Agreed special characteristics are included in the Control Plan 7.

7.2: High Impact Characteristics (HI) are related to manufacturing process Potential Failure
Controls for CC Characteristics After Point of Manufacture/Assembly
External SCCAF Reference Guide 3.3: Two way communication between PD and Manufacturing Activities Modes of subsequent operations within the facility of the manufacture of the HI
• DFMEA and PFMEA should be executed and updated as part of a simultaneous 5.4: Inspection/Measurement at End of Manufacturing/Assembly Process characteristic, but that do not adversely impact customer satisfaction.
F o r F u rt h e r i n f o rm a t i on s e e S C C A F H a n d b o o k Critical Characteristics are 100% measured at end of line or equivalent and non-conforming
engineering activity. HI characteristics are indicated by process failure modes with failure mode severity from 5
SCCAF (Special Characteristics Communication and Agreement
parts are clearly identified and scrapped or re-worked / reprocessed to 8 and occurrence greater than 3. High Impact Characteristics require emphasis in Quality
Form) is the form used in the process for Selection, Identification, • Where possible improvements to the product design and/or the manufacturing
through the approved process to meet specification. Any reworked products must repeat Planning actions that must be listed in a Control Plan.
and Control of Special Characteristics as defined in Ford process should be considered to remove the need for special controls. All team
and meet all CC checks. 7.3: OS and HI Characteristics relate to the process only, they exist only in the PFMEA,
Automotive Procedure FAP-03-111. members participate in the completion of the SCCAF and in the identification of
Special Characteristics. 5.5: Inspection/Measurement (by the supplier) prior to Use there is no potential OS or potential HI in the DFMEA.
In order to achieve the highest quality and lowest total cost, Product Design and Release
• The SCCAF is completed by the end of GPDS Engineering Gateway V2 based on the Critical Characteristics are 100% measured prior to use and non-conforming parts are
activities, along with Manufacturing and Assembly activities must work concurrently to
most current engineering concept design. This is in support of initial program cost & clearly identified and scrapped or returned (e.g. incoming inspection). Any reworked 8: Special Controls for SC & HI Characteristics
design, develop, and optimize both product design and associated manufacturing
processes. The key outputs of this collaborative process are an optimized process design, manufacturing assumptions and supplier quotation. products must repeat and meet all CC checks. Visual inspection (operator dependent) is not Special control requirements for Significant Characteristics (SC) and High Impact (HI)
an optimized product design, and a cross-functionally agreed list of Special Characteristics • The confirmed Special Characteristics are agreed by the PD and manufacturing source an acceptable control method. characteristics and are exactly the same.
that require ongoing measurement and control during mass production. using the SCCAF Form (FAF03-111-1/2) Other Considerations for CC Controls These Special Controls are managed by the responsible tier, and are documented on the
The focus of this guide is on the Special Characteristics Communication and Agreement o FAF03-111-2 is the form to be used for External Suppliers and is the scope of this 5.6: Destructive Testing SCCAF, identifying the tier level of the control regardless of the supply chain tier where the
Form (SCCAF) and process, roles and responsibilities, guidance regarding appropriate reference guide. Where CC Special Controls are required for destructive testing, batch certification is used, SC is manufactured. For further information see p30 of the SCCAF Handbook.
special controls, and timing for its completion as it applies to external suppliers. o FAF03-111-1 is the form to be used for Internal Ford Manufactured and Assembled including all three steps below: An appropriate process control method is determined based upon the type of characteristic:
Content. • CC controls on Key Process Input Variables for all parts manufactured / assembled 8.1: Discrete Characteristics:
The scope of this reference guide is the process for External Suppliers.
• Appropriate batch sampling for the destructive testing, to be agreed with STA and Examples of characteristics that are of the discrete type are: presence; absence;
This reference guide provides guidance on the interpretation of the relevant procedures
and process, FAP03-111, PPAP process and other procedural documents are the master. 4: Potential/Critical Characteristics (YC/CC) supplier or identified in Engineering Specifications. orientation; material type, etc.
• Batch (all components manufactured between the first and last piece inspections) is • Where feasible, these characteristics must be controlled via the use of error-proofing
4.1: Potential Critical Characteristic (YC): Characteristics that have a causal relationship
devices that prevent non-conformance.
1: Product & Process Characteristics to Potential Failure Modes having Severity of Effects rated 9-10. Designated in the held at supplier until positive test results are received.
• Where error proofing is not feasible, other possible methods that detect non-
A product characteristic is: “…a feature, such as dimension, size, shape, location, DFMEA with the YC symbol in the Classification column. 5.7: Black Box / Grey Box
conformance may be used, such as:
orientation, texture, hardness, tensile strength, coating, output voltage, colour, grain or • CAUSAL RELATIONSHIP TO POTENTIAL FAILURE MODES: When a product characteristic Where the CC is a black box / grey box performance requirement, two possible acceptable
o In-station control.
reflectivity that must be maintained to ensure intended product function”. or process parameter is either out of specification or has too much variation and controls are:
o 100% automatic inspection.
Product characteristic specification tolerances are: “… the range for each Product results in a failure mode, it is said to have a causal relationship to the failure mode. • Where containable at the rate of usage of the black box components, validate the CC
o Automated visual inspection and control (vision system).
Characteristic that must be maintained to ensure intended product function”. 4.2: Critical Characteristic (CC): Characteristics that are product or process performance requirement for 100% of the black box components prior to the point of
o Key Process Input Parameter controls with rational sample attribute measurements.
Process characteristics are: “… the measurable characteristics of process inputs and their characteristics that can affect compliance with government regulations and/or safe usage, or
• Gauging method will typically be of the attribute type.
interactions that affect the process output. Examples of process parameters include speeds, vehicle and/or product function. CC characteristics are designated with the inverted • The tier 1 supplier ensures close management and monitoring of the special controls
o Inclusion of guard banding with the attribute measurements. Refer to Ford PPAP
feeds, temperatures, chemical concentrations, pressures, and voltages.” delta symbol () on the print/CAD (Design Record). Critical Characteristics require for the black box at the point of manufacture of the characteristics, regardless of the
Customer Specifics for more details on attribute gauge qualification.
specific manufacturing, assembly, shipping and/or monitoring action to prevent tier level of manufacture, thereby ensuring compliance of the CC performance
▪ Note: Guard banding is a reduction in gauge acceptance tolerance, tighter than
2: Special Characteristics shipment of non-conforming product and the inclusion in the Control Plan. requirement. These special controls typically include poka-yoke at the point of
the engineering specification, based on the measurement system error.
The presence of one or more CC characteristics on the component makes it an Inverted manufacture of the CC, regardless of the tier level of manufacture, but may also use a
There are four types of Special Characteristics that are documented and agreed using the Note: Effective control method selection must consider process variability. For further
Delta () Component. Ford Customer Specifics to ISO/TS16949 requires approval and Manufacturing Process Control Approach through control of Key Process Input
SCCAF form: Critical Characteristics (CC); Significant Characteristics (SC); Operator Safety information see p30 of the SCCAF Handbook.
record keeping/lot traceability requirements for Inverted Delta Components. Variables of all the parts manufactured / assembled.
Characteristics (OS); and High Impact Characteristics (HI). 8.2: Continuous Characteristics:
• Process FMEA(s) and Control plan(s) for inverted delta component(s) require Ford 5.8: Materials Designated as Critical Characteristics Examples of characteristics that are of the continuous type are: geometric dimensions;
Engineering and STA approval in writing. Where a material has been designated as a CC, the following apply: product functional parameters; process parameters, etc.
• Approval required for all NTEI parts where the Supplier is design responsible: • The effective control for material as a CC is the control of the usage of the correct • Most continuous characteristics vary over time and should be monitored and
o Design FMEA(s) prepared by design responsible suppliers require Ford Engineering material, typically including: controlled using Statistical Process Control (SPC) to achieve a state of statistical
approval in writing. o Material certification by the bulk material supplier to the designated Ford material stability and control and allow for effective and timely identification of out of control
o Approval of revisions to DFMEA, PFMEA, Control Plan and SCCAF documents after specification. conditions.
initial acceptance is also required. o Poka-Yoke identification of the material to ensure the correct material is used • Sampling frequency shall be based upon process capability and a rational sampling
(examples of poka-yokes for this purpose may include: bar coding with vision system, strategy. See the AIAG SPC manual for more information.
5: Controls for CC Characteristics colour of material, hole pattern on blanks, etc.). • Gauging method will typically be of the variable type.
Overarching principle: CCs require special controls to prevent shipment of non- o Material handling processes to ensure use of only the correct material throughout • If attribute gauging is used guard banding should be considered.
manufacturing and assembly.
conforming product at all times. • For continuous characteristics related to process parameters, automated control is
These Special Controls are managed by the responsible tier, and are documented on the o Robust manufacturing / assembly process design to prevent usage of the incorrect
acceptable, coupled with rational sample product measurements, where proven to be
SCCAF, identifying the tier level of the control regardless of the supply chain tier where material (e.g. stamping tooling designed such that blanks of a specific size are
effective.
the CC is manufactured. required to stamp a part and are only stocked in the correct material, so checking
The following list (1-5) are the recommended control methods in order of preference, incoming blanks would provide sufficient control). 9: General Approach to Controls
the top method being the most acceptable. Note: This assumes that as a part of the design and verification process that the
system/component performance has been verified to meet performance requirements for Where direct measurement of product characteristics is infeasible or impractical, product
Controls for CC Characteristics at Point of Manufacture/Assembly the full range of the material specification. characteristics may be indirectly controlled through the control of relevant Key Process
The controls are incorporated close to the point of manufacture of the CC, regardless of Input Variables (process characteristics or parameters).
supply chain tier of manufacture. 6: Potential/Significant Characteristics (YS/SC) • Product characteristics must still be validated using rational samples and must be
included in the Control Plan
5.1: Poka Yoke Controls at Point of Manufacture 6.1: Potential Significant Characteristic (YS): A product characteristic designated in the
• Control emphasis is on prevention through control of process parameters. The
3: Process Key Elements A method of ensuring that the manufacture or assembly can only be completed DFMEA with the YS symbol in the Classification column, when the following criteria are
process parameters must be included in the process control column of the SCCAF as
correctly. Poka-Yoke Controls can be implemented as elements of the manufacturing met:
3.1: Timing (For additional info on SCCAF updates see p2) well as the Control Plan.
process as well as features incorporated into the product design. • Characteristic has a causal relationship to Potential Failure Modes having Severity of
The FAP03-0111 Selection, Identification, and Control of Special Characteristics does not Examples:
5.2: Manufacturing Process Control Approach Effects rated 5-8, or where agreed by the cross-functional team, having Severity of
include an update process. • Control of a welding process through control of weld current, wire feed rate & weld path.
Where it has been consistently demonstrated that control of manufacturing process Effects rated <5.
After the SCCAF is signed at the V2 gateway, a SCCAF would only require an update and re- o Confirm through a weld section using rational sampling.
• Characteristic may be influenced by the manufacturing process and may require
sign if:
variables can be 100% effective in controlling Critical Characteristics, CC special • Control of electroplating through bath chemical composition, temperature, current
controls may focus on these manufacturing process variables. Some examples are: special control to maintain the required process capability.
and plating time.
• The Engineering team identifies new or obsolete characteristics through DFMEA material specifications; weld parameter control; heat treat furnace controls; and 6.2: Significant Characteristic (SC): A product characteristic designated in the PFMEA with
o Confirm through a corrosion test using rational sampling.
updates. plating process parameters. Manufacturing process parameter control is used, with the SC symbol in the Classification column, when the following criteria are met:
More information on control and gauging of discrete and continuous characteristics can be
• Process modifications require changes to agreed controls. the product CC requirement validated at a frequency based on rational sampling that characteristic has a causal relationship to Potential Failure Modes having Severity of Effects
found:
prevents shipment of non-conforming product. Examples of such CC requirement rated 5-8, or where agreed by the cross-functional team, having Severity of Effects rated
Any changes post “xDJ” are controlled through the Drawing (WERS release) and Process • AIAG SPC Guide
validation strategies to be used with manufacturing process parameter control are <5, and.
Control Plan via an SREA after black-out period. o Available from RLIS www.rlis.ford.com (Ford Internal link)
(but not limited to): o Characteristic has an occurrence rating > 3 on the PFMEA.
3.2: Identification of Potential Special Characteristics o Available from www.aiag.org (external suppliers)
• Batch sampling with a batch and hold process. Note: SCs may be product, process, or test requirements. SCs require Special Controls and
• The DFMEA determines which product characteristics should potentially be • On Ford Supplier Portal
• First and last sampling with a batch and hold process. are included in a Control Plan.
controlled based on the product design and consideration of the manufacturing o https://web.qpr.ford.com/sta/FordspecTS.pdf (both Ford and suppliers)
• Periodic sampling with a sampling frequency such that any not conforming product has o Manufacturing Health Charts
processes used to produce it.
not left the process before a non-conformance is detected.
7: Operator Safety Characteristics (OS) & High Impact
https://web.qpr.ford.com/sta/Supplier_Manufacturing_Health_Charts.html
3.3: Identification of confirmed Special Characteristics Additionally, the end item CC must remain as a CC to ensure appropriate reaction plans Characteristics (HI) o Ford PPAP Customer Specifics
• The PFMEA analyses all steps of the manufacturing process to determine where are in place. 7.1: Operator Safety Characteristics (OS) are related to process parameters or product https://web.qpr.ford.com/sta/Ford_Specifics_for_PPAP.pdf
special process controls are needed in order to produce products that meet the
5.3: Inspection/Measurement at Point of Manufacture characteristics that may adversely affect the safety of the operator or compliance with
design intent. This need for special controls confirms the Potential Special
Critical Characteristics are 100% measured at the relevant operation/station or governmental regulations (e.g., Occupational Safety and Health Administration [OSHA] 10: Further Help on SCCAF
Characteristics from the DFMEA, as well as the possible identification of additional
immediately after manufacture/assembly and defective parts are clearly identified and requirements, Ford Health and Safety Specifications, etc.). These characteristics are • SCCAF Handbook (Ford internal link)
Special Characteristics beyond those identified by the DFMEA.
scrapped or re-worked / reprocessed through the approved process to meet required to be included in a safety sign-off as designated by local regulation. • SCCAF Webpage on www.fma.ford.com (Ford internal link)
specifications. Any reworked products must repeat and meet all CC checks. External: Consult your STA engineer or https://web.qpr.ford.com/sta/
Version 3.2 : 11x17 : Copyright © Ford Motor Company : July 2020 p1
 General Process Notes
FAF03-111-2 v2.1 July 2020
Special Characteristics Communication and Agreement - External OPTIONAL: SCCAF Draft Vers: Date: Characteristic DFMEA PFMEA
No. Specification & Tolerance Process Control Method Explanation
Description Class Class
• A specific SCCAF is required for each released component / assembly
DFMEA & Potential Special Type ONLY in
PFMEA & Special
Type ONLY in SCCAF Handbook - Global Phased (Suppliers Only -
Characteristics Yellow Boxes
Characteristics
Green Boxes PPAP - Web Site Accessible through Ford Special Characteristics for:
Agreement
See SCCAF Section Supplier Portal). ACCEPTABLE EXAMPLE
Lead / Support roles and
Ford PD engineer / Supplier Supplier / Ford PD SCCAF Handbook :
(Ford Internal Only) 2021 B123 MCA John Doe Inc. - Pleasantville Plant - USA BC3Q-6153-A
and for each supplier manufacturing location. 1.8 mm to WSS-M1A365-A21
ACCEPTABLE EXAMPLE
timing for each stage SCCAF Global FMA Website
o Even if the supplier is the same company but using multiple MATERIAL: WSD-M1A333-A1/A4 • This control confirms that the correct incoming material has been supplied
Approval Signature Name e-mail Address Approval Date Material Certification per batch with material usage controls at each station
FINISH: ALUMINIZED PER COATING WSD-M1A295-A2 to the manufacturing location and each subsequent individual manufacturing
Model Year & Program
Code:
2021 B123 MCA Part / System Number: BC3Q-6153-A
Ford D & R Engineer
Approval / Date:
manufacturing sites a separate SCCAF is required for each 1
Material
UNACEPTABLE EXAMPLE YC CC
UNACCEPTABLE EXAMPLE
station in the event that a site handles more than one type of material.
Supplier Name / Plant: John Doe Inc. - Pleasantville Plant - USA
Engineering Release
Number:
V2 Ford STA Engineer
Approval / Date:
manufacturing location.
Properties
No forbidden materials permitted [Reason: Missing actual details of spec]
PPAP / Annual Certification [Reason: Yearly is not continuous control method]
Spot check by Physics and chemical office [Reason: This example is
• An SC control can be the same as a CC as it confirms compliance for the

Supplier GSDB Code: A1234 Design Lead: Ford

1 Ford Craftsmanship 7 o Process Methods and capability can be unique to each of the
As per Drawing [Reason: Missing detailed values in the SCCAF unless
unacceptable due to the lack of definition of the actual Process Control Method]
complete batch.
Approval / Date: multiple materials for part and table on drawing]
Part / System Name: Ring - Oil Control
1 Ford Customer Plant: Saarlouis Assembly Plant - Germany
Supplier Plant Quality Manager manufacturing locations and the required signatories will be Per ES-9CP1-2078-AB [Reason: Needs section info of ES]
Approval / Date:

different. ACCEPTABLE EXAMPLE 1

V1 CPSC: 050505 DFMEA Reference: 2021 B123 - Oil Control Note: Approvals may be obtained by a physical signature or electronic sign-off. Recommended: Use DocuSign (Some Country Restrictions for External Approval) to
obtain signatures as it will provide electronic evidence to store with the completed SCCAF & SCCAF Assessment.
(See SCCAF Webpage for DocuSign help & DocuSign Country Restrictions). o Multiple supplier sites will require multiple signed documents. 3D CMM measurement with Batch & Hold (First / Last)
ACCEPTABLE EXAMPLE 2 • First off /Last off is acceptable for an agreed stable process where KPIVs
Key:
For Special Characteristic definitions refer
From DFMEA:

YC Sev 9,10 : Potential CC.

From PFMEA:

CC Sev 9,10 (Part) : Critical Characteristic. OS Sev 9,10 (Process) : Operator Safety.
• LEA D&R Engineer is responsible for obtaining the final signed ACCEPTABLE EXAMPLE 100% Go-No Go Gauge (not preferred due to difficult and expensive Gauge need to be monitored.
to Ford FMEA Handbook. Hole Diameter 15.0 mm +0.2mm/-0mm R&R) • Stamping examples such as this tend to have very little variation. If the
DFMEA : Global FMA Website (Ford Internal Only)
--
YS
Sev 5-8 and may require special control to
SC
SC Sev 5-8 & Occ 4-10 (Part) : Significant Characteristic. HI Sev 5-8 & Occ 4-10 (Process) : High Impact Characteristic.
document & storing all required SCCAFs & SCCAF Assessments in FEDE. 2 (Stamping UNACEPTABLE EXAMPLE YC CC UNACCEPTABLE EXAMPLE machines / facilities are set up correctly then the components will be stable
• DocuSign is recommended for approval of SCCAFs as it will create a
maintain process capability : Potential SC.
NotHI
Applicable
Special Characteristic Totals: YC YS
Not applicable
CC SC - OS HI Example) Per print specification [Reason: Missing view or section info] Gauge [Reason: Missing type of Gauge] through the shift.
SPC [Reason: The term SPC is too generic and needs association with a control • This control must be used in conjunction with a batch and hold process.
Note 1: Automatic calculation of totals (for guidance only).
Note 2: Count of SC may be less than count of YS 4 6 4 4 2 0 0
single document showing approval from all signatories; this should be As per Drawing [Reason: Missing view or section info]
Special Characteristics Communication and Agreement for all UN content required to support UN design and development is required by UNV2. The remaining UN content not required to support UN design and development is required by <PA>. method] Using rational sampling.
Special Characteristics Communication and Agreement for all UP content is required by UPV2. stored in FEDE as evidence and shows traceability of completion. 1 sample per week [Reason: Missing the actual control method since weekly
4 5
Where Specification & Tolerance differ in SCCAF to latest released data, released data is Master. Note: Process Control Plan should be crosschecked to released data at creation and at each new data release.

DFMEA PFMEA Review Ford DocuSign Webpage for Country Specific restrictions on the defines frequency only]
2 3 DFMEA PFMEA 6
No. Characteristic Description Specification & Tolerance
Class Class
Process Control Method use of DocuSign. ACCEPTABLE EXAMPLE 1 • Variable measurements provide continuous data and if sampled

• In addition, a copy of the approved SCCAF is required to be stored in

Material Certification per batch with material usage controls at manufacturing Hole Diameter ACCEPTABLE EXAMPLE 3D CMM measurement with SPC appropriately are very powerful in showing shift and drift in processes.
1 Sheet Steel Material Properties WSS-M1A365-A21 YC CC
stations 3 (Stamping 15.0 mm +0.2mm/-0mm YS SC • "Discrete" (Go /No Go Gauge) does not give data for SPC therefore Go /
2 Sheet Steel Material Thickness 1.8 mm Thickness to ESBAU5-1N260-A YC CC
Material Certification per batch with material usage controls at manufacturing
stations
the eAPQP using the APQP/PPAP Evidence Workbook. Example) ACCEPTABLE EXAMPLE 2 No Go should be 100%, should never be used
100% torque control
100% Go-No Go Gauge (not preferred due to difficult & expensive Gauge R&R) (see point 4 - p30 SCCAF Handbook).
3 Motor Crank Nut Torque 25Nm ± 2Nm YC CC
DC nut runner with Interlock Note: Process Characteristics:
ACCEPTABLE EXAMPLE • Paint process should be stable once correctly set up and KPIVs need to
• Can be added if required by the Supplier with specification and tolerance
CMM
4 Mounting hole diameter 2.5mm +0.0mm, -0.03mm YS -
PPk=3.45 Coat/Powder coat as per WSS-M2P177-C2 ACCEPTABLE EXAMPLE be monitored.
5 Mounting hole position
X:345 Y:150 Z:68
Positional tolerance Ø1.6mm
YS SC 100 % go / no go fixture identified and the DFMEA Classification column left blank. Paint thickness min. 20 µm - max. 35 µm Paint Thickness Ultrasound Tester with Batch & Hold • First off / Last Off per shift will enable detection of any drift or major issues
Corrosion UNACCEPTABLE EXAMPLE UNACCEPTABLE EXAMPLE with the process.
6 Bush Push In Force 8kN to 12kN YS SC 100% in process with load cell See p32 SCCAF Handbook for more information. 4 YC CC
protection 480 Hr Salt Spray. [Reason: Need regular control to ensure compliance to Salt spray test chamber [Reason: Need regular control to ensure compliance] • The measurement should include multiple locations as identified through
this test) Annual test to Spec [Reason: Need regular control to ensure compliance]Gravel the set up process and detailed in the Process Control Plan.
Design Details (DFMEA) – Yellow Section due end of V1 / Unit XMDJ Process Information and Approval (PFMEA) – Green Sections due end of Tubing shall show no red rust after 2000 hours of exposure time. [Reason:
Need regular control to ensure compliance to this test]
tester [Reason: Need regular control to ensure compliance] • Lots need to be quarantined or traceable so that if an issue is found the
suspect batch can be contained. Use rational sampling.
 Header: V2 / Unit TPVDJ • As line 4 but rational sampling with SPC will enable detection of any drift or
• Model Year and Program Code of the Vehicle or Powertrain program for this part/assembly.  PFMEA Classification: major issues with the process.
ACCEPTABLE EXAMPLE
• Name of the specific supplier and the manufacturing plant location (City & Country). • Completed with confirmed Critical and Significant characteristics (SC & CC) and manufacturing identified Special 5
Corrosion
Coat/Powder coat as per WSS-M2P177-C2 YS SC
ACCEPTABLE EXAMPLE • Frequencies should not be identified in the SCCAF as this will be
protection Paint Thickness Ultrasound Tester with SPC established during part development through the vehicle builds.
• 5 character GSDB code representing the External Supplier Manufacturing Site for this part. Characteristics (HI & OS).
Paint thickness min. 20 µm - max. 35 µm
• Frequency and sample size will be dependent on the variation of parts
• Part name / number details for all parts covered including prefix/base/suffix. • YC only converts to a CC. Every YC must result in at least one CC with linkages in the DFMEA, PFMEA and Control manufactured during the later build phases.
• Select whether the Design Lead (DFMEA owner relating to SCCAF) is Ford or Supplier. Plan. A CC will never result from a blank in the DFMEA classification, unless the YC was missed in the DFMEA 13: Weld Spatter - ACCEPTABLE EXAMPLE • Will not allow welding to begin without weld guards.
• Identify all Ford/JV Plants supplied from this Supplier manufacturing location only. (DFMEA requires update). A YC is only removed by design reduction of severity. 6 Hub Mounting
ACCEPTABLE EXAMPLE
YC CC Weld-spatter protections presence check in the welding rig with automatic
No Weld Spatter 4 x Ø 26mm
o Include the Plant, Location & Country where this part/assembly is received. Face lockout. • Controls can be same for SC as will cover each component.
• Each YS with a PFMEA Occurrence rating > 3 is confirmed as an SC.
• When a supplier uses one manufacturing location for a part and ships to multiple Ford / JV Plants only one SCCAF is • If a YS has a PFMEA Occurrence rating ≤3 than the PFMEA class is shown as blank “_” and not confirmed as an SC. • This is a good example of how the Tier 1 can clearly identify controls
required but all receiving plants should be listed. o An Occurrence rating must be from the PFMEA of the specific Supplier manufacturing location for the relevant through the supply chain.
ACCEPTABLE EXAMPLE • In this example, the clip is a Tier 2 part and the Tier 1 does not perform
 Characteristic Description: manufacturing process. Understanding of local Process Control Method is needed and PFMEA occurrence 7
Length - Lateral ACCEPTABLE EXAMPLE
YS SC Tier 1 – Receiving Inspection / Material Certification received from sub-supplier dimensional checks for the clip as part of their in-process checks.
Clips 5 +/-0.12mm per 1298 spec for PP materials
• The list of characteristics must be taken from the DFMEA. These characteristics must be specific and cover all the should be able to be demonstrated with data. Tier 2 Supplier – Variable Gauge with SPC. • Dimensional checks are performed at the Tier 2 supplier.
• The Tier 1 controls ensure that the clip is compliant and correct during
failure modes identified within the DFMEA (include Lessons Learned). o Enter either the actual Ppk value (>1.33) or the actual PFMEA occurrence rating in Process Control Method. Receiving/Incoming Inspection.
• All characteristics must be able to be measured, if a specification and tolerance cannot be identified then it is not a • A YS or YC must not convert to HI or OS.
correctly defined characteristic. • HI and OS Characteristics relate to process only and thus must have a blank in the DFMEA Class column. [Blank-> ACCEPTABLE EXAMPLE
• Review the Engineering Specification for the component and include all regular in process tests (IP) within the HI or Blank ->OS]. ACCEPTABLE EXAMPLE
100% Air blow inside tube after cutting process.
Contamination test as per ES - 3 per batch (First/Mid/Last).
document e.g. tests per batch.  Process Control Method: 8
Contamination Acceptance criteria as per ES-F3LC-2B109-BA sec 4.3
YC CC
Batch & Hold • Acceptable provided the air blow has been shown to be 100% effective
• Causes or Failure Modes cannot be simply cut and pasted from the DFMEA and will often require further definition Basic details of the planned process control method identified by the supplier. The Process Control Method must Quality UNACCEPTABLE EXAMPLE UNACCEPTABLE EXAMPLE and a batch and hold process is applied.
As per ES Spec ES-F3LC-2B109 [Reason: Needs section info of ES] Annual Review [Reason: Yearly is not continuous control method]
down to the actual design characteristic. have the test approach or measurement device description rather than a frequency. 100% Process Control [Reason: Need to define actual Process Control method]
• There should be no strikethrough (example) items on a SCCAF; if the line item is not required it should be removed. • Process control method must be the intended production control method, and be measurable and performed on Control Plan [Reason: Need to define actual Process Control method]
Do not Include an ongoing production basis. ACCEPTABLE EXAMPLE ACCEPTABLE EXAMPLE
• DV test requirements, durability or corrosion test requirements, as these are not typically measureable or • Any references to VP, PPAP, DV/PV etc. are not acceptable and should not be included (even if it is in addition to Position of Air CMM with SPC 1 set per week
controllable in ongoing production. (IP tests may be acceptable in certain cases). an adequate process control). This includes PPAP and pre-production methods and sample sizes/frequencies; 9
Conditioning
YS SC
• Variable measurements provide continuous data and if sampled
• Requirement names e.g. SU-1014. The actual characteristic needs to be defined. In certain cases the requirement these need to be included in the Process Control Plan. Example: Once per year salt spray is not adequate whereas
Condenser
brackets UNACCEPTABLE EXAMPLE
UNACCEPTABLE EXAMPLE
Shown on PFMEA and/or Control Plan [Reason: Need to state actual Process
appropriately are very powerful in showing shift and drift in processes.

can be listed in brackets () to show linkage to the characteristic. a rational sample coating thickness per batch may be acceptable. Per Print Callout [Reason: Missing the actual dimensions] Control Method]
• Measurements that are required for additional information but are not classified as a YS. • 5 pieces per batch is not a control method, CMM with (SPC) is a Process Control Method. Hazardous This does not need to be included on the SCCAF. The materials are loaded to the IMDS database at the start of the program and are not an ongoing process
10 Control of materials that are hazardous shall follow WSS-M99P9999A
• Where a PFMEA identifies a product characteristic that has been missed by the DFMEA, the DFMEA should also be • Consider what EOL (End of Line) tests are required and add these tests if appropriate. Material control.
updated to include the characteristic(s). • The process control method must be included even if the control is completed by a Tier N (2/3/4 etc.). “Control at NOTE 1: Statistical Process Control is required for all SCs and HIs, unless poke yoke / Key Process Input Variable control /100% check /effective attribute validation is
 Specification & Tolerance: Sub-Supplier” is not acceptable. Detail the actual method used by the Tier 2/3/4 in the same way as Tier 1 process possible. CC controls must always prevent shipment of non-conforming product for every part made.
• Every characteristic must have a Specification & Tolerance that is measurable. controls.
SCCAF Updates (Pre & Post PPAP)
• List the actual measurement and specification if possible as it aids the downstream process including when importing • Where a document exists describing the detail of the control method, that document should be referenced in the • Any changes to existing information contained in the SCCAF post “xDJ” are controlled through the Drawing (WERS release) and Process Control Plan via
into the ‘APQP/PPAP Evidence Workbook’ & Supplier Process Control Plans. SCCAF. an SREA after the black-out period.
• If the supplier states this is “Supplier Proprietary information”. Add the note “Supplier Proprietary Information” and • Required information for Process Control Method: • Where the only modification to the SCCAF is the “Specification and Tolerance” an update is not required as per Ford FAP process, but teams may update
list the supplier drawing number or specificiation document in which the specification and tolerance is shown. This is o CC: Include the actual Process Control Method and the frequency as this forms part of the process control if they wish. The documents that must align are the Released CAD Data / Drawing and the Supplier PFMEA and Process Control Plans.
to show that the SCCAF is not just missing the required information. method, such as: 100% inspection (not visual) or First Part / Last Part per shift with Batch and Hold. (See • Where Specification and Tolerance differ in SCCAF to latest Released CAD data / Drawing, the released data is Master.
• Specification of “According to Drawing” or “CAD” is only acceptable in very limited cases. (e.g. table of multiple shock section 5 on page 1 for acceptable process control details).
• Below is a table showing possible Design or Process Changes and the required documents to be updated.
absorber rates on the one drawing) but it must be specific and easily understood by stating the section detail, o SC: Variable Measurement: Include the actual Process Control Method but should not include the
view/table from the drawing. frequency/sample size as this will be established during part development through the vehicle builds. Required Ford Documents / Data to be modified and re-approved
• References should only be used where necessary e.g. table of multiple values, multiple dimensions making up a Frequency and sample will be dependent on the variation. (See section 8 on page 1). Program Process to CAD Model / Process
Change Type DFMEA SCCAF PFMEA
characteristic. o SC: Attribute Measurement: Include the actual Process Control Method and should be 100% checked as Stage Control Change Drawing Control Plan
• When referring to a Drawing or Specification, detail which drawing or specification number and section capability of 1.33 (production) / 1.67 (pre-production) cannot be typically demonstrated for attribute data. (See
New Special Characteristic identified in Pre P-Release SCCAF Yes Yes Yes for CC only Yes Yes
e.g.ES-AR79-5K009-AA Section 4.1 section 8 on page 1 for acceptable process control details and p30 of the SCCAF Handbook). DFMEA - YC / YS Post P-Release SCCAF Yes Yes Yes for CC only Yes Yes
• The reference must be to one of: o YS to Blank: Include the actual Process Control Method (if applicable) but should not include the frequency /
o A WERS released document (e.g. Engineering Specification, Material Specification, Table, CAD, Drawing). sample size. Enter either the actual Ppk value (must be >1.33) or actual PFMEA occurrence (must be <=3). Design Change to remove Special Pre P-Release SCCAF Yes Yes Yes for CC only Yes Yes
o Industry Standard (e.g. SAE Standards, DIN Standards).  Approval / Sign-Off: Characteristic in DFMEA - YC / YS Post P-Release SCCAF Yes Yes Yes for CC only Yes Yes
o Information attached directly to the SCCAF. • Is to be completed with all the required signatures and dates or reference to electronic approvals.
Modification to Specification or Tolerance of a Pre P-Release Evidence Work Book No * No Yes Yes Yes
• Ford documents that are not WERS released and therefore are UNACCEPTABLE as references include but are not • LEA D&R Engineer’s signed approval.
Product Characteristic Post P-Release WERS Concern No * No Yes Yes Yes
limited to: SDS Requirements, Design Rules, CETPs & PD Health Charts: o LEA D&R Engineer is responsible for the approval of all supplier manufacturing locations globally and the overall
o Referencing unreleased documents risks incorrect document or versions being used. SCCAF process. Supplier request for Modification of Process Pre PPAP SCCAF No Yes No Yes Yes
o Any document required by a supplier for ongoing production needs to be released. • The STA approval is by the STA Site Engineer assigned to the supplier manufacturing location or designee. Control Method to that agreed in SCAAF Post PPAP SREA No No No Yes Yes
 DFMEA Class: o STA Site Engineer approves the control strategy for the confirmed special characteristics (CCs, SCs and HIs).
Pre Job 1 Not Permitted - Production data required to prove Process Capability
• DFMEA classification based only on DFMEA severity rating. This may be a different engineer for each of the supplier manufacturing locations, as a separate SCCAF is Supplier Request for removal of SC due to
required for each manufacturing site. demonstrated process capability with data Post Job 1 SREA No No No Yes Yes
YC: Severity 9-10.
YS: Potential Significant Characteristic if Both criteria are met: • Craftsmanship approval is only required for parts subject to Craftsmanship / Appearance requirements. * Team should review the DFMEA using the Change Point Approach to understand if the change requires an update as per FAP07-005
1: Severity Rating 5-8 or where agreed by the cross-functional team, has Severity Rating <5. • Supplier Plant Quality Manager is the Plant Quality Manager for the specific site. NOTE 2: External SCCAF Only: In the unlikely event that a part has no Potential Special Characteristics and no confirmed Special Characteristics, the team should
2: Characteristic may be influenced by the manufacturing process (in the specific supplier plant relating to this o This will be different for each of the supplier manufacturing locations. note under the Characteristic Description “No characteristics identified” and complete the approval process for the blank SCCAF. Per PPAP customer specifics, where
SCCAF). SCCAF & SCCAF Assessment Storage: non-special characteristics are designated for process capability demonstration, those characteristics should be recorded on the SCCAF.
• All characteristics
Version 3.0 : 11x17 :taken
Copyright © Ford must
from DFMEA Motor Company
have a DFMEA : February 2020
Class. At V1 there should not be any blank DFMEA class • All SCCAFs (Internal & External) along with the relevant SCCAF Assessment must be stored as per the guidelines NOTE 3: All relevant CCs should be identified on the drawing/CAD, with an inverted delta next to the part number in the title block and next to the specified p2
line items. shown in FMA Document Storage Table document for more information see SCCAF Storage Help file. dimensions or notes. As specified in: FAP03–111 and Ford Engineering CAD Drafting Standards FECDS “E-2 SPECIAL CONTROLS.”