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ford supplier quality manual pdfThis survey will assess the Supplier risk with regards to absenteeism. If you were contacted directly from Ford please complete the respective Absenteeism Tracker and submit as soon as possible if you have not already. Submissions are required on a weekly basis by end of the day Tuesday each week. FSP is an entry point to a variety of cross-functional web applications ranging from Customer Service to Vehicle Programs. FSP is an entry point to a variety of cross-functional web applications ranging from Customer Service to Vehicle Programs. Reproduction of this document, disclosure of the information, and use for any purpose other than the conduct of business with Ford is expressly prohibited Ford Motor Company Customer-Specific Requirements For use with PPAP Scope The US English language version of this document is the official version. Any translations of this document shall: be for reference only, reference the English version as the official language, include Ford Motor Company in the copyright statement. Copies of this document are available from Ford Motor Company at through the Ford Supplier Portal and International Automotive Oversight Board at. PPAP is applicable to organizations supplying all regions within Ford Motor Company and Joint Ventures. Reproduction of this document, disclosure of the information, and use for any purpose other than the conduct of business with Ford is expressly prohibited Ford Motor Company Customer-Specific Requirements For use with PPAP Scope The US English language version of this document is the official version. Any translations of this document shall: be for reference only, reference the English version as the official language, include Ford Motor Company in the copyright statement. Copies of this document are available from Ford Motor Company at through the Ford Supplier Portal and International Automotive Oversight Board at.http://artistalexanderkanevskywinnerinternationalaward.com/clientMedia/file/ford-f100-service-manual.xml

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References Note: unless otherwise noted, all references listed throughout these Ford Specific Requirements refer to the latest edition. Advanced Product Quality Planning reference manual Chrysler, Ford Motor Company, General Motors Corp. 3 Measurement Systems Analysis reference manual DaimlerChrysler, Ford Motor Company General Motors Corp. Production Part Approval Process (PPAP). Chrysler, Ford Motor Company, General Motors Corp. Statistical Process Control (SPC) reference manual. Supplier Technical Assistance (STA) Page 2 of 15 June 2013 The information contained herein is FORD PROPRIETARY as defined in Ford's Global Information Standard II. Some hypertext links within this document may only be accessible on FSP (Ford Supplier Portal) by organizations shipping directly to Ford Motor Company (typically Tier 1). STA engineers are identified in SIM (Supplier Improvement Metrics) on the Ford Supplier Portal for each organization manufacturing site. Internal suppliers to Ford Assembly Plants (, Powertrain and Stamping Business Unit facilities) should contact their responsible approval activity. Supplier Technical Assistance (STA) Page 3 of 15 June 2013 The information contained herein is FORD PROPRIETARY as defined in Ford's Global Information Standard II. Special situations may apply where the organization is directed by Ford to contract a particular sub-tier supplier. Please contact the Ford buyer to understand the organization responsibilities where sub-tier suppliers are directed by Ford. When reviewing Design Record requirements, the drawing notes are also to be reviewed by the organization and evidence of conformance provided. Service parts requirements Packaged Service Parts Packaging: All organizations supplying service parts to North America shall comply with FCSD (Ford Customer Service Division) Packaging and Shipping requirements. 8 The Packaging and Shipping Guidelines can be accessed at: through the Ford Supplier Portal.http://www.dd-inside.de/userfile/ford-f100-repair-manual.xml All other regions shall comply with local requirements; contact your regional FCSD STA engineer for details. Rust: All organizations supplying service parts to North America shall comply with FCSD (Ford Customer Service Division) rust policy. The Packaging and Shipping Guidelines can be accessed at: through the Ford Supplier Portal. Organizations supplying FCSD Asia Pacific, FCSD Europe and FCSD South America shall comply with local requirements, contact your regional FCSD STA engineer for details. The L1794 label Package Material Specification can be found at: through the Ford Supplier Portal. Dry Friction Materials: A unique FCSD developed toxicology label or a generic toxicology label will be specified on individual dry friction service part s packaging specifications. The generic label for brake and clutch parts will be L1853. The Package Material Specification for L1853 can be found at through the Ford Supplier Portal. 10 Uniquely developed toxicology labels will have their own label number specified on the parts packaging specification. Supplier Technical Assistance (STA) Page 4 of 15 June 2013 The information contained herein is FORD PROPRIETARY as defined in Ford's Global Information Standard II. Branding Requirements Organizations shall comply with the E108 Branding directive as indicated in both and the E-3 Ford Engineering CAD and Drafting Standard (FECDS): Organizations shall utilize the DVM-0011-19 - Parts Trademark Compliance Check sheet via the Ford Supplier Portal to verify compliance with E-108 requirements. 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Advanced Product Quality Planning and Control Plan reference manual 2.8 Chrysler, Ford Motor Company, General Motors Corp. Production Part Approval Process (PPAP) Chrysler, Ford Motor Company, General Motors Corp. Statistical Process Control (SPC) reference manual. Additional references are listed as requirements in section 4. Some hypertext links within this document may only be accessible on FSP (Ford Supplier Portal)) by organizations contracted by Ford Motor Company (typically Tier 1). The part remains active until tooling scrap authorization is given by the appropriate customer activity. For parts with no customer-owned tooling or situations where multiple parts are made from the same tool, written confirmation from Ford Engineering and the Buyer is required to deactivate a part. 3.2 Aftermarket Parts Replacement parts not procured or released by Ford Motor Company for service part applications which may or may not be produced to original equipment specifications. 3.3 APPC Average Purchased Part Capacity: Capacity, is the organization s capacity commitment (in part count per week) to meet the Average Production Weekly capacity requirement and recorded in Ford s capacity planning systems GCP or MCPV. 3.4 Average Production Weekly (APW) Average Production Weekly; capacity requirement for sustained production based on a 5 day work week. If these activities are open to the public, advertised, and not customer specific, they are considered training rather than consulting. Analysis of motion refers to capabilities of people with respect to tasks (e.g. lifting, twisting, reaching) to prevent or relieve problems of strain, stress, excessive fatigue, etc. Examples include right and left mirrors, blue or black interior consoles for the same vehicle and application Families of Control Plans: Families of Control Plans are Control Plans for multiple parts where the parts are substantially similar in application, design, manufacture, requirements and specification. GPDS Awareness Training is available at the Ford Supplier Portal log into Ford Supplier Portal, and under Applications select Ford Supplier Learning Institute (FSLI) then search for GPDS Awareness 5 June 2013 Initial process studies should be conducted at different points in the evolution of processes (e.g. on one manufacturing line or tool, then on the remaining manufacturing lines or tools and subsequently on any revised manufacturing lines or tools,). These studies provide the data to determine the process stability and control along with identifying the distribution (e.g. Normal or Uniform Distribution) for a statistically valid analysis Maximum Production Weekly (MPW) Maximum Production Weekly; capacity requirement based on a 6 day work week with no additional tooling, equipment or facilities. Organizations: see the Capacity Planning Web Guide available through MPPC Maximum Purchased Part Capacity: Capacity, is the organization s capacity commitment (in part count per week) to meet the Maximum Production Weekly capacity requirement and recorded in Ford s capacity planning systems GCP or MCPV Must A mandatory requirement 3.21 Organization Facility adding manufacturing value to production materials: providers of production or service parts, or of finishing services such as heat treating, plating, painting directly to Ford Motor Company. Ford Motor Company will continue to use that term when negotiating with the organization. Program specific Engineering Statement of Work defines program specific engineering responsibilities. PPM data can be used to prioritize corrective actions Process Approach A method to measure and improve organizational performance in terms of customer 6 June 2013. Note: Engineering Standards may be obtained from the following sources: Information Handling Services Mail Stop C102, 15 Inverness Way East, Englewood, CO USA web site Telephone: North America:, global:, Trubiquity Star Batt Drive, Rochester Hills, MI USA Telephone: USA Please see the web site for other regional telephone numbers web site ). These requirements are detailed on Ford Supplier Portal (Important Documents RSMS Communication Package). 8 June 2013 ES test failure shall be cause for the organization to stop production shipments immediately and take containment actions. The organization shall immediately notify Ford Engineering, STA and the using Ford Motor Company facility of any test failure, suspension of shipments, and identification of any suspect lots shipped. After the root cause(s) of ES test failure are determined, corrected, and verified, the organization may resume shipments. Suspect product shall not be shipped without sorting or reworking to eliminate the nonconformance. Inspection and Measurement Records Records of inspection shall be maintained for each customer specification, unless waived in writing by STA. The actual test result (variable or attribute) shall be recorded. Production inspection and test records (e.g. control charts, inspection and test results) shall be retained for one calendar year after the year in which they were created. Audits Records of internal quality system audits and management review shall be retained for three years. Retention periods longer than those specified above may be specified by an organization in its procedures. Specified retention requirements may be revised at the direction of Ford Motor Company Office of General Counsel. The organization shall implement a Quality Operating System as specified in the Q1 9 June 2013. The training shall include the appropriate Ford systems. Ford training opportunities are available through Ford Supplier Learning Institute log into Ford Supplier Portal and then go to the Ford Supplier Learning Institute (FSLI) application. Additional training is available through Personnel are to be trained to the current processes and requirements, e.g. trained to the published version of process requirements. Note: where equipment is not dedicated to the Ford part being reported for PPC, the shared loading plan must be used in the Capacity Analysis Report. The Capacity Analysis Report is available through Reporting of Purchased Part Capacity to Ford may include the following: Quarterly Reporting of PPC to Ford s capacity planning systems Responding to a Request for Quote Responding to a capacity study Capacity Verification associated with PPAP Any other Ford request for reporting Purchased Part Capacity Note: for the APPC and MPPC to be acceptable, the APPC and MPPC must meet or exceed the required capacity - APW in a 5 day operating pattern and MPW in 6 day operating pattern respectively. Personnel completing the Capacity Analysis Report (CAR) are required to have completed Capacity Analysis Report training available via and report training completion on the Capacity Analysis Report. (Training completion reporting available on version 5 CAR) Manufacturing Flow The organization shall have evidence of Lean manufacturing implementation plans as defined in the link below and in the Q1 Manufacturing Site Assessment. The nature of the problem shall be communicated to Ford and immediate actions taken to assure supply of product to Ford. There may be an Engineering Statement of Work (available from the Ford Product Development Engineer), an Assembly Statement of Work, a Manufacturing Statement of Work or other types available from the appropriate Ford organization. See the Global Product Development System (GPDS) for specific timing.This applies to priority and non-priority suppliers, see Supplier Engagement Process on Even if the Supplier has not received a Schedule A notification letter for a program, but has New Tooled End Items (NTEIs) for a Ford program launch, the Supplier is still required to complete a Schedule A for each program milestone for all NTEIs and retain the final Schedule A in the PPAP file for the life of part (production and service) plus one year. Prototypes When the organization is also sourced with the production of prototypes, effective use should be made of data from prototype fabrication to plan the production process. The organization records the dimensional data per the Prototype Build Control Plan, reviews the measured characteristics with Ford PD Engineer and obtains approval on the results from the Ford PD Engineer with confirmed acceptance of parts. If prototype parts are not fully compliant to specification, Ford PD Engineering can approve use of the part with a WERS Alert. Approvals required for all parts where the Supplier is Design Responsible Design FMEA(s) prepared by design responsible suppliers require Ford Engineering approval in writing. Approval of revisions to these documents after initial acceptance per the above is also required. FMEAs The organization shall prepare documented process FMEAs for all the Ford parts it manufactures. Design responsible organizations Where the organization is responsible for design, the organization shall prepare documented design FMEAs for all Ford parts it designs. Families of FMEAs FMEAs may be written for families of parts, where typically the only difference in the parts is dimensional, not form, application or function. The organization should obtain STA review and concurrence prior to use of family process FMEAs. The organization should obtain Ford PD review and concurrence prior to use of family design FMEAs. FMEA documentation Suppliers are to provide copies of FMEA documents to Ford Motor Company upon request. FMEA requirements Suppliers shall comply with the Ford FMEA Handbook requirements see FSP Library Services (subsection FMEA). Suppliers complying with the Ford FMEA Handbook will meet the FMEA and related requirements of the Q1 Manufacturing Site Assessment. Special Characteristic traceability for build to print organizations For build to print organizations, the organization shall obtain from Ford DFMEA information (including potential Critical Characteristics - YCs and potential Significant Characteristics YSs) to develop the PFMEA and special characteristics (CC, SC, HI and OS, as appropriate). The organization shall document special characteristics on the Special Characteristics Communication 13 June 2013 Control Plans All Ford Motor Company parts shall have Control Plans (or Dynamic Control Plans DCP if required by Powertrain). Ongoing Engineering Specification testing documentation Product Validation Engineering Specification and testing frequency requirements shall be clearly noted in the Control Plan and PFMEA. Pre-Launch Control Plans contain enhanced control methodologies and frequencies to demonstrate conformance to requirements during the initial production runs and specify the measurement techniques and data collection requirements. Note: the Production Control plan may be used for demonstration of Phase 3 with STA concurrence Submission of Pre-Launch Control Plan Data Suppliers providing parts to Ford Powertrain plants shall submit, to the Ford Powertrain Plant, the Pre-Launch Control Plan data for all and parts as specified by Ford. Focus on prevention Design and process controls shall focus on prevention rather than detection and correction. Incoming inspection should be considered when developing control strategies to prevent the use of non-conforming incoming material. Supplier Notification Change of Monitoring of Special Characteristics When data from control charts and ES tests indicate a high degree of capability, the organization may request a revision to the testing and inspection requirements for parts with Special Characteristics (see Glossary). Ford Engineering and Supplier Technical Assistance approval of a revised Control Plan will authorize the revision. Approval shall be obtained prior to implementing the change. The organization shall submit requests for approval via the SREA (Supplier Request for Engineering Approval). Control Item ( ) Fasteners The following control shall be included in the Control Plan for fasteners that are Control Items: Material Analysis - Heat-Treated Parts Prior to release of metal from an identified mill heat, a sample from at least one coil or bundle of wire, rod, strip, or sheet steel shall be analyzed and tested to determine its conformance to specifications for chemical composition and quenched hardness. A sample from each additional coil or bundle in the heat shall be tested for either chemical composition or quenched hardness. The results shall be documented and referenced to the steel supplier's mill heat number. This requirement applies to both purchased material and material produced by the organization. Note: external material test facilities used shall meet the requirements specified in section 4.33 of this document (Laboratory Requirements). Material Analysis - Non Heat-Treated Parts The identification of each coil or bundle of wire, rod, strip, or sheet steel shall be visually checked to determine that the mill heat number agrees with the steel supplier's mill analysis document and applicable specifications. Each coil or bundle shall be tested for hardness and other applicable physical properties.The Special Characteristics definitions are available in the Ford FMEA Handbook. Unique symbols identifying safety and regulatory characteristics on components equivalent to the inverted delta ( ) symbol. Information on GPDS is available through FSP (Ford Supplier Portal ) log into Ford Supplier Portal and then go to the Ford Supplier Learning Institute (FSLI) application. Product Development 16 June 2013. Design verification methods shall be recorded with the test results and submitted to Ford Product Engineering for approval. These requirements apply to all suppliers; regardless of the supplier s or part s PPAP submission level or design responsibility. This applies to all phases of product development, including prototypes. Individual Statements of Work may specify alternate responsibilities. See GPDS for additional information on prototype programs on Ford Supplier Portal. The organization is responsible for the quality of product from all tiers of sub-tier suppliers per the Q1 requirements. The organization is to ensure that sub-tier suppliers meet all requirements of PPAP. This also applies to Ford-directed sub-tier suppliers without a Multi-Party Agreement. Submission of Sub-tier supplier PPAP For organizations with a Ford designated PPAP level 3 or 5, any PPAP package submitted to Ford shall contain evidence of sub-tier supplier component part approvals. This evidence of component part approvals may be a summary (approved PSWs, a listing of PSW approvals or equivalent). The organization is also to have the approved sub-tier supplier PPAP information available for review. Ford reserves the right to request details of level 1 PPAP packages from suppliers, including associated sub-tier supplier PPAP submissions. Organization initiated changes Per PPAP, all organization initiated design change requests shall be made via WERS, unless the organization or sub-tier supplier does not have access to WERS. 17 June 2013 Supplier initiated design requests without WERS may use the SREA form as a template for submitting the proposed design change to the Ford Product Development Engineer. See All changes require PPAP approval and functional trial approval or PPAP approval and functional trial waiver prior to shipping production quantities. Supplier Request for Engineering Approval (SREA) What the SREA represents An SREA represents only the plan for a proposed organization manufacturing process or sub-supplier change. The SREA must be approved prior to the organization implementing the change.