Status Report (linked)
2) APQP Status Report (manual)
1 Information sheet
23 worksheets for 23 Ford APQP elements. One sheet for
each element.
Ford APQP Status Report uses milestones from
Ford FPDS – Ford Product Development System.
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Backgrounds of APQP for Emerging Market
Re-sourcing Programs --- Ford APQP
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Backgrounds of APQP for Emerging Market
Re-sourcing Programs --- FPDS
FPDS – Ford Product Development System
Ford uses FPDS to Plan, Design, Develop and Launch
new vehicles.
Championed by Ford PD.
Contains 15 milestones. 12 of them are used in Ford
APQP Status Report .
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FPDS
Optimize
Vehicle
System
Subsystem
Component
Product/Process
Design
C
ascade Ve
rif
y
Design/
Mfg.
Confirmation
Launch/
Mass Prod.
Confirmation
Update
Corporate
Memory
MANAGE
Define
Architecture
Program
Input
DEFINE
DESIGN
VERIFY AND LAUNCH
PS1KO PS2 SI PASC PH ST PR CP J1 FSLS
LR
CC
041 30 -350
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FPDS – Definitions 15 Milestones
<KO> – Kick-Off (The beginning of program specific work)
<PS1> – Pre<SI>#1 (Mission/vision & target customers defined)
<PS2> – Pre<SI>#2 (Target ranges assessed)
<SI> – Strategic Intent (Initial program direction established)
<SC> – Strategic Confirmation (Teams confirms strategy/viability)
<PH> – Proportions & Handpoints (Vehicle proportion frozen)
<PA> – Program Approval (All targets become objectives)
(ST) – Surface Transfer (Interior/exterior surface provided)
<PR> – Product Readiness (Designs ready for CP builds)
(CP) – Confirmation Prototype (First CP vehicle available)
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FPDS – Definitions 15 Milestones (cont’d)
<CC> – Change Cut-Off (Commitment to Job #1 timing)
<LR> – Launch Readiness (Engineering Sign-off complete)
<LS> – Launch Sign-Off (Ready to Launch)
<J1> – Job #1 Achieved (Start Production)
<FS> – Final Status
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Backgrounds of APQP for Emerging Market
Re-sourcing Programs --- EMLP
EMLP – Emerging Market Launch Plan
Developed to track status of Emerging Market re-
sourcing programs within Ford.
Championed by Ford EMS PD.
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Backgrounds --- EMLP (cont’d)
EMLP – Emerging Market Launch Plan
7 milestones, from program approval to part arrival at Ford receiving
plant.
GSSM+2W – GSSM+2 weeks. EMLP kick-off; issue sourcing agreement.
PR – Product Readiness. 2D drwgs/3D model/DFMEA received by supplier.
CP – Confirmation Prototype. Prototype parts built; “DV” test started.
ESO – Engineering Sign Off. “DV” test completed;
PSW/LS – PSW/Launch Sign. PSW and functional sign-off completed.
SJ1 – Supplier Job 1. Supplier ships out first production shipment.
IPD – In Plant Date. Parts received at Ford plant(s).
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Two Systems, One Objective
Flawless Launch!!
APQP feeds EMLP
EMLP
(Championed by Ford PD)
APQP
(Championed by Supplier)
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APQP for Emerging Market Re-sourcing
vs. Ford APQP
APQP for EM Re-sourcing uses 7 EMLP
milestones (for re-sourcing programs);
APQP uses 12 FPDS milestones (for new
programs).
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APQP for Emerging Market Re-sourcing
vs. Ford APQP
FPDS Milestones
Remain for Reference
EMLP Milestones
Added
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APQP for Emerging Market Re-sourcing
vs. Ford APQP
APQP for EM Re-sourcing uses 7 EMLP
milestones (for re-sourcing programs); APQP
uses 12 FPDS milestones (for new programs).
APQP for EM eliminates New Program specific
requirements, which are not required for Re-
sourcing Programs, from APQP . Maintains
original APQP requirements as guideline.
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APQP for Emerging Market Re-sourcing
vs. Ford APQP
Eliminates New Program
specific requirements
Maintains original APQP
requirements as guideline
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APQP for Emerging Market Re-sourcing
vs. Ford APQP
APQP for EM Re-sourcing uses 7 EMLP milestones (for re
-sourcing programs); APQP uses 12 FPDS
milestones (for new programs).
APQP for EM eliminates New Program specific
requirements, which are not required for Re-sourcing
Programs, from APQP . Maintains original APQP
requirements as guideline.
Checklist includes additional EMLP unique Supplier
responsible requirements for the 23 elements. (At bottom
of the checklist for each element.)
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APQP for Emerging Market Re-sourcing
vs. Ford APQP
Additional EMLP unique Supplier
responsible requirements
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APQP for Emerging Market Re-sourcing
vs. Ford APQP
APQP for EM Re-sourcing uses 7 EMLP milestones (for re-sourcing
programs); APQP uses 12 FPDS milestones (for new
programs).
APQP for EM eliminates New Program specific requirements, which
are not required for Re-sourcing Programs, from APQP .
Maintains original APQP requirements as guideline.
Checklist includes additional EMLP unique Supplier responsible
requirements for the 23 elements. (At bottom of the checklist for
each element.)
Worksheet of “Action Plan” has been added to APQP for EM, to
reduce “copies and pastes” of action plans from 23 elements to the
summary sheet.
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APQP for Emerging Market Re-sourcing
vs. Ford APQP
Sheet of “Action Plan” has
been added.
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APQP for Emerging Market Re-sourcing
vs. Ford APQP
APQP for EM Re-sourcing uses 7 EMLP milestones (for re-sourcing
programs); APQP uses 12 FPDS milestones (for new
programs).
APQP for EM eliminates New Program specific requirements, which
are not required for Re-sourcing Programs, from APQP .
Maintains original APQP requirements as guideline.
Checklist includes additional EMLP unique Supplier responsible
requirements for the 23 elements. (At bottom of the checklist for
each element.)
Worksheet of “Action Plan” has been added to APQP for EM, to
reduce “copies and pastes” of action plans from 23 elements to the
summary sheet.
For forward model (new) programs, Ford APQP should be
used.
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Complete APQP Status Report –
For EM Re-sourcing programs
1. Complete Information
Sheet
Input milestone dates. Should
be same as timing plan.
Input Part Number and
PPAP information.
Input team information, for
both supplier and Ford.
Input program change
history, if any.
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Complete APQP Status Report –
For EM Re-sourcing programs -- continue
2. Complete Program
Information on sheet
of “APQP Status
Report (linked)”.
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Complete APQP Status Report –
For EM Re-sourcing programs -- continue
3. Review status of 23 elements.
Next slide uses status review of element 11,
drawing and specs, at PR as an example.
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Sample Check sheet at PR
Light Gray shaded cells:
Review expectation at these
milestones.
If R or Y, this issue
requires corrective action
If R or Y, review at next
milestone (until it’s G), even if
“Finish Target” date is passed.
Overall status is worst rating of
all expectations. Manual input
is NOT required.
Record identified issue and
corrective action here.
Status Can be updated
continuously until
Milestone Date is met
Prior Milestone
Status is Frozen
Input actual start and finish
dates for each expectation.
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Rating and Assessment – G/Y/R Status
Risk Color Definition
High Red Target dates and/or deliverables are at risk. A recovery
work plan is not available and/or implemented, or the work plan
does not achieve program targets.
Moderate Yellow Target dates and/or deliverables are at risk, but a resourced
recovery work plan has been developed to achieve program
targets, and has been approved by the appropriate
Management Team.
Low Green Target dates and deliverables are on track and meeting
objectives.
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Complete APQP Status Report –
For EM Re-sourcing programs -- continue
4. Complete the summary sheet on “APQP Status Report (linked)”.
Auto-linked to the overall
status of the checksheet
for this element.
Overall status is worst rating of
all elements. Manual input is
NOT required.
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Complete APQP Status Report –
For EM Re-sourcing programs -- continue
4. Complete action plan on summary sheet.
Do not input action plans on the bottom part of “APQP Status
Report (linked)”.
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Complete APQP Status Report –
For EM Re-sourcing programs -- continue
4. Complete action plan on summary sheet - continue.
Header information is linked
from “APQP Status Report
(linked)” sheet.
Copy and paste action plans for
all R and Y issues from 23
elements.
Input Element #.
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APQP Status Report
Supplier must submit Status Report to the CSO STA
every month, and two weeks before each milestone.
STA Site Engineer verifies supplier APQP status and
report-outs meet milestone timing.
Ford Cross functional team must hold regular APQP
reviews (minimum at each milestones) with Supplier to
evaluate overall program health.
Supplier must maintain evidence book for each
element. Submit supporting documentation upon
request.
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Use of Ford APQP Status Report
Q&A
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APQP Reference Information
Obtain a copy of APQP Status Reporting System
for EM from your STA.
Download APQP Status Reporting Guideline from
FSN Website at:
or the Ford Intranet at (for Ford employee only):
Ford APQP Status Report (for new programs) can
also be obtained by using above links.
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Use of Ford APQP Status Report
Thank You!
