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GLOBALPURCHASINGSupplierTechnicalAssistancePhasedPPAPEdition1,October2002PhasedProductionPartApprovalProcessPhasedPPAPFordMotorCompanySupplierTechnicalAssistanceOctober,2002TableofContentsAcknowledgementsForewordCONTENTSPhasedPPAPIntroduction3PPAPMilestones4PhasedPPAPOverview5PhasedPPAPProcessFlow6Run-at-Rate7Phase1PPAP–QualityVerification8Phase2PPAP–ProductionVerification9Phase3PPAP–CapacityVerification10CustomerDispositionofthePSW13Expectations14AppendixA15AppendixB21AppendixC22AppendixD24AcknowledgementsThedevelopmentofPhasedPPAPandthesupportingsystemshasrepresentedasubstantialundertaking.WewouldliketothankthemembersoftheForddevelopmentteamaswellasacknowledgekeysuppliersfortheirtimeandeffortinthisproject,including:DanaLearMagnaMeridianAutomotiveSYSystemsTechnologiesTRWVisteonForeword–PhasedPPAPVisionPartnerwithsupplierstodriveflawlessexecutioninvehiclelaunchanddeliverproductsthatsurpasscustomerexpectations.TeamworkFordMotorCompanyanditssuppliersmustworktogethertodeliveraqualitypart,producedon-time,thatmeetsallFordengineeringrequirements.Toaccomplishthisgoal,Fordanditssuppliersmustplacetrust,integrityandaccuracyaboveallelseintheProductionPartApprovalProcess.SupplierResponsibilityinFlawlessLaunchSupplierdeliversasuccessfullaunchwithnoqualityorcapacityissuesthataffecttheFordproductionprocess.WhatPhasedPPAPMeanstoFordMotorCompanyPhasedProductionPartApprovalProcess(PPAP)istheprocessinwhichthesupplierdemonstratestheycanproducequalitypartsandprovidethesepartstoFordattherequiredvolume.SuccessfulcompletionofPhasedPPAPdemonstratessupplierreadinessusingtheproductionmachinery,tooling,andfacilitieswiththeintendedpersonnelattheintendedproductionratethatiscapableofmeetingtheFordrequiredvolumes(asspecifiedontheRequestforQuotation).PhasedPPAPIntroductionAsaresultofreviewingindustrybestpractices,FordhasmodifiedPPAPintoa‘threephased’approachthatwillindependentlyverifyproductquality,productionreadinessandcapacitypriortoJob#1.PhasedPPAPwillprovidethelaunchteamwithanimprovedmethodofriskmanagementandprovideaconsistentmethodforasuppliertodetermineiftheymeetFordprojectedprogramvolumes(SeeAppendixA).PhasedPPAPensuresthatthesupplierprocesshasthepotentialtoproduceaqualityproductthatconsistentlymeetsFordrequirementsduringanactualproductionrunatthequotedproductionrate.PhasedPPAPseparatesthePPAPprocessintothreephases:Phase1iscalled'QualityVerification'Phase2iscalled‘ProductionVerification’Phase3iscalled‘CapacityVerification’.ThisPhasedapproachrequiresthesuppliertoprovidepromisedatestoFordforeachofthethreeevents,andadditionallyincludestherequirementforthesuppliertoindicatethatRunatRatehasbeensuccessfullycompleted.(AppendixB,Table1summarizestheserequirements)Note:Forlesscomplexcomponents/commodities/productionstreams,itispossibletocompletemultiplephasesasasingleevent.PhasedPPAPOverviewScopePhasedPPAPredefinesboththeinterpretationandexecutionoftheProductionPartApprovalProcess(PPAP)(includingthePartSubmissionWarrant(PSW))andisrequiredforthefollowing:1.Anewpartorproduct(i.e.,aspecificpart,materialorcolornotpreviouslysuppliedtothespecificcustomer).2.Correctionofadiscrepancyonapreviouslysubmittedpart.3.Productmodifiedbyanengineeringchangetodesignrecords,specifications,ormaterials.4.AnysituationsrequiredbySectionI.3.1fromtheAIAGPPAPManual,3rdEd.(SeeAppendixC).Theserequireme...