交运制造
FORD流程简介
—上海交运集团股份有限公司汽车零部件制造分公司
1
交运制造
早期参与
团队
标准化
管理/汇报
采用唯一的，全球通用到，有纪律的流程
尽量减少返工和重复。
在产品开发过程早期，与供应商更融洽地合作
利用福特跨功能团队与供应商一起在现场工作
(4次拜访)
使用共同的，明确的交付报告和结构化的
管理评审模式
GPDS（ Global Product Development System）
—是FORD公司全球产品开发体系，替代原FPDS福特产品开发体系
GPDS 全球产品开发体系
交运制造
3
GPDS 供应商管理过程-总览
PTC/
M1DJPTCC
PA FDJ PEC
LR/
FEC
M1 VP TT PP MP1
Unit
PTC
Unit
PA
27MBJ1 25MBJ1
17MBJ1 13MBJ1 8MBJ1 5MBJ1 0MBJ1
供应商选
点开始
高影响供
应商选择
跨功能小组形成
启动会议
开始
第一次现场
评审
第二次现场
评审
第三次现场
评审
第四次现场
评审
解决问题
决定：
是否进
行试生
产？
更新供应商 APQP/PPAP 准备状态评估报告 (A表)
(655/654)
交运制造
PTC-Program Target Compatibility 项目目标整合
PA-Program Approval 项目批准
FDJ-Final Data Judgement 工程数据发布
VP-Verification Prototype (OTS)样件验证
PEC-Preliminary Engineering Completion 工程数据冻结
项目节点（里程碑）
交运制造
LR-Launch Readiness 生产准备就绪（可生产）
TT-Tooling Trial 工装样件 （PSW1）
PP-Pilot Production 试生产（可售）(PSW2)
MP1-Mass Production 1 量产 (PSW3)
Job #1— 整车投产
项目节点（里程碑）
交运制造
6
PTC/
M1DJPTCC PA FDJ
M1
Unit
PTC
Unit
PA
27MBJ1 25MBJ1
17MBJ1 13MBJ1 5MBJ1 0MBJ1
(655/654)
PEC
LR/
FEC VP TT PP
8MBJ1
MP1
供应商选
点开始
关键供
应商选择
跨功能小组形成
启动会议
开始
第一次现场
评审
第二次现场
评审
第三次现场
评审
第四次现场
评审
解决问题
决定：
是否进
行试生
产？
更新供应商 APQP/PPAP 准备状态评估报告 (A表)
OTS PPAP
Phase0/1
PPAP
phase2
PPAP
phase3
FORD项目跟踪（装车）节点
项目批准 工程数
据发布
手工样
件OTS
交运制造FORD项目开发节点
交运制造PPAP 的18项
1. Design Records设计记录
2. Engineering Change Documents工
程变更文件
3. Engineering Approval 工程批准
4. Design FMEA设计FMEA
5. Process Flow Diagrams过程流程
图
6. Process FMEA过程FMEA
7. Control Plans控制计划
8. Measurement System Analysis
Studies测量系统分析研究
9. Dimensional Results尺寸报告
10. Records of Material / Performance
Test Results材料和性能测试结果及纪
录
11. Initial Process Studies初始过程能
力研究
12. Qualified Laboratory Documentation
有资格的实验室文件
13. Appearance Approval Report外观批准
报告
14. Sample Production Parts生产样件
15. Master Sample标准样件
16. Checking Aids检查辅具
17. Customer-Specific Requirements顾客
特殊要求
18. Production Part Approval Process
Submission Warrant (PSW)零件提交保
证书
交运制造Phased PPAP 要求
Phased PPAP是FORD对PPAP流程管理的特殊
要求
主要目的是提高正式生产是的质量表现
需要供应商证明以下要点：
—制造能力
—产品质量
—产能能力
交运制造全球阶段性PPAP:是在怎样的基础上建立起来的
Phase 3 Phase 3
Capacity VerificationCapacity Verification
产能验证产能验证
Phase 2Phase 2
Production VerificationProduction Verification
生产验证生产验证
Phase 1Phase 1
Quality VerificationQuality Verification
质量验证质量验证
Phase 0Phase 0
Run-at-RateRun-at-Rate
节拍生产节拍生产
加强沟通
1. 一至性的沟通
2. 关注少数重要的优先点。
3. 言简意赅
4. 帮助使用者区分优先级
5. 去除障碍
改善工作流程
1. 简化
2. 稳定化
3. 标准化
4. 节奏化
5. 持续性
交运制造供应商阶段性PPAP过程图
STATUS:
Phase 2
Completed
Phase 2
Warrant
[#18]
Yes
Status Tracking
Database
2 3
4
P
ro
ce
ed
to
n
ex
t p
ag
e
Submit to
Customer
Important note:
Phase 2 and Phase 3 can happen
concurrently if all Inputs and
Outputs are satisfied
No
INPUTS
Released
design
[#1,2,3 & 4]
Trained
supplier
production
operators
Sub-supplier(s)
material status
from Tier-x
R@R
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@Rate input
requirements in place
for the production
stream?
Yes
START
No
Capacity
Analysis
Worksheet
Status Tracking
Database
1
4
P
ro
ce
ed
to
n
ex
t p
ag
eR
eq
ui
re
d
In
pu
ts
Submit to
Customer
Note: [#x] refers to the Element Number in PPAP 4th Edition that
will assist in confirming requirements
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 elements been
satisfied?
Yes
Status Tracking
Database
1
4
2
4
Important note:
For suppliers with only one
production stream completion of
Phase 1 & 2 occur at the same
time
P
ro
ce
ed
to
n
ex
t p
ag
e
Return to
Phase 0 for
corrective
action
No
Submit to
Customer
Phase 1
Warrant
[#18]
Phase 2
Warrant
Scheduled
down time
defined (TPM,
change over,
Breaks etc.)
Sub supplier
material status
from Tier-x
Phase 3
EVENT:
Conduct
Capacity
Verification Run STATUS:
Phase 3
Completed
Quantity
required is
customer DPV
for one full day
All personnel
for all shifts,
trained
Are the
CVR input
requirements in place
for all production
streams?
Yes
END
Status Tracking
Database
Return to
affected phase
and start
corrective action
Phase 3
Warrant
[#18]
& Capacity
Analysis
Report
Determine
Root Cause &
Plan Corrective
Action
Was the
control plan followed
& acceptable parts
produced?
Did the
volume of acceptable
parts produced meet or
exceed the required
DPV?
No
Yes
No
3
R
eq
ui
re
d
In
pu
ts
Phase 0 Phase 1 Phase 2
Phase 0
Run-at-Rate
Phase 1
Quality Verification
Phase 2
Production Verification
Phase 3
Capacity Verification
1 - 设计记录
2 - 工程变更文件
3 – 顾客工程批准
4 - 设计FMEA
5 - 过程流程图
6 - 过程FMEA
7 - 控制计划
8 - 测量系统分析
16 – 检查辅具
17 – 顾客特殊要求
9 - 尺寸报告
10 – 材料和性能检测报
告
11 - 初始过程能力研究
12 - 有资格的实验室文
件
13 – 外观批准报告
14 – 生产样件
15 – 标准样件
18 – 零件提交保证书
phase1 PSW
零件提交保证书
phase2 PSW(要素18)
所有的生产线进行节拍生
产 (要素1 – 8, 16, 17)
对所有的生产线进行质量
验证
(要素9 – 15) 产能分析报告
零件提交保证书
phase3 PSW (要素
18)
产能分析报告
Have Run-at-Rates
(Phase 0) been
conducted and Quality
Verifications (Phase 1)
been satisfied for ALL
production streams?
交运制造Phased PPAP与PPAP的比较
Phased PPAP organizes the process into four phases
Phase 0: Run-at-Rate 按节拍生产
Phase 1: Quality Verification 质量确认（一条生产线）
Phase 2: Production Verification 产品验证 （多条生产线）
Phase 3: Capacity Verification 产能验证
PPAP
X 1 PP FEU Job 1
Phased PPAP Phase 0 Phase 1 Phase 2 Phase 3
交运制造阶段PPAP的要求
1. Phase 0：Run-at-Rate初始按节拍生产
正式的生产场地、生产人员
正式的设备、工装 夹具、模具、量检具
文件齐全：EWO/DFMEA/ FC/ PFMEA/CP/培训记录/顾客特殊要求
至少300件连续生产
产能分析、MSA
交运制造Building on the Basics: Phase 0
STATUS:
Phase 2
Completed
Phase 2
Warrant
[#18]
Yes
Status Tracking
Database
2 3
4
P
ro
ce
ed
to
n
ex
t p
ag
e
Submit to
Customer
Important note:
Phase 2 and Phase 3 can happen
concurrently if all Inputs and
Outputs are satisfied
No
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 elements been
satisfied?
Yes
Status Tracking
Database
1
4
2
4
Important note:
For suppliers with only one
production stream completion of
Phase 1 & 2 occur at the same
time
P
ro
ce
ed
to
n
ex
t p
ag
e
Return to
Phase 0 for
corrective
action
No
Submit to
Customer
Phase 1
Warrant
[#18]
Phase 2
Warrant
Scheduled
down time
defined (TPM,
change over,
Breaks etc.)
Sub supplier
material status
from Tier-x
Phase 3
EVENT:
Conduct
Capacity
Verification Run STATUS:
Phase 3
Completed
Quantity
required is
customer DPV
for one full day
All personnel
for all shifts,
trained
Are the
CVR input
requirements in place
for all production
streams?
Yes
END
Status Tracking
Database
Return to
affected phase
and start
corrective action
Phase 3
Warrant
[#18]
& Capacity
Analysis
Report
Determine
Root Cause &
Plan Corrective
Action
Was the
control plan followed
& acceptable parts
produced?
Did the
volume of acceptable
parts produced meet or
exceed the required
DPV?
No
Yes
No
3
R
eq
ui
re
d
In
pu
ts
Phase 0 Phase 1 Phase 2
Phase 1
Quality Verification
Phase 2
Production Verification
Phase 3
Capacity Verification
9 - Dimensional Results
10 - Records of Material /
Performance Test Results
11 - Initial Process Studies
12 - Qualified Laboratory
Documentation
13 - Appearance Approval Report
14 - Sample Production Parts
15 - Master Sample
18 - PPAP Warrant
PPAP Warrant (element 18)
Run-at-Rate for all production
streams (element 1 – 8, 16, 17)
Quality Verification for all
production streams
(element 9 – 15)
Capacity Analysis Report
PPAP Warrant (element 18)
Have Run-at-Rates
(Phase 0) been
conducted and Quality
Verifications (Phase 1)
been satisfied for ALL
production streams?
INPUTS
Released
design
[#1,2,3 & 4]
Trained
supplier
production
operators
Sub-supplier(s)
material status
from Tier-x
R@R
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@Rate input
requirements in place
for the production
stream?
Yes
START
No
Capacity
Analysis
Worksheet
Status Tracking
Database
1
4
P
ro
ce
ed
to
n
ex
t p
ag
eR
eq
ui
re
d
In
pu
ts
Submit to
Customer
Note: [#x] refers to the Element Number in PPAP 4th Edition that
will assist in confirming requirements
Phase 0
Run-at-Rate
1 - 设计记录
2 - 工程变更文件
3 – 顾客工程批准
4 - 设计FMEA
5 - 过程流程图
6 - 过程FMEA
7 - 控制计划
8 - 测量系统分析
16 – 检查辅具
17 – 顾客特殊要求
产能分析报告
交运制造Phase 0: 节拍生产
输入
设计发布
(PPAP #1, 2, 3, 4)
供应商应该有可销售产品的
设计记录，包括下层件的详
细信息。
所有的电子档数据，都需要
有硬拷贝的文件来进行追踪，
以及评审。
Start
Released Design
[#1, 2, 3, 4]
Trained supplier
production
operators
Sub-supplier(s)
material status
from Tier-X Run-at
-Rate
Quantity of parts
required as
defined by
customer (default
300 consecutive
parts)
Job 1 location
(final site and line)
Production
process including
control plan, flow
diagram
instructions, and
Process
Parameters
[#5, 6, 7]
Production tools,
facilities, and
gauging
[#8, 16, 17]
Planned
production cycle
times required to
support daily
production volume
Are the Run-
at-Rate input
requirement
s in place for
the
production
stream?
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?Implement
corrective
action on
input
EVENT:
Conduct Run-
at-Rate
STATUS:
Phase 0
Complete
Capacity
Analysis
Report
Status
Tracking
Database
4
1
YES
NO
NO
NO
NO
NO
YES
YES
YES
Submit
to customer
Outputs from the event
YES
交运制造Phase 0: 节拍生产
输入
经过培训的操作员
供应商必须出示证据，以证
明所有涉及到的现场操作员，
已经得到了针对新模具、设
备、流程等方面的培训。
Start
Released Design
[#1, 2, 3, 4]
Trained supplier
production
operators
Sub-supplier(s)
material status
from Tier-X Run-at
-Rate
Quantity of parts
required as
defined by
customer (default
300 consecutive
parts)
Job 1 location
(final site and line)
Production
process including
control plan, flow
diagram
instructions, and
Process
Parameters
[#5, 6, 7]
Production tools,
facilities, and
gauging
[#8, 16, 17]
Planned
production cycle
times required to
support daily
production volume
Are the Run-
at-Rate input
requirement
s in place for
the
production
stream?
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?Implement
corrective
action on
input
EVENT:
Conduct Run-
at-Rate
STATUS:
Phase 0
Complete
Capacity
Analysis
Report
Status
Tracking
Database
4
1
YES
NO
NO
NO
NO
NO
YES
YES
YES
Submit
to customer
Outputs from the event
YES
交运制造Phase 0: 节拍生产
输入
顾客定义的生产量
•一般默认为300件连
续性的产品
供应商必须使用计划
的量产状态下的节拍，
设备，人员和至少一
套模具来进行此次生
产。
Start
Released Design
[#1, 2, 3, 4]
Trained supplier
production
operators
Sub-supplier(s)
material status
from Tier-X Run-at
-Rate
Quantity of parts
required as
defined by
customer (default
300 consecutive
parts)
Job 1 location
(final site and line)
Production
process including
control plan, flow
diagram
instructions, and
Process
Parameters
[#5, 6, 7]
Production tools,
facilities, and
gauging
[#8, 16, 17]
Planned
production cycle
times required to
support daily
production volume
Are the Run-
at-Rate input
requirement
s in place for
the
production
stream?
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?Implement
corrective
action on
input
EVENT:
Conduct Run-
at-Rate
STATUS:
Phase 0
Complete
Capacity
Analysis
Report
Status
Tracking
Database
4
1
YES
NO
NO
NO
NO
NO
YES
YES
YES
Submit
to customer
Outputs from the event
YES
交运制造
•底盘件：最少300件
•钣金件：最少30-100件
•内外饰件：最少30-100件
•电器件：最少300件
• 动力系统件：最少300件
•排气系统：最少300件
•燃油系统：最少300件
节拍生产数量
交运制造
[19]
Phase 0: 节拍生产
输入
•供应商量产零件所使用
的生产场地
•所有的量产件需要在计
划的量产场地使用为量产
开发的模具，检具，过程，
材料，人员，环境和过程
设置进行生产。
•所有的过程参数，必须
在节拍生产前完成验证并
确认。
Start
Released Design
[#1, 2, 3, 4]
Trained supplier
production
operators
Sub-supplier(s)
material status
from Tier-X Run-at
-Rate
Quantity of parts
required as
defined by
customer (default
300 consecutive
parts)
Job 1 location
(final site and line)
Production
process including
control plan, flow
diagram
instructions, and
Process
Parameters
[#5, 6, 7]
Production tools,
facilities, and
gauging
[#8, 16, 17]
Planned
production cycle
times required to
support daily
production volume
Are the Run-
at-Rate
input
requirement
s in place for
the
production
stream?
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?Implement
corrective
action on
input
EVENT:
Conduct Run-
at-Rate
STATUS:
Phase 0
Complete
Capacity
Analysis
Report
Status
Tracking
Database
4
1
YES
NO
NO
NO
NO
NO
YES
YES
YES
Submit
to customer
Outputs from the event
YES
交运制造
[20]
Phase 0: 节拍生产
输入
生产过程包括控制计划，
过程流程图和过程参数
[PPAP #5,6,7]
•供应商必须有一个能
够清晰描述生产步骤和
顺序的过程流程图
•供应商必须要有过程
FMEA
•供应商必须要有过程
控制计划
Start
Released Design
[#1, 2, 3, 4]
Trained supplier
production
operators
Sub-supplier(s)
material status
from Tier-X Run-at
-Rate
Quantity of parts
required as
defined by
customer (default
300 consecutive
parts)
Job 1 location
(final site and line)
Production
process including
control plan, flow
diagram
instructions, and
Process
Parameters
[#5, 6, 7]
Production tools,
facilities, and
gauging
[#8, 16, 17]
Planned
production cycle
times required to
support daily
production volume
Are the Run-
at-Rate input
requirement
s in place for
the
production
stream?
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?Implement
corrective
action on
input
EVENT:
Conduct Run-
at-Rate
STATUS:
Phase 0
Complete
Capacity
Analysis
Report
Status
Tracking
Database
4
1
YES
NO
NO
NO
NO
NO
YES
YES
YES
Submit
to customer
Outputs from the event
YES
交运制造
[21]
Phase 0: 节拍生产
输入
量产模具，设备和检
具[PPAP #8,16,17]
•供应商必须确认使
用的设备、模具、检
具状态是否为新开的，
整修的还是迁移的
•用于量产的资源是
否符合顾客要求的数
量和质量标准
Start
Released Design
[#1, 2, 3, 4]
Trained supplier
production
operators
Sub-supplier(s)
material status
from Tier-X Run-at
-Rate
Quantity of parts
required as
defined by
customer (default
300 consecutive
parts)
Job 1 location
(final site and line)
Production
process including
control plan, flow
diagram
instructions, and
Process
Parameters
[#5, 6, 7]
Production tools,
facilities, and
gauging
[#8, 16, 17]
Planned
production cycle
times required to
support daily
production volume
Are the Run-
at-Rate input
requirement
s in place for
the
production
stream?
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?Implement
corrective
action on
input
EVENT:
Conduct Run-
at-Rate
STATUS:
Phase 0
Complete
Capacity
Analysis
Report
Status
Tracking
Database
4
1
YES
NO
NO
NO
NO
NO
YES
YES
YES
Submit
to customer
Outputs from the event
YES
交运制造
[22]
Phase 0: 节拍生产
输入
供应商计划产能的生
产节拍必须满足顾客
的需求
•供应商必须提供证
据证明在计划的量产
现场都能满足要求的
情况下，生产线能够
生产出满足顾客日产
量的产品。
Start
Released Design
[#1, 2, 3, 4]
Trained supplier
production
operators
Sub-supplier(s)
material status
from Tier-X Run-at
-Rate
Quantity of parts
required as
defined by
customer (default
300 consecutive
parts)
Job 1 location
(final site and line)
Production
process including
control plan, flow
diagram
instructions, and
Process
Parameters
[#5, 6, 7]
Production tools,
facilities, and
gauging
[#8, 16, 17]
Planned
production cycle
times required to
support daily
production volume
Are the Run-
at-Rate input
requirement
s in place for
the
production
stream?
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?Implement
corrective
action on
input
EVENT:
Conduct Run-
at-Rate
STATUS:
Phase 0
Complete
Capacity
Analysis
Report
Status
Tracking
Database
4
1
YES
NO
NO
NO
NO
NO
YES
YES
YES
Submit
to customer
Outputs from the event
YES
交运制造
2. Phase 1：质量确认
零件尺寸报告
材料、性能检测报告
初始过程能力研究， Ppk=
生产样件
分供方的PSW已签署
提交Phase1 PSW
阶段PPAP的要求
交运制造
3. Phase 2：产品验证
所有生产线按节拍生产（Phase0要求）
所有生产线的质量验证（Phase1要求）
分供方全部完成Phase2
提交Phase2 PSW
注：针对多条生产线生产同一产品，若只有一条线可省略。
阶段PPAP的要求
交运制造
4. Phase 3：产能验证
Phase2 认可的 PSW
所有班次人员完成培训
分供方产能分析
产能分析报告，GP9 证明在5天/周和3班/天的情况下能满足顾客LCR
提交Phase3 PSW
阶段PPAP的要求
交运制造
每次提交PPAP时，需要向STA提交检查清单
只有该检查清单的所有要素均备STA认可，才能签署PSW 所有班次人
员
具体要求请联系STA
阶段PPAP检查清单
交运制造
所有CC/SC/HIC 需要使用计量型量具
所有CC/SC/HIC尽可能采用放错，如不能则需要SPC控制
过程能力 Cpk＞， Ppk＞
所有过程控制需满足FORD特殊要求，如CQI-9
过程能力要求
交运制造
Thank You!
交运制造项目管理
项目管理三大要素—质量、进度、资源
产品项目特点:
项目时间性较强
具备一定的要求或标准—顾客输入
产品项目的开展遵循规定的路径—顾客要求
成本限定性较强—目标成本分解
交运制造
阶段评审（质量阀）
项目进度
问题清单
经验教训
商务问题
人力资源
变更管理
发货跟踪
项目管理
交运制造
样件确认是一个宝贵的机会，关键的闸口
•是否只有个别样本？ (质量阀)
•小批运行能力
•是否来自于确定制程？
•外观要求确立
•产品规格确立
•试验条件确立
•检验规格是否确定
•材质是否已经明确达到要求？
样件确认：
交运制造
32
PTC/
M1DJPTCC PA FDJ
M1
Unit
PTC
Unit
PA
27MBJ1 25MBJ1
17MBJ1 13MBJ1 5MBJ1 0MBJ1
(655/654)
PEC
LR/
FEC VP TT PP
8MBJ1
MP1
供应商选
点开始
关键供
应商选择
跨功能小组形成
启动会议
开始
GAMMA PPAP
Phase0/1
PPAP
phase2
PPAP
phase3
FORD项目跟踪（装车）节点
项目批准 工程数
据发布
手工样
件OTS
交运制造项目成功的因素：
项目的目标、范围是否明确；
是否获得领导的积极支持；
项目的组织是否健全、稳定；
是否建立了有序的、有效的、良好的沟通渠道；
是否具有有效、全面的项目管理，严格的变更
控制；
是否建立了良好的、积极的、团队合作的工作
氛围；
交运制造项目关键工作要素：
交运制造
35
项目阶段常见问题 QSB
问题分析响应缓慢 快速响应
调试件流入到顾客生产现场 不合格品控制
操作检验流程不完善，发生问题 岗位验证
员工操作随意性大 标准化操作
员工没有培训到位 标准化的操作工培训
防错出现问题，批量产生缺陷 防错验证
问题解决措施迟迟无法落实 分层审核
预见到重大问题，最终还是发生 风险降低
零件污染，影响外观和功能 异物控制
二、三级零件质量问题 供应链管理
变更导致的问题 变更管理
项目阶段常见问题：
交运制造质量风险识别
交运制造质量风险遏制
GP12
8D
PR&R
CS
手段：
飞行检查
产品审核
过程审核——FTQ、RPN降低
交运制造
1. 试产阶段之后，批量交付之前，必须进行产品审核,之后按计划定期
进行复审。
2. 必须从已生产的成品中----待交付状态抽取样本
3. 产品审核所需零件抽样数量应根据产品复杂程度和以往的经验一般
来说一个零件号至少要抽5~10 件
4.在确定了与顾客要求有偏离时,要求供应商制定立即整改措施，在整
改措施和结果得到批准前，所有相关货品处于隔离状态。
5. 在检验零件的同时也要对检验和测量设备的品质和性能进行评价,连
同供应商一方的测量作业人员能力，并在过程审核中给予重视,如发
现与要求有偏差也必须商定整改措施.
产品审核
交运制造质量验证与确认：
一、逐工序验证
使用控制计划—进行每道工序过程审核
好处：便于操作
使用限制：试产不足时难以操作
二、产品验证—产品审核
使用事先制订的特性列表—包含包装、可靠
性、材质等
好处：严格，全面
使用限制：测试条件和人员要求
交运制造刚开始量产阶段--发货控制期
GP12
交运制造
• 客户端图纸上规定的特殊特性
• 与客户端装配有关的尺寸或参数
• 可能造成客户停线
• 特殊过程所产生的结果
• 贯穿性的参数
• 具有可靠测量条件
特殊特性的后续作用：
质量保证的基础
关键过程定位
过程能力分析
建立特殊特性列表-尽早辨识
交运制造项目风险：
项目风险是项目在其周期内不期望发生事件的客
观不确定性
是所有影响项目目标实现的不确定因素的集合
包括：事件（不希望发生的变化）事件概率、
事件影响、风险源等因素。
交运制造项目风险：
项目风险的识别：
确定风险的来源；
风险产生的条件；
描述风险的特征；
分析风险对项目的影响
风险的种类：
要求不明确、技术、管理、质量、资源、法
规、物料
交运制造典型项目风险举例：
物料不能按时到位，或时间到了仍存在质量
问题
产品测试条件欠缺，或潜在所需成本高
客户的设计总处于更改之中，要求仍有不明
确之处
生产工艺水平缺失
项目周期太紧，没有时间进行完整的前期质
量控制
风险突破：技能，权限，沟通
交运制造
Thank You!
