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Guidelines
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PPAP Element
Design change level should match on all documents.
Part description in the engineering change column should be the same as
on authorized Engineering Change Documents/WERS.
All print requirements, e.g. dimensions, material specs, performance specs
and notes, should be numbered for traceability to measurements.
Design Record
Drawings shall be reviewed with Ford Eng. for customer attachment points
and other critical dimensional call outs.
CCs () shall precede part number for all inverted delta parts.
Compliance to Restricted Substance Management standards (WSSM99P9999-A1) and Ford Eng. Material Specification shall be noted on the
drawing.
Copy of B.O.M.
Reporting of Part
The part does not contain any restricted or reportable substance (IMDS).
Material Composition Verify if plastic parts are marked with appropriate ISO marking codes per
and Marking of Polymeric ISO 11469 (plastic > 100g) or ISO 1629 (rubber > 200g)
Include copies of Ford Engineering Release Notice.
Authorized Engineering
Design Change/s (suffix bump) shall have an approved notice.
Change Document
All change/s shall have an approved SREA.
Customer Engineering
Approval
DFMEA
1. Severity 9 or 10 shall have YC classification; All 9's and 10's shall have a
recommended action plan.
2. Severity = 5-8 AND Occurrence = 4-10 shall have YS classification
3. A YC/YS Matrix summarizing these characteristics is recommended.
PFMEA
All CC/SC's identified in the YC/YS Matrix shall be captured in either Tier 1
or Tier 2 PFMEA.
PFMEA classification shall include CC if severity = 9 or 10, or SC if severity
= 5-8 & occurrence = 4-10.
PFMEA Severity levels must not be below DFMEA levels (May be higher in
certain circumstances). When DFMEA is not available the PFMEA should
be review by Ford engineering for approval.
All Inverted Delta () characteristics identified on PFMEA shall be reviewed
and agreed by Ford Engineering and approved by PD/STA.
Control Plan
All Inverted Delta () parts shall have Control Plans reviewed and approved
by PD and STA.
All CC/SC identified in the PFMEA shall be cascaded to the Control Plan
and special controls identified with appropriate Reaction Plan.
Reaction Plan must contain specific instructions on how to contain defects
and correct any process issues.
Measurement Systems
Analysis
Dimensionals
Material, Performance
Test Results (Per
Engineering and Material
Specification)
Studies required for all new or modified gages, measurement and test
equipment.
Calibration traceable to NIST. Software validated by standard data sets.
Variable Gage R&R studies shall have a minimum of 5 distinct categories,
Gage R&R as a % of contribution < 10%, % of study variation should be <
10% but <30% may be accepted.
Operator-part interaction should be accounted for by using the ANOVA
method.
Dimensional results traceable to ballooned drawing, including reference
dimensions.
Tier 2 PPAPs, including any deviations, shall be made available upon
request.
DVP&R and PVP&R shall contain actual test results, indicate PASS, and be
reviewed and signed off by Ford Eng. Any PV waivers must be in writing and
part of the PPAP file.
Material certificates, if any, shall be no less than a year old.
Where no CC/SC identified, supplier shall designate control characteristics
on Control Plan and conduct studies (no out-of-control processes)
5 Samples minimum
Guidelines
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PPAP Element
Initial Process Study
Analysis should be completed with Minitab, and data should be checked for
normality. If non-normal, data should be transformed (P value >.05)
Suppliers shall use the Ppk process capability index (Ppk >1.67)
125 pc capability study (25 sub groups, 5 parts per sub group) is required,
but you may discuss deviation from this requirement with your STA.
Qualified Lab
Documentation
AAR
Sample Part
Master Sample
Checking Aids
FCSD Specific
Requirements
When applicable
3 minimum
PSW
Bulk Material
Requirements Checklist
FCSD Miscellaneous
Items
When applicable