FROM THE GLOBAL PHASED PPAP REQUIREMENTS HANDBOOK

Process Map Phase 0 Run-at-Rate

Objectives: To confirm that all production input requirements are available and
understood, and can support a limited production run.
To provide an early indicator that the design of the process/tool/facility has the potential
to produce at rate the required number of acceptable parts as determined by the Pre-
Launch control plan.
Refer to web link https://web.qpr.ford.com/sta/Capacity_Analysis_Report.xls for
Capacity Analysis Report and supporting documentation.

Phase 0
Run-at-Rate
START

INPUTS
Released Are the
design Run-at-Rate input EVENT:
Yes
[#1,2,3 & 4] requirements in place Conduct Run-
for the production at-Rate
Trained stream?
supplier Outputs from
production the event STATUS:
operators Phase 0 1
No
Completed
Sub-supplier(s) Was the
material status No Pre-Launch
from Tier-x Control Plan
Run-at-Rate followed?
Required Inputs

Quantity of
parts required
as defined by Yes
Supplier

Capacity
customer
Analysis
(default 300
Report
consecutive Were the
No prescribed number
parts)
of acceptable parts
Job 1 Location produced?
(final site &
line)
Yes Submit to Proceed to next page
Production Customer
process
including
Were the
control plan, No parts produced
flow diagram Status Tracking
in the defined
instructions & Database
period?
Process
parameters
[#5,6 & 7]
Yes
Production
Tools, Facilities
& Gauging Did all
[#8,16 & 17] No operations Yes
meet their planned
Planned cycle time
production Implement ?
cycle times Corrective
required to Action on Input
support Daily
Production
Volume 4

Note: [#x] refers to the Requirement Number in PPAP 4th Edition

that will assist in confirming requirements

1 12h May, 2008

FROM THE GLOBAL PHASED PPAP REQUIREMENTS HANDBOOK

Process Map Phase 1 Quality Verification

Objectives: To determine if all customer engineering design record and specification
requirements are properly understood by the Supplier. To provide an early indicator that
the design of the process/tool/facility has the potential to produce product consistently
meeting these requirements during an actual production run at the quoted production
rate by operating a minimum of one selected production stream. Phase 1 demonstrates
that all PPAP requirements have been met for one production stream.

Phase 1 Quality Verification

Continue Production Part

Approval Process (PPAP) using
parts from Phase 0
Have the 18
Yes STATUS:
1 PPAP requirements
Phase 1
Parts made during Phase 0 must been 2
Completed
satisfied?
meet all 18 PPAP Requirements for
one production stream.
See Appendix D
No

Phase 1
Warrant
[#18]

Submit to
Proceed to next page
Customer

Status Tracking
Database
Important notes:
For suppliers with only one
production stream completion of
Phase 1 & 2 occur at the same
time.
It is required that prior to Phase 1 Return to
Phase 0 for
submission that sub-supplier(s) corrective
material status from Tier-x has action
also achieved Phase 1.

4 4

2 12h May, 2008

From the Global Phased PPAP Requirements Handbook
Process Map Phase 2 Production Verification
Objectives: To determine if all customer engineering design record and specification requirements are
properly understood by the Supplier, and that ALL production streams have the potential to produce
product consistently meeting these requirements during an actual production run at the quoted production
rate. Phase 2 demonstrates that all PPAP requirements are met for all production streams.
Note: The approach adopted for PPAP of multiple production streams is scenario-specific and must be
agreed between the Supplier and STA. In general terms each production stream should be assessed for
Run-at-Rate and Quality Verification separately. Consideration should also be given to the risk that the
introduction of further production streams may impact the validity of the Phase 1 approval. (e.g., Phase 1
achieved on cavity #1 of a four cavity tool - the introduction of cavity #2, 3 & 4 may impact the cavity #1
part and it may no longer be to specification).

P h ase 2 P rod u ctio n V erificatio n

H ave R un-at-R ates

(P hase 0) been conducted
and Q uality V erifications Yes ST AT U S :
2 (P hase 1) been satisfied for Phase 2 3
A LL production C om pleted
stream s ?

No

Phase 2
W arrant
[#18]

S ubm it to
C ustom er
Proceed to next page

S tatus T racking
D atabase

Im portant note:
P hase 2 and P hase 3 can happen
concurrently if all Inputs and
O utputs are satisfied.

3 12th May, 2008

From the Global Phased PPAP Requirements Handbook

Process Map Phase 3 Capacity Verification

Objective: Verify the Supplier's production system can support customer declared
volume requirements while meeting Phase 2 requirements.
Refer to web link https://web.qpr.ford.com/sta/Capacity_Analysis_Report.xls for Capacity Analysis
Report and supporting documentation.

Phase 3
C a p a c ity V e r ific a tio n

A re th e
EVENT:
A ll p e rs o n n e l C V in p u t Yes C ond uct
fo r a ll s h ifts , re q u ire m e n ts in p la c e
C a p a c ity
tra in e d fo r a ll p ro d u c tio n
V e rific a tio n R u n STA TU S:
s tre a m s ? END
P ha se 3
C o m p le te d

Q u a n tity
3 re q u ire d fo r
W a s th e
c u s to m e r D P V
No P ro d u c tio n c o n tro l
ru n fo r o n e fu ll
p la n fo llo w e d &
day
a c c e p ta b le p a rts
p ro d u c e d ?
Required Inputs

P h ase 3
W a rra n t
Yes [# 1 8 ]
P hase 2 & C a p a c ity
W a rra n t A n a ly s is
R e p o rt

D id th e S u b m it to
S c h e d u le d No v o lu m e o f a c c e p ta b le C u s to m e r
d o w n tim e p a rts p ro d u c e d m e e t o r
d e fin e d (T P M , e x c e e d th e re q u ire d
c h a n g e o v e r, DPV?
B re a k s e tc .) S ta tu s T ra c k in g
D a ta b a s e
Yes

S u b s u p p lie r C o m p le te
m a te ria l s ta tu s C a p a c ity
D e te rm in e
fro m T ie r-x A n a ly s is
R o ot C au se &
P hase 3 W o rk s h e e t
P la n C o rre c tiv e
A c tio n

R e tu rn to
a ffe c te d p h a s e
a n d s ta rt
c o rre c tiv e a c tio n

P h ase 0 P hase 1 P ha se 2 P hase 3

4 12th May, 2008