WIXLIB

APQP ReportingProcessAdvanced Product Quality PlanningRelease Level: 3.2Ford APQP Guideline (copyright , 2003)Page 10 of 85August 2003Uncontrolled Copy

Advanced Product Quality PlanningRelease Level: 3.2Ford APQP Guideline (copyright , 2003)Page 11 of 85August 2003Uncontrolled Copy

APQP Status ReportThe Ford APQP Status Report summarizes the program status using the 23 Ford APQPelements. It summarizes the information and provides an assessment at thecomponent/subsystem level, the system/organization level(s), and finally the programlevel. The individual issues at each level are to be documented and tracked, as well asraised to management for assistance in solving/closing if they cannot be handled at theworking level.Please note the different levels of reporting, and the summarizing process as shown onpage11. Submit the Status Report to the customer at all major program reviews (e.g. FPDSMilestones).Customers or suppliers shall conduct more frequent status reviews as needed.The customer shall provide a list of all scheduled program status review dates to thesupplier.Submit supporting documentation upon customer request.The subsystem team completes the status report for its product, with componentsupplier status summarized on the Subcontractor APQP status line. The subsystemteams submit the report to their customer, the system team.The system/organization team will then complete the status report for their product, withtheir subsystem supplier status summarized onto the Subcontractor APQP status line.The system teams submit the data to their customer, the vehicle team.Ratings and AssessmentG/Y/R StatusGreen-Yellow-Red status communicates the progress toward the successful completionof an APQP Element by the program need date. Program need date is the last possibledate an element can be completed and not adversely affect quality or timing of theprogram. The “GYR Status” column of the report shows the assessment for eachelement.Definitions/Risk factors for Green, Yellow, and Red are listed in the table below.DEFINITIONSRisk/Status AssessmentRiskHighColorDefinitionRedTarget dates and/or deliverables are at risk. A recovery work plan is notavailable and/or implemented, or the work plan does not achieve programtargets.Moderate Yellow Target dates and/or deliverables are at risk, but a resourced recoverywork plan has been developed to achieve program targets, and has beenapproved by the appropriate Management Team.NoneGreen Target dates and deliverables are on track and meeting objectives.Advanced Product Quality PlanningRelease Level: 3.2Ford APQP Guideline (copyright , 2003)Page 12 of 85August 2003Uncontrolled Copy

APQP Status Report FormAdvanced Product Quality PlanningStatus ReportSupplier/Org:Location:Supplier Code:1Contact Name/Tel:4Program:Model Year:FPDS Milestone:Review Date:23FPDS MILESTONEAPQP ELEMENT6789101112 SI SC PH PA (ST) PR (CP) CC LR LS (J1)yyyy/mm/dd1. Sourcing DecisionPart Name:Part Number:Notice Level:User y/mm/ddyyyy/mm/ddyyyy/mm/ddyyyy/mm/ddyyyy/mm/dd FS yyyy/mm/ddyyyy/mm/dd132. Customer Input Requirements3. Craftsmanship4. Design FMEA5. Design/Manufacturing Review(s)6. Design Verification Plan & Report7. Subcontractor PSW Status8. Facilities, Tools & Gages9. Prototype Build Control Plan10. Prototype Build(s)11. Drawings & Specifications12. Team Feasibility Commitment13. Manufacturing Process Flowchart14. Process FMEA15. Measurement Systems Evaluation16. Pre-Launch Control Plan17. Operator Process Instructions18. Packaging Specifications19. Production Trial Run20. Production Control Plan21. Preliminary Process Capability Study22. Production Validation Testing23. Part Submission Warrant (PSW)OVERALL APQP STATUS RATING (GYR)1415161718Element / Activity#ActivityIssue(s) for Red/Yellow Elements(summarize the concern & resulting risk)Corrective Action / Resolution Plan(e.g. revise timing, allocate rAdvanced Product Quality PlanningRelease Level: 3.2Ford APQP Guideline (copyright , 2003)Page 13 of 85August 2003Uncontrolled Copy

Filling Out the Status Report FormThe following section describes how to fill in each of the fields on the Status Report.Refer to the status report example on the previous page for the number in each field.1. Org/SupplierEnter your organization or your company name. If you are delivering the product to anotherdepartment within the manufacturing facility, a department number or group name may beentered here.2. LocationEnter the location of the facility manufacturing the system/subsystem or component ifapplicable.3. Supplier CodeEnter the UCCS code for the manufacturing facility if applicable.4. Contact Name/Telephone NumberIdentify Program Manager and phone number.5. ProgramEnter the name of the program.6. Model YearEnter the Model Year of the program.7. FPDS Milestone/Team EventEnter the current FPDS Milestone / Team Event that you will be reporting on.8. Review DateEnter the date of the review of this report.9. Part NameEnter the name of the part being reviewed (if applicable).10. Part NumberEnter the part number of the part being reviewed (if applicable).11. Notice LevelEnter the notice level of the part being reviewed (if applicable).12. User PlantEnter the plant(s) where this vehicle / engine / transmission will be built.Advanced Product Quality PlanningRelease Level: 3.2Ford APQP Guideline (copyright , 2003)Page 14 of 85August 2003Uncontrolled Copy

Filling Out the Status Report Form (cont.)13. G/Y/R StatusEnter status for the 23 Elements14. Element / ActivityEnter your home Element Number for which the issue is being reported and the Activityreporting on the issue.15. Issue(s) for Red/Yellow ElementsSummarize the concern and resulting risk here.16. Corrective Action / Resolution PlanEnter a summary of the corrective action for the issue being addressed and the resolutionplan to correct the issue (an 8D that is tracking the issue may be referenced here).17. TimingEnter the Open date for the issue, and when it is resolved, enter the closing date.18. ResponsibilityEnter the name of the Ford Motor Company and/or the Supplier person responsible forfollow-up on this issue.Quality of Event ChecklistsIn Appendix B, is an example of a completed Quality-of-Event Checklist along with thewebsite location of the Excel file that contains the 23 Element Checklists. Thesechecklists cover the basic requirements for successful completion of the elements, butmay not be inclusive. These checklists are to be used as a guideline in assessing yourstatus. The Element expectations on these checklists have been grouped for Milestonereporting following the FPDS process. The boxed areas should be completed by theappropriate milestone. For next milestone report requirements, update the previousmilestone boxed areas as needed. The APQP Status Report Form is linked to thechecklists and the Information Worksheet for ease of reporting.Risk AssessmentEvery APQP team should conduct a risk assessment as soon as possible after formingthe team. The purpose of the risk assessment is to determine what elements in theAPQP process a supplier, organization, or program team must complete. ReferenceAppendix B, for an example of a risk assessment form.Advanced Product Quality PlanningRelease Level: 3.2Ford APQP Guideline (copyright , 2003)Page 15 of 85August 2003Uncontrolled Copy

Risk Assessment (cont.)Elements to be evaluated in the Risk Assessment include:1) Quality History High warranty or Things Gone Wrong (TGWs)on current model or surrogate product Frequent Quality Rejects (QRs) and/or campaigns at the receiving plant (Assy& Stmp. Plants, Supplier Plants, etc.) Similar component or system was the cause of a recall action2) Supplier Profile New supplier or new manufacturing location Product or manufacturing technology is new to the supplier manufacturinglocation Supplier's historic launch performance is poor Supplier resources are stretched due to significant amount of new business Supplier location is not Q1 or is a Q1 revoked-supplier3) Engineering Profile New design Manufacturing techniques are new to the industry Similar products are subject to numerous design changes that threatenprogram timing High product or process complexity Product is strategically important due to high visibility or functionalperformance4). Performance versus Targets Design goals (weight, materials, functional performance, etc.) will be difficultto achieve Reliability goals will be difficult to achieve Quality goals (warranty, TGWs, scrap rates, rework rates, etc.) will be difficultto achieve Program timing is compressed Cost targets are aggressive5). AdjustmentsIf any of the concerns listed above are present, the customer may require all APQPelements to be completed and reported. If the program is considered to be low risk, thesupplier may skip certain APQP elements. For example, if the product is carryover withminor changes, existing control plans may be used, and packaging evaluations may notbe required. The customer must agree in writing to all deviations from the APQPprocess. If the customer and the supplier agree that an element/expectation is notrequired, the supplier should write "NA" for not applicable in the correspondingMilestone column on the Quality-of-Event Checklists.Advanced Product Quality PlanningRelease Level: 3.2Ford APQP Guideline (copyright , 2003)Page 16 of 85August 2003Uncontrolled Copy

APQP TimingAdvanced Product Quality PlanningRelease Level: 3.2Ford APQP Guideline (copyright , 2003)Page 17 of 85August 2003Uncontrolled Copy

Ford / Supplier Systems "V" ModelC u s to m e r F o c u sC u s to m e rM u s t / W a n ts KO C u s to m e rS a tis fa c tio nC u s to m e r E x p e rie n c e a n d F e e d b a c kF o rd(S u p p lie r's(S u p p lie r'sIn te rn a l) F o rd S I In te rn a l) J1 J1 J1 G e n e ric S y s te m s E n g in e e rin gV e h ic le L e v e l In p u ts S I F o rdP ro g ra m T im in gR e la tio n s h ip to S u p p lie rT im in g J1 "V " M o d el S I R e la tio n s h ip to P ro g ra m a n d S u p p lie r T im in gT h e T o ta l F o rd P ro g ra m T im in g isd e te rm in e d , a n d p ro v id e d to th eT ie r 1 a n d T ie r 2 S u p p lie rs .V e h ic le L e v e lR e q u ire m e n ts (V D S )It is v e ry im p o rta n t to u n d e rs ta n dth a t th e T ie r 1 a n d T ie r 2s u p p lie rs a re b ro u g h t o n a td iffe re n t tim e s , w ith tig h te rp ro c e s s tim in g re q u ire m e n ts .S u p p lie rs m u s t b e a b le to p e rfo rma ll o f th e n e c e s s a ry e le m e n tso f A P Q P a n d th e p ro g ra m , w ith inth is tim in g .S y s te m /S u b s y s te m L e v e l (S D S )T o o lin g &T h e ir o w n in te rn a l J o b # 1 m u s to c c u r b e fo re th e a c tu a l J o b # 1 o fth e p ro g ra m , a n d th e y m u s t b a c ku p th e ir tim in g fro m th e a c tu a lP ro g ra m J o b # 1 to a s s u re th e ya re a b le to d e liv e r o n tim e .T ie r 2 S u p p lie rT o o lin g & T ie r 1 S u p p lie rF o rd T o ta l P ro g ra m T im in gIt is th e re fo re e v e n m o re c ritic a lth a t a ll d e s ig n a n d q u a lityd is c ip lin e s a re p la n n e d fo r, a n dfo llo w e d , v e ry e a rly o n , to p re v e n tla te e n g in e e rin g c h a n g e s . IfN O T , th e y a re N O T a b le tore c o v e r in m a n y c a s e s .P a rt/C o m p o n e n t F a b ric a tio n /V e rific a tio nP a rt /C o m p o n e n t D e s ig n(C o m p o n e n t D e s ig n S p e c - C D S )T o ta l P ro g ra m F P D S M ile s to n e sT ie r 1 S u p p lie r M ile s to n e sT ie r 2 S u p p lie r M ile s to n e s S I S tra te g icIn te n t CC C h a n g e C u to ffS y s te m s O rie n te d v ie w o f A P Q PAdvanced Product Quality PlanningRelease Level: 3.2Ford APQP Guideline (copyright , 2003)(C P )C o n firm a tio nP ro to ty p e J1 Job #1M a n u fa c tu rin g a n d D e liv e ry O rie n te d v ie w o f A P Q PPage 18 of 85August 2003Uncontrolled Copy

APQP Generic Program Timing Gantt ChartAPQP Generic Program Timing Gantt ChartMonths Before Job #1 (MBJ1)All new vehicle: S6New Exterior, modified lower struc: S5New Exterior, c/o lower structure: S4Moderate Freshening: S3Minor Freshening: S2Trim: S1ElementFPDS MilestonesFERPSWRequirement(Approx. 17Months1PP 484.5

Ford APQP Guideline (copyright , 2003) August 2003 Uncontrolled Copy APQP Status Report The Ford APQP Status Report summarizes the program status using the 23 Ford APQP elements. It summarizes the information and provides an assessment at the component/subsystem level, the system/organization level(s), and finally the program level.