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This check List must be submitted to FCSD STA before submitting a PPAP package.

Guidelines

Select Status

Comments

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

If required by print note, Ford Engineering approval of a sample part must be


included.

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.

Ford Engineering may


waive the SREA.

Process flow shall cover dock to dock process steps.


Operation numbers among PF, PFMEA and Control Plan should be aligned.
Process Flow
Process flow to include FCSD order filling process(Service Part Picking,
packaging, labeling, auditing, and shipping)

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)

FCSD PPAP Checklist

5 Samples minimum

Ford Engineering may


approve deviations.
Include data and approval
with the PPAP submission.
125 pieces min. = 25
subgroups of 5
Only required for SCs.

Guidelines

Select Status

Comments

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

Lab certified to ISO/TEC-17025.

Include AAR record when applicable.

When applicable

Representative part samples shall be sent to the approving STA


If it is not feasible to ship a sample part, multiple detailed pictures of the
part(s) with distinctive features among parts within the same part family
identified and highlighted.

3 minimum

Master Sample identified, approved and preserved in suitable location. Also


establish approved boundary samples for appearance attributes.
Picture of Matser Sample to be included in PPAP package or submitted to
approving STA before final PPAP approval may be granted.
Master Sample is also required for interim PPAP and STA is not permitted to
provide waivers for this requirement without discussing with management.
Include location where Checking Aids are found. Must include certification
frequency.
Service Part visual aid should include Master Part Record with photo, Label,
and packaging requirements.
1. Supplier shall become aware of all of FCSD specific requirements and
consult STA as needed.
2. For total suppliers, include component bar code labels.
3. Include sample job aid illustrating type of instructions provided to
operators.
4. If shipping in bulk, show how the process allows for successful QR
dispute
5. PD signature is required for inverted delta parts.
6. Include a summary report of the PCS claims and historical rejects.
Supplier shall become aware of all of FCSD specific requirements and
consult STA as needed.
For total suppliers, include component bar code labels.
Include sample job aid illustrating type of instructions provided to operators.
If shipping in bulk, show how the process allows for successful QR dispute
PD signature is required for inverted delta parts.

PSW

Include a summary report of the PCS claims and historical rejects.


Include Engineering as well as Service part number
Verify Part Numbers, especially suffixes and colors.
Include a copy of the GPMA screen
Include all component parts signed PSW forms approved by the tier-1
supplier.
Make sure all blanks are filled.
Report average weight of 10 pieces in Kg to 4 decimal places - must match
weight reported on IMDS screen.
Photographic evidence of proper tool tagging (tools post 5-Jan-2009)
a. Line 1: Property of Ford Motor Company
b. Line 2: <Tool Order #>-<Amendment #>-<Line Item #>
Compliance to part branding directive E108 or a valid waiver or exemption
number.

Applicable to all parts


manufcatured after August
2003.

Copy of IMDS Screen


Total Service suppliers must have completed a Packaging Spec and
submitted into FCSD packaging web site.

Bulk Material
Requirements Checklist

FCSD Miscellaneous
Items

No packaging specifications approval by FCSD required for bulk shipping to


packagers.

When applicable

It is the Manufacturing supplier's responsibility to deliver the parts to the


packager is saleable conditions - rust and damage free.
An approved WERS alert is required to authorize shipment of parts without
PPAP approval.
A PPAP for Service is not required if the same exact part has an approved
PPAP from Ford Production.

FCSD PPAP Checklist

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