External Supplier APQP/PPAP Evidence

PROTOTYPE OR PRODUCTION MEASUREMENT RESULTS

Schedule A/B Deliverable 12-20-27
(Prototype Parts Are 100% Measured, Dimensionally Known)
(Production
Prototype or Parts Achieve 100% of Print Specifications)
Production Process
Special Characteristics Production
Measurement Results
Capability Results ###
A. Program Information Formatted to Print US Date
(Letter/Legal)
Supplier
Required Delivery
Program In-Plant Promise Build Event
Model Year Code Product Name Build Event Date Date Vehicle Sets
Required
Produced

B. Production Supplier / Product Information

Tier 1 Supplier Name Site Code Tier 1 Supplier Location

City / Region / Country

Engineering New Tooled

Part Name Ford Part Number Change Level End Item(Y/N)

C. Manufacturing Information
Check Check Check
One
Manufacturing Site One Manufacturing Process One Tooling Type
Carry-over production site Carry-over production process Carry-over production tooling
New production site New production process New production tooling
Prototype site Prototype process Prototype / soft tooling

D. Deviations FTT
Measurement Results Reason Alert #
None required, all delivered parts meet 100% of Part Deviation Engineering
the requirements in time to support the build Notice Notification
Quality or Timing

FORD STA Page 1 of 34 Date Issued: 14-Jul-2009

Form #:PP-S-F085 Date Revised: 29-Apr-2013
GIS2 Classification: Proprietary Version 5
 External Supplier APQP/PPAP Evidence
PROTOTYPE OR PRODUCTION MEASUREMENT RESULTS
Schedule A/B Deliverable 12-20-27
(Prototype Parts Are 100% Measured, Dimensionally Known)
F9:
(Production Parts Achieve 100% of Print Specifications)
5 digit GSDB code for Manufacturing Location

G27: (e.g. Red Border Notice)

K12: (e.g. Print Revision Level)

FORD STA Page 2 of 34 Date Issued: 14-Jul-2009

Form #:PP-S-F085 Date Revised: 29-Apr-2013
GIS2 Classification: Proprietary Version 5
 APQP/PPAP External Supplier Evidence
Special Characteristics
Process Flow
Lead for activity When (VO) Input Process Output

For PTO follow SPECIAL CHARACTERISTICS

PTO Equivalent Falure Mode Avoidance - Potential
Timing Critical/Significant Characteristics
documented through the Special
GPDS: <UPV2> Design Record Characteristics Agreement form FAF
Upper Body 03-111-2 (Deliverable #3) Special Char Agreement Form or
Ford PD DFMEA/ PFMEA
<UNV2> FAF 03-111-2
Under Body Engineering Specifications
FAP 03-111

GPDS:<UPV2> Special Characteristics (CC, SC, HI) agreed

Upper Body FAF 03-111-2
Supplier to and received by Suppliers (Deliverable #5)
<UNV2> Utilize import function macro or through the Special Characteristics
Under Body manual data entry Agreement form FAF 03-111-2 EXTERNAL SUPPLIER SPECIAL
CHARACTERISTICS worksheet
Required evidence available upon
request for priority and non-priority
suppliers
DATA STORAGE AND MANAGEMENT REVIEW
Priority Supplier List
Program STA New Tooled End Item
Initial selection of No Required evidence available upon
Priority sites will Site Readiness request for priority and non-priority
occur by <PTC> Part Criticality Priority Supplier suppliers
(unless otherwise Program Induced Risk
identified)

Yes

Results maintained Review the results of the

Ford PD / Site STA with APQP records Special Charcteristics list EXTERNAL SUPPLIER SPECIAL
GPDS: <PA>
/ Supplier and next deliverable during GPDS on-site visit #1 CHARACTERISTICS worksheet
evidence form

No
Special
Ford PD / STA / Charactreistics
Ongoing
Supplier Modified

Yes

Update External Supplier

Characteristics worksheet EXTERNAL SUPPLIER SPECIAL
Supplier Ongoing
CHARACTERISTICS worksheet

Required evidence available upon

request for priority and non-priority
suppliers
FORD PRODUCT DEVELOPMENT Page 3 of 34 Date Issued: 14-Jul-2009
GIS1 Item Number: N/A Date Revised: 29-Apr-2013
GIS2 Classification: Proprietary Version 5
 Special Characteristics Communication and Agreement
1A. PFMEA & Type ONLY
1. DFMEA and Type ONLY in Yellow
potential special Boxes
Special in Green Special Characteristics for:
Characteristics Boxes
characteristics
Agreement

John Doe Inc. /

Lead / Support roles and
Ford PD engineer / Supplier Supplier/ Ford PD 2013 Scorpion 6.7L BC3Q-6153-AB
timing for each stage Pleasantville Plant
Special Characteristics Approvals required at UNV2 / UPV2 / PA as per FAP 03-111
Ford D & R Engineer Signature Name e-mail Date
Program: 2013 Scorpion 6.7L Part Number: BC3Q-6153-AB Approval/Date:
Engineering Release Ford STA Engineer Signature Name e-mail Date
Supplier Name/Plant: John Doe Inc. / Pleasantville Pl TBC
Number: Approval/Date:
Ford Craftsmanship/Sys Engr'g Signature Name e-mail Date
Supplier SIM Code: A1234 Design Lead Brand: Ford Approval/Date:
Part / System Supplier Plant Quality Manager Signature Name e-mail Date
Name:
Ring - Oil Control Ford Customer Plant: Ford Dearborn Assembly Plant Approval/Date:

Key: From DFMEA: From PFMEA: Note: approvals may be electronic: complete the approval block above to identify the approvers, and include "/s/" ahead
of the name typed into the "signature" box to indicate electronic approval and approve in e-mail with this file as an
Sev 9,10. Potential Sev 9,10 (Part). Sev 5-8 AND Occ 4-10. Significant attachment.
YC CC. CC Critical Characteristic. SC Characteristic.

For Special Characteristic -- SC

definitions refer Sev 5-8 and may
to Ford FMEA Handbook. require special
Sev 9,10 (Process). Sev 5-8 AND Occ 4-10. High Impact
YS control to maintain OS Operator Safety. HI Characteristic.
process capability.
Potential SC.
HI
Not Applicable Not applicable
Special Characteristic Totals: YC YS CC OS SC HI
Note 1: Automatic calculation of 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
totals (for guidance only).
design and development is required by <PA>.
Note 2: Count of SCs may be less
than count of YSs
2 2 2 0 1 0
Special Characteristics Communication and Agreement for all UP content is required by UPV2.

Stage 1. DFMEA Stage 1A. PFMEA

PFMEA
No.

Characteristic Description Specification & Tolerance DFMEA Class Process Control Method
Class
1 Closed Gap 0.25 to 0.50 mm YC CC Vernier caliper
2 Axial Width 2.5 +0.01, -0.03 mm YS SC go / no go fixture
3 Brake assembly caliper bolt torque 20 nm +/- 3 nm YC CC DC nut runner
4 Door trim fastener hold depth 5mm +/- 1mm YS Visual
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

Date Issued: 14-Jul-2009

Date Revised: 29-Apr-2013
Version 5
 APQP/PPAP External Supplier Evidence
t PRODUCTION PROCESS CAPABILITY RESULTS
e
ll
Clear
Historical
Capability
Form Data
Archives Satisfies Schedule A Deliverable #38 / Schedule B Element #35
i
Supplier Code:
GPDS: Due at <TT>
Part Number:

Characteristic Study Parameters Gauge R&R Process Control Distribution Analysis Capability Results

Characteristic % PPAP Meets Capability

DFMEA PFMEA Pass Through % Demonstrated Evidence: Resultant
Number

Manufacturing Error dependent on sub- Study Ppk Values Requirement

Classification Classification On Control Characteristic Process Control Population Sample Tolerance Method of Number of Distribution P-value or
Characteristic Specification
(YC, YS) (CC, SC, HI, Plan (Y/N)
Operation
(PTC)
Proofed
Method
supplier (Include
Size Size
Variation
(Target Stability and Points Not in Type Best Fit
PPAP Ppk ≥ 1.67 Actions Taken
Identifier (Y/N) PTC) (Target Production Production Ppk ≥ 1.33
Other) (Y/N) ≤ 10%) Control Control Coefficient
(Y/N) ≤ 10%) Ppk Values (Y/N)

1
2
3
4
5
6
7

r
8
9
10
11
12
13
14
15
16
17
18
19
20
i
21
22
23
24
25
26
27
28
29

FORD STA Date Issued: 14-Jul-2009

Page 5 of 34
Form #: PP-S-F085 Date Revised: 29-Apr-2013
GIS2 Classification: Transient record Version 5
 Print External Supplier APQP/PPAP Evidence
Cover PROTOTYPE OR PRODUCTION Delete MEASUREMENT RESULTS
Page & Schedule AAll Deliverable #12 or #20
Supplier Code: Executiv Measu GPDS: due at
Part Number: e Clear Formrement
Archive Historical Data
Summar
y Archiv Summary Results
Evidenc es
e Form PFMEA All Parts
Number

DFMEA On Control Quantity

Classification Process Control Inspection Meet
Characteristic Specification Classification Plan Inspected X-Bar Range Comments / Actions Taken
(CC, SC, HI, Method Frequency Specification
(YC, YS) (Y/N) (pcs.)
Other) (Y/N)

FORD PROUCT DEVELOPMENT Page 6 of 34 Date Issued: 14-Jul-2009

GIS1 Item Number: N/A Date Revised: 29-Apr-2013
GIS2 Classification: Transient record Version 5
 External Supplier APQP/PPAP Evidence
PROTOTYPE OR PRODUCTION MEASUREMENT RESULTS
Instructions
ROLES AND RESPONSIBILITIES
What Who When (Vehicle Operations) When (Powertrain - VP Builds) When ( Powertrain - X0, XM, M1 )
Within 2 weeks after Build Phase DJ event
PO-S-25 for X0
Production drawing & specificaitons avialable to Ford Product <uPA> to 1 month after <FDJ>
Development (PD)
GPDS: <FDJ> + 1 Month PO-T-55 for XM
supplier (Deliverable #6) based on the Plan for Every Part
PO-T-70 for M1
(GPDS Process Sheets for Ford Internal Use)

<uPA> based on the Plan for Every Part

<uPA> to <uDC>
PP-S-05 for X0
PP-U-50 for VP
Prototype Inspection Requirements Identified Ford PD N/A PP-T-20 for XM
(GPDS Process Sheets for Ford
PP-T-35 for M1
Internal Use)
(GPDS Process Sheets for Ford Internal Use)

Failure Mode Avoidance - Design Failure Mode Effects

GPDS: <UPV2>
Analysis & Potential Critical/Significant Characteristics
Upper Body <uPA> based on the Plan for Every see terms and Definitions below for applicability
(YC & YS's) compelted/received (Deliverable #3) Ford PD
<UNV2> Part per Powertrain Unit build phase
through the Special Characteristics Agreement (FAP
Under Body
03-111) & Form (FAF 03-111-2)

Special Characteristics (CC, SC, HI) agreed to and

received by Supplier (Deliverable #5) through the see terms and Definitions below for applicability
Ford PD / Supplier GPDS: 1 Month prior to <FDJ> <uPA>
Special Characteristics Agreement (FAP 03-111) & per Powertrain Unit build phase
Form (FAF 03-111-2)
Prototype Build Control Plan Completed (Deliverable
Supplier / Ford PD GPDS: 2 Months Prior to <VP> 2 Month prior to <uTD> N/A
#11)
GPDS: In support of Powertrain GPDS: In support of Powertrain Unit rough or
Produce Prototype Parts Supplier GPDS: In support of <VP> IPD
<VP> In Plant Date (IPD) purchased finish In Plant Date (IPD)
GPDS: In support of Powertrain Unit Build Phase
Conduct inspection method of Prototype Parts per GPDS: In support of Powertrain IPD. All required X0, XM and M1 prototype
Supplier GPDS: In support of <VP> IPD
Prototype Control Plan <PA> IPD inspection is performed as agreed upon by the
Product Engineer and the Supplier
Completes the PROTOTYPE MEASUREMENT GPDS: Prior to shipment of <VP> GPDS: Prior to shipment of GPDS: Prior to shipment of prototype parts to
Supplier
RESULTS proforma as evidence of Deliverable #12 IPD Powertrain <VP> IPD Powertrain Unit build Phase
GPDS: Prior to Powertrain <VP> GPDS: Prior to shipment of prototype parts to
Review the results of the Prototype Parts produced Ford PD GPDS: Prior to <VP> MRD
MRD Powertrain Unit build Phase
Prototype Parts are 100% measured, dimensionally
GPDS: Prior to shipment of GPDS: Prior to shipment of prototype parts to
known and signed off by Ford Engineering (Deliverable Ford PD GPDS: Prior to <VP> MRD
Powertrain <VP> MRD Powertrain Unit build Phase
#12)
Any exception to the design specification requires an
approved part design deviation notice (Must use e- GPDS: Prior to shipment of GPDS: Prior to shipment of prototype parts to
Ford PD GPDS: Prior to <VP> MRD
Warrant for Powertrain. Other (e.g. WERS Alert for Powertrain <VP> MRD Powertrain Unit build Phase
vehicle) prior to shipment.

Supplier Ships part to meet in plant date (IPD) GPDS: Prior to shipment of GPDS: Supplier Promise Date must support rough
Supplier GPDS: <VP> MRD
commitment for the Prototype Build Phase Powertrain <VP> MRD or finished Powertrain Unit build phase IPD(s)

Parts produced from Run at Rate at cycle time on one

Supplier GPDS: Prior to <TT> IPD GPDS: prior to <uTT> MRD N/A
production stream (including sub-suppliers)
GPDS: Prior to shipment of
Powertrain <uTT> MRD Supplier
PartsAchieve 100% of print specifications (minimum 5 GPDS: Supplier Promise Date must support rough
Supplier GPDS: Prior to <TT> IPD Promise Date must support rough or
piece layout) or finished Powertrain Unit build phase IPD(s)
finished Powertrain Unit build phase
IPD(s)
Parts produced from Run at Rate at cycle time on
additional production streams as applicable (including Supplier GPDS: prior to <PP> IPD GPDS: prior to <uPP> MRD N/A
sub-suppliers)
PartsAchieve 100% of print specifications (minimum 5
piece layout) from additional production streams as Supplier GPDS: Prior to <PP> IPD GPDS: Prior to <uPP> MRD N/A
applicable

Any exception to the design specification requires an

Ford PD (Alert) / GPDS: Prior to shipment of parts for GPDS: Prior to shipment of parts for
approved part design deviation notice (e.g. WERS Alert) N/A
STA (Interim PPAP) <TT> or later builds <TT> or later builds
prior to shipment. Including interim PPAP approval

FORD PRODUCT DEVELOPMENT Page 7 of 34 Date Issued: 14-Jul-2009

GIS1 Item Number: N/A Date Revised: 29-Apr-2013
GIS2 Classification: Proprietary Version 5
 External Supplier APQP/PPAP Evidence
PROTOTYPE OR PRODUCTION MEASUREMENT RESULTS
Instructions
PROGRAM,
Enter the keySUPPLIER, PRODUCT,
information the AND PROTOTYPE
program, production MANUFACTURING
supplier, product, INFORMATION
and prototype manufacturing
information for the build event
TERMS AND DEFINITIONS
TERMS DEFINITIONS
A. Program Information
Model Year The model year the vehicle is released
Program Code The program code represents the Ford designation for the Vehicle or PTO program
Product Name Product name is for the 'Vehicle' or 'PTO' name
Build Event The build event for the GPDS program milestone under review
Required In-Plant Date The required date Ford designates all components received per the material required date
(MRD) at the Ford designated facility for builds prior to <PEC> milestone
The required date Ford designates all components received in-plant (IPD) at the Ford
designated facility for builds after <PEC> milestone. Powertrain uses material required date
(MRD) for all builds.

Build Event Planned quantity of vehicles or powertrain quantity for the Build Event. Powertrain should
Quantity include internal Powertrain Dyno requirements which are not covered in vehicle build.
Required Ford determined number of vehicles/powertrains to be built per GPDS build event
Produced Supplier number of vehicle/powertrain sets built per ford the GPDS build event
B. Production Supplier / Product Information
Tier 1 Supplier Name Tier 1 Supplier responsible for the end item
Mfg. Site Code Mfg. Site code is the Global Supplier Data Base (GSDB) Site Code containing 5-digits
Tier 1 Supplier Location Production manufacturing location of the Tier 1 Supplier
Supplier Delivery Promise Date The date entered into GPIRS or VPP by the supplier when the end item will be received In-
Plant at the Ford designated facility.
Part Name Powertrain
General namehasgiven
2 In Plant
to theDates (IPD) per build phase to support machining and assembly
end item
and that precedes the vehicle IPD.
Ford Part Number Ford designated component, sub-assembly or assembly number
Engineering Change Level Engineering change level for a part is the design record revision level (i.e. Part Print) as
(e.g. Print Revision Level) identified by a 4-part alphanumeric code (typically 14 characters in length) containing the
following:
a) Change Level Indicator (CLI) identifying the releasing authority
b) Part drawing revision letter (single letter)
c) Electronic Release System code (WERS = 8-digit concern number)
d) Release Status of the part in the electronic release system (WERS = 3-digit increments of
any notices attached to the part)
Engineering Change Level is also reported on the PSW.
Powertrain prorotype parts for builds (X0, XM, M1) can be ordered under an experimental
part number

Engineering Change Level - For Engineering Prototype CMMS manual powertrain prototype release (used by PPM)
Releases (X0, XM, M1) Example: B2010EF16A252001
New Tooled End Item (Y/N) A)
Is aBcomponent,
= is alpha by system default
sub-assembly or (assembly
B assumes engine
with a new) design for the given Program Code
C. Prototype Manufacturing Information
Manufacturing Site Location where the end item were manufactured for the build event
Carry-over production site Same location as previous model year or common platform
New Production site New facility designated as production intent to produced the end item
Prototype site Facility responsible for producing the end item for the specific build events (i.e. not
production intent)
Manufacturing Process Manufacturing process for the end item producing for the build event. The scope of
information is the end item manufacturing process(es) only
Carry-over process Same manufacturing process as previous model year or common platform
New production process At least one operation contains new manufacturing process(es) to produced the end item
for the specific build event (i.e. production intent process)
Prototype process At least one operation contains a prototype process(es) to produced the end item for the
specific build event
Tooling Type Manufacturing tooling for the end item producing for the specified build event. The scope
of information is the end item manufacturing process(es) only
Carry-over production tooling Same manufacturing tooling as previous model year or common platform
New Production Tooling At least one operation contains new manufacturing tooling to produced the end item or the
specific build event (i.e. production intent process)
Prototype/ soft tooling At least one operation contains prototype tooling in the process utilized to produce the end
item for the specific build event (i.e. not production intent)
D. Deviations
None required, all delivered parts meet 100% of the Prototype Parts are 100% measured, dimensionally known and signed off by Ford
requirements in time to support the build Engineering or Production Parts Achieve 100% of print specifications (minimum 5 piece
layout)
Part Deviation Notice (e.g. Red Border Notice) A Supplier notification that they cannot meet the Ford order requirements for either quality
or timing
Quality or Timing Categorize the reason why the Ford order requirements cannot be met
Engineering Notification Provide the Deviation Notification: approved Alert number for the specification deviations.
Note: North American Powertrain deviations for prototype builds prior VP are identified on
the e-Warrant.

EXTERNAL SUPPLIER PROTOTYPE OR PRODUCTION MEASUREMENTS RESULTS PAGE

SPECIAL NOTES
This information satisfies External Supplier APQP/PPAP Readiness Assessment - Schedule A Deliverable #12 or #20
or #27
Provide the print
Report data for allspecifications
required printdata item by itemengineering requirements and/or process characteristics. Supplier must have all information available for
specifications,
review. For presentations
Early Powertrain prototypeand the(X0
builds executive
- M1): print summary
Suppliers to Ford
will report themanagement
results of thesort to put the
prototype 20 most important
measurements characteristics
using this at the top ofcompliance
format to demonstrate the of
completed
the template.
functional and dimensional results for the part level ordered. Ford North America Powertrain requires approved e-Warrant deviation for each
characteristic
This form is tothat doesinnot
be used meetofthe
place AIAGrequirements
PPAP Manual priorAppendices
to shipmentC,ofD,the part.
and E

FORD PRODUCT DEVELOPMENT Page 8 of 34 Date Issued: 14-Jul-2009

GIS1 Item Number: N/A Date Revised: 29-Apr-2013
GIS2 Classification: Proprietary Version 5

PROTOTYPE OR PRODUCTION MEASUREMENT RESULTS
TERMS AND DEFINITIONS
TERMS
Characteristic (For VP Builds and beyond)
Characteristic (X0, XM and M1)
Specification
DFMEA Classification (YS, YC)
PFMEA Classification (CC, SC, HI, Other)
Process Control Method (VP and beyond)
Process Control Method (X0, XM, and M1)
On Control Plan (Y/N)
Quantity Inspected (pcs.)
Results: X-bar
Results: Range
All Parts Meet Specification (Y/N)
Comments / Actions Taken
Data Reporting
FORD PRODUCT DEVELOPMENT
GIS1 Item Number: N/A
GIS2 Classification: Proprietary
External Supplier APQP/PPAP Evidence
Instructions
DEFINITIONS
All required print specification, engineering requirements and/or process characteristics
are to be measured and reported on this template. For the simple print, sort as appropriate,
for example, by characteristic type. All characteristics will be included in the printed report.
For executive summary printing mode: sort the characteristics, so that the first 20 lines
contain the 20 most important (CC,SC & process) characteristics.
All required print specification, engineering requirements and/or process characteristics as
agreed upon by the Product Engineer and the Supplier are to be measured and reported on
this template. All characteristics will be included in the printed report.
Specification for the inspection item defined on the design record (print or E.S.)
Classification as identified on the DFMEA as "Potential Critical Characteristic" (YC) or
"Potential Signficant Characteristic" (YS).
Note: Specific Special Characteristic designation may not be identified for the X0, XM or M1
prototype
Classification as identified by the PFMEA. Other characteristics are print requirements that
are not identified as Special Characteristics.
Note: Specific Special Characteristic designation may not be identified for the X0, XM or M1
prototypes.
How are the parts inspected or measured as defined in the Prototype Control Plan? If the
control method is different than the method identified on the Special Characteristics
Agreement then report the reasons in the Comments / Actions Taken cell.
How are the parts inspected or measured as agreed upon with the Product Engineer for
prototype build: X0, XM, M1? If the control method is different than the method identified
on the Special Characteristics Agreement then report the reasons in the Comments /
Actions Taken cell.
Is the characteristic contained on the prototype build, prelaunch, or production control plan
of the reporting supplier for the parts produced supporting this build event?
Not applicable for builds prior to <VP> for Powertrain (X0, XM, M1).
How many pieces are contained in the inspection results data set? Prototype part quantity
to be inspected as required by Ford Product Engineer
Calculated average (mean) from inspection results data set. The mean (arithmetic average)
is the sum of all the observations divided by the number of observations
Calculates of the difference between the largest and smallest data values
All parts measured meet the characteristic specification
Make comments specific to the inspection item and include the action plan if the inspection
item does not meet the specification
The supplier must complete the measurements and report for all characteristics.
Note: For North American Powertrain prototype builds prior to VP include results with the
e-Warrant Submission
Page 9 of 34 Date Issued: 14-Jul-2009
Date Revised: 29-Apr-2013
Version 5
Site Capability
PD Matched Pair CDS STA Matched Pair:

Control Part Name(s)

/ Part Number(s)
(separate w/ commas)

Capability Plan Date to

Status Demonstrate
Assessment Overview: Planned Date Actual Date (G/Y/R) Capability:
Initial Assessment
Follow-up Assessment

Ppk Ppk
Controlled Characteristic Meeting Ppk Ppk < Ppk 0 to Ppk 0.5 1.0 to 1.33 to Ppk >= Ppk Not
Detail Counts Required Requirement 0 0.49 to 0.99 1.32 0.166 1.67 Reported
Initial Assessment
Follow-up Assessment

Date Issued: 14-Jul-2009

Date Revised: 29-Apr-2013
Version 5
 APQP/PPAP External Supplier Evidence
PRODUCTION PROCESS CAPABILITY RESULTS
Instructions
ROLES AND RESPONSIBILITIES
What Who When (VO) Print
For PTO follow PTO Equivalent Instruction
timing
s, Process
Failure Mode Avoidance - Design Failure Mode Effects
Analysis & Potential Critical/Significant Characteristics (YC
GPDS: <UPV2> Flow, and
Upper Body
& YS's) compelted/received (Deliverable #3) through the
Special Characteristics Agreement (FAP 03-111) & Form
Ford Product Development (PD)
<UNV2> Examples
Under Body
(FAF 03-111-2)
Special Characteristics (CC, SC, HI) agreed to and GPDS: <UPV2>
received by Supplier (Deliverable #5) through the Special Upper Body
Ford PD / Supplier
Characteristics Agreement (FAP 03-111) & Form (FAF 03- <UNV2>
111-2) Under Body
Production drawing & specification available to supplier
Ford PD GPDS: <FDJ> + 1 Month
(Deliverable #6)
Pre-Launch Control Plan is completed and has linkages to
Supplier / Ford STA / Ford PD GPDS: <PEC>
DFMEA and PFMEA (Deliverable #15)
Gauge Repeatability & Reproducibility (R&R) results meet
Supplier / Ford STA GPDS: <TT> IPD
PPAP Ford customer specifics (Deliverable #18)

Parts produced from Run at Rate at Cycle Time off of one

GPDS: <TT> IPD
production stream (Including Sub-Suppliers) (Deliverable Supplier
#19)

GPDS: <TT> IPD

Perform inspection method and collect data for analysis (inc Supplier

Analyze data set for statistical process control of the

GPDS: <TT> IPD
specified special characteristics (including Sub-Suppliers Supplier
data where applicable) PPAP Phase 1
Requirements
Analyze the data set for normality (or appropriate
GPDS: <TT> IPD
distribution) of the specified special characteristics Supplier
(including Sub-Suppliers data where applicable)
GPDS: <TT> IPD
Perform capability calculation using Ppk Formula Supplier

Completes the EXTERNAL SUPPLIER PRODUCTION GPDS: <TT> IPD

Supplier
PROCESS CAPABILITY RESULTS proforma

Initial process capability results (Ppk) have achieved

Supplier / Ford STA GPDS: <TT> IPD
results ≥1.67 for one production stream (Deliverable #21)

Production Run at Cycle Time to demonstrate Quality and

Capacity Capability on All Additional Production Sreams Supplier GPDS: <PP> IPD
(Including all Sub-Suppliers) (Deliverable #27)

Perform inspection method and collect data for analysis of

the specified special characteristics for all additional
Supplier GPDS: <PP> IPD
production streams (including Sub-Suppliers data where
applicable)

Analyze data set for statistical process control of the

specified special characteristics for all additional production Supplier GPDS: <PP> IPD
streams (including Sub-Suppliers data where applicable) PPAP Phase 2 Requireme
Analyze the data set for normality (or appropriate
distribution) of the specified special characteristics for all
Supplier GPDS: <PP> IPD
additional production streams (including Sub-Suppliers
data where applicable)
Perform capability calculation using Ppk Formula Supplier GPDS: <PP> IPD

Completes the EXTERNAL SUPPLIER PRODUCTION

Supplier GPDS: <PP> IPD
PROCESS CAPABILITY RESULTS proforma

Initial process capability results (Ppk) have achieved

Supplier / Ford STA GPDS: <PP> IPD
results ≥1.67
Final Process Capability established (Deliverable #29) Supplier / Ford STA GPDS: <MP2>
Production process capability results (Ppk) have achieved
Supplier / Ford STA GPDS: <MP2> and On-going
results ≥ 1.33

FORD STA Page 11 of 34 Date Issued: 14-Jul-2009

Form #: PP-S-F085 Date Revised: 29-Apr-2013
GIS2 Classification: Proprietary Version 5
 APQP/PPAP External Supplier Evidence
PRODUCTION PROCESS CAPABILITY RESULTS
Instructions
PROGRAM, SUPPLIER, PRODUCT, AND MANUFACTURING INFORMATION
TERMS AND DEFINITIONS
TERMS DEFINITIONS
A. Program Information
Model Year The model year the vehicle is released

Program Code The program code represents the Ford designation for the Vehicle or PTO
program
Product Name Product name is for the 'Vehicle' or 'PTO' name

Build Event The build event for the GPDS program milestone under review

B. Production Supplier / Product Information

Tier 1 Supplier Name Tier 1 Supplier responsible for the end item

Mfg. Site Code Mfg. Site code is the Global Supplier Data Base (GSDB) Site Code containing 5-
digits identifying the supplier manufacturing site
Tier 1 Supplier Location Production manufacturing location of the Tier 1 Supplier
Phase PPAP Status: The Phase PPAP Status: date entered into VPP or MPP by the supplier for PPAP
commits for the Phase PPAP deliverables
Promise Date Promise date entered into VPP or MPP by the supplier for PPAP commits for the
Phase PPAP deliverables
PPAP Approval Date Completed PPAP approval for the Phase PPAP Deliverables
Part Name General name given to the end item

Ford Part Number Ford designated component, sub-assembly or assembly number

Engineering Change Level
(e.g. Print Revision Level)
Engineering change level for a part is the design record revision level (i.e. Part
Print) as identified by a 4-part alphanumeric code (typically 14 characters in
length) containing the following:
a) Change Level Indicator (CLI) identifying the releasing authority
b) Part drawing revision letter (single letter)
c) Electronic Release System code (WERS = 8-digit concern number)
d) Release Status of the part in the electronic release system (WERS = 3-digit
increments of any notices attached to the part)
Engineering Change Level is also reported on the PSW.

Example: WPTSE12178961024
a) WPTS = Powertrain Systems Engine Mounts
b) E = engineering release
c) 12178961 = WERS notice
d) 024 = 24 WERS notices attached to this concern

New Tooled End Item (Y/N) Is the component, sub-assembly or assembly a new design for the given
Program Code?
C. Manufacturing Information
Manufacturing Site Location where the end item is manufactured for the build event

Carry-over production site Same location as previous model year or common platform

New Production site New facility designated as production intent to produce the end item

Prototype site Facility responsible for producing the end item for the specific build events (i.e.
not production intent)

Manufacturing Process Manufacturing process for the end item producing for the build event. The
scope of information is the end item manufacturing process(es) only
Carry-over process Same manufacturing process as previous model year or common platform

New process At least one operation contains new manufacturing process(es) to produced the
end item for the specific build event (i.e. production intent process)
Prototype process At least one operation contains a prototype process(es) to produced the end
item for the specific build event

Tooling Type Manufacturing tooling for the end item producing for the specified build event.
The scope of information is the end item manufacturing process(es) only

Carry-over tooling Same manufacturing tooling as previous model year or common platform

New Production Tooling At least one operation contains new manufacturing tooling to produced the end
item or the specific build event (i.e. production intent process)
Prototype/ soft tooling At least one operation contains prototype tooling in the process utilized to
produce the end item for the specific build event (i.e. not production intent)

FORD STA Page 12 of 34 Date Issued: 14-Jul-2009

Form #: PP-S-F085 Date Revised: 29-Apr-2013
GIS2 Classification: Proprietary Version 5
 APQP/PPAP External Supplier Evidence
PRODUCTION PROCESS CAPABILITY RESULTS
Instructions
Process Capability Data Represent

One Production Stream
All Production Streams
D. Deviations
None required, production process is capable
(PPAP Ppk ≥ 1.67 or Production Ppk ≥ 1.33)
Action taken for non-capable process
(PPAP Ppk < 1.67 or Production Ppk < 1.33)
Demonstrate that Initial Process Capability studies have been completed using
Run-at-Rate parts from the same production stream
Demonstrate that separate Initial Process Capability studies have been
completed using Run-at-Rate parts from each production stream.
Parts achieved PPAP Ppk ≥ 1.67 or Production Ppk ≥ 1.33 from the production
streams studied
The modified control method shall include techniques to incorporate mistake
proofing methods into the manufacturing process to prevent the shipment of
non compliant product to Ford facilities.
Note: examples of mistake proofing methods include the modification of
manufacturing processes to detect and discard non compliant product (e.g.,
poke-yoke), or a gauge to ensure product compliance to specification where the
process does not meet the capability requirements. This is not the addition of a
temporary manual inspection process at the end of the line.

Engineering notification Provide the Deviation Notification. Example: approved WERS Alert number for
the specification deviations with the interim PPAP submission.

EXTERNAL SUPPLIER PRODUCTION PROCESS CAPABILITY RESULTS PAGE

SPECIAL NOTES
This information satisfies External Supplier APQP/PPAP Readiness Assessment - Schedule A Deliverable #38 / Schedule B Element #35
Include all special characteristics
When specified by Ford, submit completed process control capability evidence at a weekly frequency from MP1 to MP1 + 90 days
When reporting capability for multiple events, multiple worksheets may be created to stack the data with a descriptor to differentiator
TERMS AND DEFINITIONS
TERMS DEFINITIONS
Characteristic Print specification item to be measured
Specification Specification for the characteristic defined on the design record (print or E.S.)

DFMEA Classification (YS, YC)
PFMEA Classification (CC, SC, HI, Other)
On Production Control Plan (Y/N)
Manufacturing Operation Identifier
Pass Through Characteristic (PTC) (Y/N)
Classification as identified on the DFMEA as "Potential Critical Characteristic"
(YC) or "Potential Signficant Characteristic" (YS).
Classification as identified by the PFMEA. Other characteristics are print
requirements that are not identified as Special Characteristics
Is the characteristic contained on the production control plan of the reporting
supplier?
Supplier's Production Manufacturing Operation identifier is a code or number
unique to the operation identified on the process flow chart and process control
plan
A Pass through Characteristic (PTC) is a product characteristic whose fit or
function qualities are not validated, verified or functionally tested within the
manufacturing or assembly process in question (external suppliers and
internally Ford-made parts). PTC are generally finished characteristics with part
print tolerances or specifications that are not verified in house or at the supplier,
and where defective parts can be passed on to the customer (defined as Vehicle
Operations or the buying public).
Examples may include:
Engine Thermostats
Torque Converter studs
Cylinder Head – FEAD mounting holes
Transmission Case – Starter mounting holes
Threaded hole supplied by an external supplier, not used in Powertrain Plant

Error Proofed (Y/N) Does the characteristic have an error proof method? This is required for CCs
and Ford identified PTCs.
Process Control Method How are the parts inspected or measured? If the control method is different than
the method identified on the Special Characteristics Agreement then report the
reasons in the Comments / Actions Taken cell.
Characteristic dependent on sub-supplier (Include PTC) Does the characteristic control require process control at a sub-supplier? This
(Y/N) applies to all characteristics classifications and include PTCs.
Study Parameters Study parameters refers to the sample size and population where the capability
study data is collected
Population What is the population (or estimate) size that contains the samples?
Sample Size How many pieces are contained in the inspection results data set?

FORD STA Page 13 of 34 Date Issued: 14-Jul-2009

Form #: PP-S-F085 Date Revised: 29-Apr-2013
GIS2 Classification: Proprietary Version 5
 APQP/PPAP External Supplier Evidence
PRODUCTION PROCESS CAPABILITY RESULTS
Instructions
Gauge R&R Repeatability and reproducibility of the measuring system

% Study Variation Measurement System Standard Deviation as a percentage of Total Observed

Process Standard Deviation (using Standard Deviation).
The Measurement System is used for Process monitoring and the samples
reflect the entire process range --> %GRR will be compared to TV(Total
Variation)

% Tolerance Measurement Error as a percentage of Tolerance

Demonstrated Method of Stability and Control
The Measurement system is used for Product Control --> %GRR
will be compared to the specification tolerance
Identify the method of statistical process control evaluation. Statistical process
control evaluation techniques include X-bar and R, or X-bar and S, or I-MR.
Note: For charting, X-bar and R or X- bar and S, 25 subgroups of 3 to 5 pcs

Evidence: Number of Points Not in Control Report the number of data points not in control. Out of control coniditions occur
when there is data outside the control limits. An out of control condition for the
X-bar chart is defined as 1 point greater or less than 3 standard deviations from
the mean. If more that 1 data point is not in-control then action is required.

Distribution Analysis The data distribution needs to be evaluated and identified for the appropriate
capability analysis calculation. For example, a normal distribution test requires
a P-value greater than 0.05 to assume normality. Non-normal data requires data
transformation

Distribution Type Select the type of distribution identified for the capability analysis. Refer to a
known distributions based on the physics or specific types of process available
through your STA engineer.

Resultant P-value or Best Fit Coefficient
Results: PPAP Ppk or Production Ppk
Report the distribution fit statistical hypothesis p-value or the best fit coefficient
from the distribution identification fit technique as appropriate
Process Capability Formula: Ppk
Example below is a calculation for a normal distribution
(Other capability distribution calculations may be applied where appropriate per
ISO 21747)

(USL−X) (X−LSL)
Ppk=min or
3 σ^ S 3 σ^ S
Where standard deviation is defined as:

√
n (X i−X)2
Ppk: { σ^ S= ∑ ¿
i=1 n−1

Meets Capability Requirement Conditional formatting will automatically populate the cell based on the process
PPAP Ppk ≥ 1.67 capability results meeting the PPAP Ppk requirement or the Production Ppk
Production Ppk ≥ 1.33 requirements. PPAP Ppk ≥ 1.67
(Y/N) Production Ppk ≥ 1.33
Note: Capability can NOT be determined until t
Comments / Action Taken Conditional formatting will identify through field transition to clear when
comments for action taken is needed based on meeting the capability
requirements. Make comments specific to the special characteristic and include
actions taken for low initial p

Data Reporting The supplier must complete the measurements and report for all special
characteristics. The first 20 characteristics are selected for report out to Ford
management

FORD STA Page 14 of 34 Date Issued: 14-Jul-2009

Form #: PP-S-F085 Date Revised: 29-Apr-2013
GIS2 Classification: Proprietary Version 5
 External Supplier APQP/PPAP Evidence
PROTOTYPE OR PRODUCTION MEASUREMENT RESULTS
Process Flow
Lead for activity When (VO) Input Process Output

For PTO follow RESULTS FOR PROTOTYPE PARTS

PTO Equivalent
Timing
GPDS: <UPV2> Falure Mode Avoidance - Special
Upper Body Special Char Agreement Form (FAF Characteristics agreed to and recieved by
Ford PD Suppliers (Deliverable #5) through the Special Special characteristics
<UNV2> 03-111-2)
Under Body Characteristics Agreement Form within this Control methods
workbook or FAF 03-111-2

Prototype Tool Orders

GPDS: 2 months release to suppliers in
Ford PD Program requirements support of Verification Prototype Tool Order
after <FDJ>
Prototype (VP) Build

Note: All Long

Lead Tools by
<FDJ>

Prototype Parts order with quantity and Prototype Parts Order: quantity and
Ford PD GPDS: <FDJ> Program requirements
timing to suppliers in support of VP Build timing

GPDS:2 Months Prototype Parts Order: quantity and Prototype Build Control Plan
Supplier / Ford PD
Prior to <VP> timing Prototype Build Control Plan Including process parameters,
Special Char Agreement (FAF 03- Completed (Deliverable #11) gauges, inspection methods,
111-2) tolerances, and reaction plan(s)

GPDS: In support
Supplier Hard tool or prototoype tools PRODUCE PROTOYPE PARTS
of <VP> MRD

Verify that gauges and test Corrective action for

equipment are accurate, non-conformancing
GPDS: In support Quantity Inspected (pcs) per Supplier records data per the
Supplier repeatable, and reproducible with product
of <VP> MRD Prototype Build Control Plan Prototype Build Control Plan
adequate discrimination with
production intent fixtures

FORD PRODUCT DEVELOPMENT Page 15 of 34 Date Issued: 14-Jul-2009

GIS1 Item Number: N/A Date Revised: 29-Apr-2013
GIS2 Classification: Proprietary Version 5
 External Supplier APQP/PPAP Evidence
PROTOTYPE OR PRODUCTIONQuantity
MEASUREMENT
Inspected (pcs) per
Prototype Build Control Plan
RESULTS
Process Flow
RESULTS

Prototype part inspection and

Supplier GPDS: In support measurement data X-Bar
of <VP> MRD X-Bar
Range
Prototype part inspection and
Range measurement data

Completes the PROTOTYPE OR

GPDS: In support Prototype part inspection and PRODUCTION MEASUREMENT RESULTS PROTOTYPE OR PRODUCTION
Supplier proforma as evidence of Deliverable #12
of <VP> MRD measurement data MEASUREMENT RESULTS
(Prototype)
Include COMMENTS / ACTIONS
TAKEN when all parts do not meet
specification for the given
characteristic

PROTOTYPE DATA REVIEW

Program STA Priority Supplier List

Initial selection of
Priority sites will No
On Priority
occur by <PTC> Supplier List
(unless otherwise
identified)

Yes

Ford PD / Review the results of the Prototype

Supplier Technical Supplier documented PROTOTYPE Parts produced during GPDS on- PROTOTYPE OR PRODUCTION
Assistance GPDS: In support OR PRODUCTION site evaluation #2 MEASUREMENT RESULTS with
of <VP> MRD MEASUREMENT RESULTS team input

No

FORD PRODUCT DEVELOPMENT Page 16 of 34 Date Issued: 14-Jul-2009

GIS1 Item Number: N/A Date Revised: 29-Apr-2013
GIS2 Classification: Proprietary Version 5
 External Supplier APQP/PPAP Evidence
PROTOTYPE OR PRODUCTION MEASUREMENT RESULTS
Process Flow
No

Ford PD
GPDS: In support PROTOTYPE OR PRODUCTION Prototype Parts Ford PD Approves
of <VP> MRD MEASUREMENT RESULTS No part deviation
signed-off by Ford
Engineering notice Obtain approval/sign-off on results
from Ford PD Engineer

Yes Any exception to the design

Yes
specification requires an approved
temporary engineering specification
GPDS: In support PROTOTYPE OR PRODUCTION Update cover page with Alert (e.g. WERS Alert) prior to shipment.
Supplier Number
of <VP> MRD MEASUREMENT RESULTS

GPDS: In support Agreement to ship the prototype Suppler Ships part to meet Material Required Parts shipped in support of <VP>
Supplier Date (MRD) for <VP> Build
of <VP> MRD parts MRD

FORD MANAGEMENT REVIEW

No Review Required evidence available upon

Program STA Requested request for priority and non-priority
GPDS: <VP> PROTOTYPE OR PRODUCTION suppliers
MEASUREMENT RESULTS

Yes
Results maintained
with APQP records
Send file to Site STA Engineer PROTOTYPE OR PRODUCTION
Supplier APQP/PPAP Evidence Workbook
MEASUREMENT RESULTS

Sort data into top 20 most important Select 'Print Cover Page &
characteristics Executive Summary Evidence PROTOTYPE OR PRODUCTION
Site STA Form' button to print top 20
GPDS: <VP> (e.g. importance to part MEASUREMENT RESULTS (Top
functionality) characteristics 20 Characteristics)

Organizes per Functional area Send file to STA Program team Functional area PROTOTYPE OR
GPDS: <VP>
Program STA (Body, Electrical, Chassis, etc.) PRODUCTION MEASUREMENT
RESULTS

FORD PRODUCT DEVELOPMENT Page 17 of 34 Date Issued: 14-Jul-2009

GIS1 Item Number: N/A Date Revised: 29-Apr-2013
GIS2 Classification: Proprietary Version 5
 External Supplier APQP/PPAP Evidence
PROTOTYPE OR PRODUCTION MEASUREMENT RESULTS
Process Flow

Ford Management Roll up all functional area data Ford Management review of
GPDS: <VP> data & feed back actions to STA All functional area PROTOTYPE
Engineer OR PRODUCTION
MEASUREMENT RESULTS

Lead for activity When (VO) Input Process Output

For PTO follow RESULTS FOR PRODUCTION PARTS

PTO Equivalent
Timing
GPDS: In Support Pre-launch Control Plan Including
Supplier / Ford Agreed FAF 03-111-2
of <TT> or <PP> Pre-launch Control Plan process parameters, gauges,
PD / STA PFMEA / Process Flow Diagram
IPD Completed (Deliverable #15) inspection & control methods,
tolerances, and reaction plan(s)

Facilities / Hard tools / Production

GPDS: In Support Process / Equipment / Gauges are Run@Rate - Produce Phase 0 Parts
(Deliverable #19 or #27) Phase 0 Parts
Supplier of <TT> or <PP> at the final manufacturing site
IPD production location - Home Line
(including sub-suppliers)

Verify that gauges and test Corrective action for

GPDS: In Support equipment are accurate, Parts achieve 100% of print non-conformancing Supplier records data per design
Supplier of <TT> or <PP> repeatable, and reproducible with specifications (Mininum 5 Piece product record and pre-launch control plan
IPD adequate discrimination with Layout) (Deliverable #20 or #27)
production intent fixtures

RESULTS

Supplier GPDS: In Support Part inspection and measurement X-Bar

of <TT> or <PP> data X-Bar
IPD Range

Range

FORD PRODUCT DEVELOPMENT Page 18 of 34 Date Issued: 14-Jul-2009

GIS1 Item Number: N/A Date Revised: 29-Apr-2013
GIS2 Classification: Proprietary Version 5
 External Supplier APQP/PPAP Evidence
PROTOTYPE OR PRODUCTION MEASUREMENT RESULTS
Process Flow

Completes the PROTOTYPE OR

GPDS: In Support PRODUCTION MEASUREMENT RESULTS
Part inspection and measurement PROTOTYPE OR PRODUCTION
Supplier of <TT> or <PP> proforma as evidence of Deliverable #20 or
data MEASUREMENT RESULTS
IPD #27 (Production)
Include COMMENTS / ACTIONS
TAKEN when all parts do not meet
specification for the given
characteristic

PRODUCTION DATA REVIEW

Program STA Initial selection of Priority Supplier List

Priority sites will On Priority
No
occur by <PTC> Supplier List
(unless otherwise
identified)

Yes

Supplier Technical Review the results of the parts

Assistance / Ford produced during GPDS on-site
Supplier documented PROTOTYPE evaluation #3 PROTOTYPE OR PRODUCTION
PD GPDS: In Support OR PRODUCTION MEASUREMENT RESULTS with
of <TT> or <PP> MEASUREMENT RESULTS team input
IPD

No

GPDS: In Support Parts achieve

PROTOTYPE OR PRODUCTION Ford PD Approves
Supplier Technical of <TT> or <PP> 100% of print No
MEASUREMENT RESULTS part deviation
Assistance / Ford IPD specifications
(Mininum 5 Piece notice Obtain approval on results from
PD
Layout) STA as an element of PPAP

Yes Any exception to the design

specification requires an approved
Yes temporary engineering specification
GPDS: In Support Update cover page with Alert
PROTOTYPE OR PRODUCTION (e.g. WERS Alert) prior to shipment.
Supplier of <TT> or <PP> Number
MEASUREMENT RESULTS
IPD

FORD PRODUCT DEVELOPMENT Page 19 of 34 Date Issued: 14-Jul-2009

GIS1 Item Number: N/A Date Revised: 29-Apr-2013
GIS2 Classification: Proprietary Version 5
 External Supplier APQP/PPAP Evidence
PROTOTYPE OR PRODUCTION MEASUREMENT RESULTS
Process Flow

GPDS: In Support Suppler Ships part to meet In-Plant Date (IPD) Parts shipped in support of <TT> or
Supplier of <TT> or <PP> Agreement to ship the parts Build after Phase 1 / 2 Approval or Interim <PP> IPD
IPD Acceptance

FORD MANAGEMENT REVIEW

No Review Required evidence available upon

Program STA GPDS: In Support Requested request for priority and non-priority
PROTOTYPE OR PRODUCTION suppliers
of <TT> or <PP>
MEASUREMENT RESULTS
IPD
Yes
Results maintained
with APQP records
Send file to Site STA Engineer PROTOTYPE OR PRODUCTION
Supplier APQP/PPAP Evidence Workbook
MEASUREMENT RESULTS

Sort data into top 20 most important Select 'Print Cover Page &
GPDS: In Support characteristics Executive Summary Evidence PROTOTYPE OR PRODUCTION
Site STA Form' button to print top 20
of <TT> or <PP> (e.g. importance to part MEASUREMENT RESULTS (Top
IPD functionality) characteristics 20 Characteristics)

GPDS: In Support Organizes per Functional area Send file to STA Program team Functional area PROTOTYPE OR
Program STA of <TT> or <PP> (Body, Electrical, Chassis, etc.) PRODUCTION MEASUREMENT
IPD RESULTS

Ford Management GPDS: In Support Roll up all functional area data Ford Management review of
of <TT> or <PP> data & feed back actions to STA All functional area PROTOTYPE
IPD Engineer OR PRODUCTION
MEASUREMENT RESULTS

FORD PRODUCT DEVELOPMENT Page 20 of 34 Date Issued: 14-Jul-2009

GIS1 Item Number: N/A Date Revised: 29-Apr-2013
GIS2 Classification: Proprietary Version 5
 External Supplier APQP/PPAP Evidence
PROTOTYPE OR PRODUCTION MEASUREMENT RESULTS
Schedule A/B Deliverable #12 OR #20
(Prototype Parts are 100% Measured, Dimesionally Known)
(Production Parts Achieve100% of Print Specification)
###
A. Program Information Date 13-Jul-09

Supplier
Required Delivery
Program In-Plant Promise Build Event
Model Year Code Product Name Build Event Date Date Vehicle Sets
2011 U502 Explorer VP 17-Jul-09 17-Aug-09 Required 94
Produced 150

B. Production Supplier / Product Information

Tier 1 Supplier Name Site Code Tier 1 Supplier Location
CMI - Muskegon U044M Muskegon, MI USA
City / Region / Country

Engineering Change New Tooled

Part Name Ford Part Number Level End Item (Y/N)
REAR KNUCKLE ASSEMBLY BB53-5B758(9)-AC WPTSE12178961024 Y

C. Manufacturing Information
Check Check Check
One
Manufacturing Site One Manufacturing Process One Tooling Type
✘ Carry-over production site CMI - Muskegon ✘
Carry-over production process Carry-over production tooling
New production site New production process New production tooling
Prototype site ✘ Prototype process ✘ Prototype / soft tooling

D. Deviations
Measurement Results Reason Alert #
None required, all delivered parts meet 100% of ✘ Part Deviation Timing Engineering
the requirements in time to support the build Notice Notification
Quality or Timing

FORD PRODUCT DEVELOPMENT Date Issued: 14-Jul-2009

Form #:PP-S-F085 Date Revised: 29-Apr-2013
GIS2 Classification: Proprietary Version 5
 External Supplier APQP/PPAP Evidence
PROTOTYPE OR PRODUCTION MEASUREMENT RESULTS
Schedule A/B Deliverable #12 OR #20
B30: (Prototype
(PPAP Ppk = 1.67 or Production Ppk = 1.33) Parts are 100% Measured, Dimesionally Known)
(Production Parts Achieve100% of Print Specification)
F9: 5 digit GSDB code for Manufacturing Location

G27: (e.g. Red Border Notice)

G30: (PPAP Ppk < 1.67 or Production Ppk < 1.33)

K12: (e.g. Print Revision Level)

FORD PRODUCT DEVELOPMENT Date Issued: 14-Jul-2009

Form #:PP-S-F085 Date Revised: 29-Apr-2013
GIS2 Classification: Proprietary Version 5
 External Supplier APQP/PPAP Evidence
PROTOTYPE OR PRODUCTION MEASUREMENT RESULTS
Schedule A/B Deliverable #12 OR #20 GPDS: Due at <VP>
Supplier Code: Q183D
Part Number: DG9P-7H074

Summary Results

On
PFMEA All Parts
Number

DFMEA Prototype Quantity

Classification Process Control Inspection Meet
Characteristic Specification Classification Control Inspected X-Bar Range Comments / Actions Taken
(CC, SC, HI, Method Frequency Specification
(YC, YS) Plan (pcs.)
Other) (Y/N)
(Y/N)

Material Yield
1
Strength
207 Mpa min YC CC Y tensile bars 1 per batch 4 217.75 3 Y none required

Material
Ultimate Tensile
2 Strength 276 Mpa min YC CC Y tensile bars 1 per batch 4 290.75 11 Y none required

FORD PROUCT DEVELOPMENT Page 23 of 34 Date Issued: 14-Jul-2009

GIS1 Item Number: N/A Date Revised: 29-Apr-2013
GIS2 Classification: Transient record Version 5
 APQP/PPAP External Supplier Evidence
PRODUCTION PROCESS CAPABILITY RESULTS
Lead for
activity
When (VO) Input Process Flow Process Output

For PTO follow

PTO Equivalent
Timing
Falure Mode Avoidance - Special
Characteristics agreed to and
GPDS: <UPV2> recieved by Suppliers (Deliverable
Upper Body Special Char Agreement Form (FAF 03- #5) through the Special Special characteristics
Ford Product <UNV2> 111-2) Control Methods
Development Characteristics Agreement Form
Under Body within this workbook or FAF 03-111-2
DFMEA
Preliminary PFMEA

Supplier
Technical Pre-Launch Control Plan is completed
GPDS: <PEC> On Control Plan (Y/N) and Control Plan Linkage
Assistance (Deliverable #15)
(STA) Manufacturing Operation Identifier

Manufacturing Operation Identifier

Pass through characteristics identified on

Supplier GPDS: <PEC> the control plan, as appropriate (For Pass Through Characteristic (PTC) Error Proof methods
Powertrain Programs only) and Error Proofed

Supplier / Ford Process control method Inspection methods, gauges, and

GPDS: <PEC> Inspection methods and gauges
STA / PD test equipment

Supplier / Ford Sub-supplier process flow / PFMEA / Characteristic dependent on sub- Sub-supplier control plan contains
GPDS: <PEC> supplier (Include PTC as
STA / PD control plan process control methods
appropriate)

STUDY PARAMETERS

Phase 0: In Conduct a valid production run(s) per the

Supplier / Ford support of <TT> Phase PPAP requirements. (i.e. Run-at- Population Size Run-at-rate
STA IPD Rate completed on production homeline Parts available for measurement
Phase 2: In equipment, process, and tooling)
support of <PP>
Sample Size
IPD Phase 0 (Deliverable #19), Phase 2
Phase 3: In (Deliverable #27) and Phase 3 (Deliverable
support of <MP2> #29)

GAUGE R&R
Remove special
Supplier / Ford Complete Measurement System Analysis causes and
Phase 0: In using Automotive Industry Action Group %Study Variation Gauge Repeatability &
STA implement corrective
support of <TT> (AIAG) Measurement System Analysis actions Reproducibility (R&R) results meet
IPD (MSA) and Ford's Customer Specifics to Ford customer specifics
%Tolerance
Phase 2: In PPAP for Gauge R&R (Deliverable #18)
support of <PP>
IPD

FORD STA Page 24 of 34 Date Issued: 14-Jul-2009

Form #: PP-S-F085 Date Revised: 29-Apr-2013
GIS2 Classification: Proprietary Version 5
 Complete Measurement System Analysis
Phase 0: In using Automotive Industry Action Group
support of <TT> (AIAG) Measurement System Analysis
IPD
Phase 2: In
(MSA) and Ford's Customer Specifics to
PPAP for Gauge R&R
APQP/PPAP External Supplier Evidence
support of <PP>
IPD PRODUCTION PROCESS CAPABILITY RESULTS
Process Flow
PROCESS CONTROL

No No
Phase 0: In Identified special Stable and in-control statistical
Statistical process control tools (Xbar and Evidence process control tools (Xbar and R or
Supplier support of <TT> demonstrates cause remove
IPD R or Xbar and S, or IM-R or other method) from data set Xbar and S, or IM-R or other
stability & control method)
Phase 2: In
support of <PP>
IPD
Phase 3: In Yes Yes
support of <MP2>

Phase 0: In Statistical software (e.g. MINITAB) DISTRIBUTION ANALYSIS

Supplier support of <TT>
IPD Normality tests
Phase 2: In No No
Data is No
support of <PP> Known Non-normal
IPD Known Expected Distribution List normally Distribution Type
Distribution ID data is
Phase 3: In distributed Resultant P-Value
Fit transformed
support of <MP2> Best Fit Coefficient for alternative
Data transformation method (Box-Cox or
distributions
Johnson Transformations) as needed
Yes Yes Yes
Distribution ID fit statistical analysis
CAPABILITY RESULTS
Mistake-proof modified
Statistical software (e.g. MINITAB) control method is in
place if the process Perform capability calculationusing
Supplier
Phase 0: In Ppk calculation capability does not Ppk Formula
support of <TT> meet the requirements
IPD
Phase 2: In
support of <PP>
IPD
Phase 3: In
support of <MP2>
Yes Capability PPAP Ppk requirement OR
Pending PPAP or PPAP previously Study is No Production Ppk requirement
achieved evidence for
PPAP

Phase 0: In Statistical software (e.g. MINITAB)

Supplier No PPAP Ppk process
support of <TT> Ppk calculation Meets PPAP Ppk of 1.67
capability meets
IPD
1.67 Requirement Or Actions Taken
Phase 2: In
support of <PP>
IPD
Phase 3: In
support of <MP2>
Yes
Meets Production Ppk of 1.33
No Production Ppk
process capability Or Actions Taken
Statistical software (e.g. MINITAB) meets 1.33
Supplier On-going
Ppk calculation Requirement
production

Yes
Supplier
Phase 0: In
support of <TT> PRODUCTION PROCESS CAPABILITY Completed PRODUCTION
IPD RESULTS Report results on PRODUCTION PROCESS CAPABILITY RESULTS
Phase 2: In PROCESS CAPABILITY RESULTS
support of <PP> proforma
Include ACTIONS TAKEN when
IPD capability requirements for the
Phase 3: In given characteristic are not met
support of <MP2>

FORD STA Page 25 of 34 Date Issued: 14-Jul-2009

Form #: PP-S-F085 Date Revised: 29-Apr-2013
GIS2 Classification: Proprietary Version 5
 APQP/PPAP External Supplier Evidence
PRODUCTION PROCESS CAPABILITY RESULTS
Process Flow
DATA STORAGE AND MANAGEMENT REVIEW

No
Initial selection of
Priority sites will
Program STA occur by <PTC> Priority Supplier List Priority Supplier
(unless otherwise
identified)

Yes

Phase 0: In Results review during GPDS on-site

Site STA File results in support
support of <TT> Conduct a valid production trial run(s) per Visit #3 and Visit #4 EXTERNAL SUPPLIER
of PPAP
IPD the Phase PPAP requirements. (i.e. Run- PRODUCTION PROCESS
Ford PD
Phase 2: In at-Rate completed on production homeline CAPABILITY RESULTS
support of <PP> equipment, process, and tooling)
IPD
Phase 3: In
support of <MP2>
No
GPDS: TT / Unit Program
<TT> and Review
Program STA Programs request supplier proformas
GPDS: PP MRD / Requested
Unit <PP> MRD

Yes

Supplier GPDS: TT / Unit

<TT> and Send file to STA Program team as EXTERNAL SUPPLIER
Programs request supplier proformas requested
GPDS: PP MRD / PRODUCTION PROCESS
Unit <PP> MRD CAPABILITY RESULTS

Select 'Print Cover Page & Executive

GPDS: TT / Unit Sort data into top 20 most important Summary Evidence Form' button to
Site STA <TT> and characteristics Functional area EXTERNAL
print top 20 characteristics SUPPLIER PRODUCTION
GPDS: PP MRD / (e.g. importance to part functionality)
Unit <PP> MRD PROCESS CAPABILITY RESULTS
(sort Top 20)

All functional area requested supplier Ford Management review of data &
Ford GPDS: TT / Unit proformas feed back actions to STA Engineer All functional areas\ EXTERNAL
Management <TT> and
SUPPLIER PRODUCTION
GPDS: PP MRD /
PROCESS CAPABILITY RESULTS
Unit <PP> MRD

ONGOING PRODUCTION CAPABILITY

Supplier / Post <FSR> As requested by Ford Program

Site STA When specified by Ford, submit completed process capability evidence PRODUCTION PROCESS
CAPABILITY RESULTS

FORD STA Page 26 of 34 Date Issued: 14-Jul-2009

Form #: PP-S-F085 Date Revised: 29-Apr-2013
GIS2 Classification: Proprietary Version 5
 APQP/PPAP External Supplier Evidence
PRODUCTION PROCESS CAPABILITY RESULTS
Satisfies Schedule A Deliverable #38 / Schedule B Element #35
(Initial Process Capability Results (Ppk) >= 1.67)
###
A. Program Information Date 5-Aug-09
Program
Model Year Code Product Name Build Event
2010 B299N Fiesta TT

Phase PPAP Status

✘

B. Production Supplier / Product Information

✘ ✘

Phase 1 Phase 2 Phase 3

Tier 1 Supplier Name Site Code Tier 1 Supplier Location Promise Date 10-Aug-10 1-Oct-10 20-Dec-10
✘
CMI - Muskegon U044M Muskegon, MI USA PPAP Approved Date 4-Aug-10
City / Region / Country

✘
✘
Engineering Change New Tooled
Part Name Ford Part Number Level End Item (Y/N)
REAR KNUCKLE ASSEMBLY BB53-5B758(9)-AC WPTSE12178961024 Y

C. Manufacturing Information
Check Check Check
One
Manufacturing Site One Manufacturing Process One Tooling Type
Carry-over production site CMI - Muskegon Carry-over production process Carry-over production tooling
New production site New production process New production tooling
Prototype site Prototype process Prototype / soft tooling

Process Capability Data

Represent:
One production stream
All production streams

D. Deviations
Process Capability Results Alert #
None required, production process is Actions taken for non-capable process Engineering
capable (See page 2 for Actions Taken) notification

FORD STA Date Issued: 14-Jul-2009

Form #:PP-S-F085 Date Revised: 29-Apr-2013
GIS2 Classification: Proprietary Version 5
 APQP/PPAP External Supplier Evidence
B30: PRODUCTION
(PPAP Ppk = 1.67 or Production Ppk = 1.33) PROCESS CAPABILITY RESULTS
F9: Satisfies Schedule A Deliverable #38 / Schedule B Element #35
5 digit GSDB code for Manufacturing Location
(Initial Process Capability Results (Ppk) >= 1.67)
G27: (e.g. Red Border Notice)

G30: (PPAP Ppk < 1.67 or Production Ppk < 1.33)

K12: (e.g. Print Revision Level)

FORD STA Date Issued: 14-Jul-2009

Form #:PP-S-F085 Date Revised: 29-Apr-2013
GIS2 Classification: Proprietary Version 5
 APQP/PPAP External Supplier Evidence
PRODUCTION PROCESS CAPABILITY RESULTS
Satisfies Schedule A Deliverable #38 / Schedule B Element #35 GPDS: Due at <TT>
Study Distribution
Characteristic Gauge R&R Process Control Capability Results
Parameters Analysis
Characteristic % PPAP Meets Capability
DFMEA PFMEA Pass Through % Demonstrated Evidence: Resultant
Number

On Manufacturing Error dependent on Study Ppk Values Requirement

Classification Classification Characteristic Process Control Population Sample Tolerance Method of Number of Distribution P-value or
Characteristic Specification
(YC, YS) (CC, SC, HI,
Control Operation
(PTC)
Proofed
Method
sub-supplier
Size Size
Variation
(Target Stability and Points Not in Type Best Fit
PPAP Ppk ≥ 1.67 Actions Taken
Plan (Y/N) Identifier (Y/N) (Include PTC) (Target Production Production Ppk ≥ 1.33
Other) (Y/N) ≤ 10%) Control Control Coefficient
(Y/N) ≤ 10%) Ppk Values (Y/N)
1 Hole size 10.5 +/- 0.5mm YC CC Y OP10 N Y Air Gage N 300 125 10.54% 9.55% X-bar and R 1 N 100% in-line air gage
2 Hardness 80 - 120 BHN YS SC Y Subsupplier Y N Equotip Y 300 30 18.66% 3.33% I-MR 0 Normal 0.06 1.68 Y
Material Yield
3 207 Mpa min YC CC Y Subsupplier Y N tensile bars Y 300 30 2.09% 2.22% I-MR 0 Normal 0.76 2.01 Y
Strength
Material Ultimate
4 276 Mpa min YC CC Y Subsupplier Y N tensile bars Y 300 30 3.45% 2.77% I-MR 0 Weibull 0.88 1.77 Y
Tensile Strength
5 Material Elongation 7% min YC CC Y Subsupplier Y N tensile bars Y 300 30 9.09% 4.67% I-MR 0 Weibull 0.06 1.88 Y
100% press force
6 Press - in load UCA min 29 KN YS SC Y OP40 N Y Load cell N 300 125 2.55% 5.99% X-bar and R 2 N
monitoring

Box-Cox
7 UCA Bore diameter 10 ± 0.5 mm YS SC Y OP20 N Y CMM N 300 125 12.45% 11.11% X-bar and R 0 0.2 1.67 Y
Transformed

8 UCA Position 0.5 mm max YS SC Y OP20 N N CMM N 300 125 18.56% 15.88% X-bar and R 0 Lognormal 0.85 1.81 Y

Johnson
9 UCA Roundness max 0.5 YS SC Y OP30 N Y tallyrand N 300 125 21.50% 17.76% X-bar and R 0 0.001 1.34 N 100% in-line air gage
Transformed

10 Bushing span 7.36-7.49 mm YS SC Y OP20 N N optical comparator Y 300 125 4.65% 7.88% X-bar and R 0 Normal 0.34 2.33 Y

FORD STA Date Issued: 14-Jul-2009

Page 29 of 34
Form #: PP-S-F085 Date Revised: 29-Apr-2013
GIS2 Classification: Proprietary Version 5
 APQP/PPAP External Supplier Evidence
PRODUCTION PROCESS CONTROL RESULTS
Required When Specified by Ford Motor Company (MP1 to MP1 + 90 Days)
GPDS: MP1 to MP1 + 90 Days
Supplier Code:
Print Cover Page
Part Number:
Delete All
& Executive
Archive HistoricalClear
Data FormMeasurement
Summary
Archives
Evidence Form Characteristic
Study
Parameters
Gauge R&R Process Control

Characteristic %
DFMEA PFMEA On Pass Through % Demonstrated Evidence:
Number

Manufacturing Error dependent on Study

Classification Classification Production Characteristic Process Control Population Sample Tolerance Method of Number of
Characteristic Specification
(YC, YS) (CC, SC, HI, Control Plan
Operation
(PTC)
Proofed
Method
sub-supplier
Size Size
Variation
(Target Stability and Points Not in Actions Taken
Identifier (Y/N) (Include PTC) (Target
Other) (Y/N) (Y/N) ≤ 10%) Control Control
(Y/N) ≤ 10%)

FORD STA Date Issued: 14-Jul-2009

Page 30 of 34
Form #: PP-S-F085 Date Revised: 29-Apr-2013
GIS2 Classification: Transient record Version 5
 APQP/PPAP External Supplier Evidence
PRODUCTION PROCESS CONTROL RESULTS
ROLES AND RESPONSIBILITIES Instructions
What Who When
Drawing and Specification released to supplier (Deliverable
Ford Product Development (PD) GPDS: 1 month before<FDJ>
#25)
Failure Mode Avoidance - Special Characteristics
cascaded to suppliers (Deliverable #9) through the Special Ford PD GPDS: <PA>
Characteristics Agreement (FAP 03-111)
Production Control Plan is completed and has linkages to
Supplier / Ford STA / Ford PD GPDS: <TT>
DFMEA and PFMEA (Deliverable #20)

Measurement System Analysis Gauge R&R results ≤ 10%

Supplier / Ford STA GPDS: <TT>
per PPAP Ford customer specifics (Deliverable #30)

Execute control plan and monitor process for statistical

Supplier On-going
process control
Report process control results on the EXTERNAL
SUPPLIER PRODUCTION PROCESS CONTROL Supplier Weekly from MP1 to MP1 + 90 days
RESULTS proforma
All production processes are stable and in-control; actions
Supplier / Ford STA On-going
taken for out of control processes

PROGRAM, SUPPLIER, PRODUCT, AND MANUFACTURING INFORMATION

TERMS AND DEFINITIONS
TERMS DEFINITIONS
A. Program Information
Model Year The model year the vehicle is released

Program Code The program code represents the Ford designation for the Vehicle or PTO
program
Product Name Product name is for the 'Vehicle' or 'PTO' name

Build Event The build event for the GPDS program milestone under review

B. Production Supplier / Product Information

Tier 1 Supplier Name Tier 1 Supplier responsible for the end item

Mfg. Site Code Mfg. Site code is the Global Supplier Data Base (GSDB) Site Code containing 5-
digits identifying the supplier manufacturing site
Tier 1 Supplier Location Production manufacturing location of the Tier 1 Supplier
Phase PPAP Status: The Phase PPAP Status: date entered into VPP or MPP by the supplier for PPAP
commits for the Phase PPAP deliverables
Promise Date Promise date entered into VPP or MPP by the supplier for PPAP commits for the
Phase PPAP deliverables
PPAP Approval Date Completed PPAP approval for the Phase PPAP Deliverables
Part Name General name given to the end item

Ford Part Number Ford designated component, sub-assembly or assembly number

Engineering Change Level Engineering change level for a part is the design record revision level (i.e. Part
(e.g. Print Revision Level) Print) as identified by a 4-part alphanumeric code (typically 14 characters in
length) containing the following:
a) Change Level Indicator (CLI) identifying the releasing

Example: WPTSE12178961024
a) WPTS = Powertrain Systems Engine Mounts
b) E = engineering release
c) 12178961 = WERS notice
d) 024 = 24 WERS notices attached to this concern

New Tooled End Item (Y/N) Is the component, sub-assembly or assembly a new design for the given
Program Code?
C. Manufacturing Information
Manufacturing Site Location where the end item is manufactured for the build event

FORD STA Page 31 of 34 Date Issued: 14-Jul-2009

Form #: PP-S-F085 Date Revised: 29-Apr-2013
GIS2 Classification: Proprietary Version 5
 APQP/PPAP External Supplier Evidence
PRODUCTION PROCESS CONTROL RESULTS
Carry-over production site Instructions
Same location as previous model year or common platform

New Production site New facility designated as production intent to produce the end item

Prototype site Facility responsible for producing the end item for the specific build events (i.e.
not production intent)

Manufacturing Process Manufacturing process for the end item producing for the build event. The
scope of information is the end item manufacturing process(es) only
Carry-over process Same manufacturing process as previous model year or common platform

New process At least one operation contains new manufacturing process(es) to produced the
end item for the specific build event (i.e. production intent process)
Prototype process At least one operation contains a prototype process(es) to produced the end
item for the specific build event

Tooling Type Manufacturing tooling for the end item producing for the specified build event.
The scope of information is the end item manufacturing process(es) only

Carry-over tooling Same manufacturing tooling as previous model year or common platform

New Production Tooling At least one operation contains new manufacturing tooling to produced the end
item or the specific build event (i.e. production intent process)
Prototype/ soft tooling At least one operation contains prototype tooling in the process utilized to
produce the end item for the specific build event (i.e. not production intent)
D. Deviations
All production processes are stable and in-control Demonstrated method of stability and control evidence indicates all points are in
control
Actions taken for out of control processes The modified control method shall include techniques to incorporate mistake
proofing methods into the manufacturing process to prevent the shipment of
non compliant product to Ford facilities.
Note: examples of mistake proofing methods include the modification of
manufacturing processes to detect and discard non compliant product (e.g.,
poke-yoke), or a gauge to ensure product compliance to specification where the
process does not meet the capability requirements. This is not the addition of a
temporary manual inspection process at the end of the line.

FTT Report the manufacturing process First Time Through (FTT) as a planned (target)
Planned and demonstrated (actual) result. FTT is the percentage of units processed at
Demonstrated the Evaluation Point (EP) that meet Quality Guidelines the first time without
being repaired, retested, returned from within the plant, or scrapped.

FTT @ an EP = Total Units Processed - Units Not OK

Total Units Processed X 100 %

EXTERNAL SUPPLIER PRODUCTION PROCESS CAPABILITY RESULTS PAGE

SPECIAL NOTES
This information satisfies External Supplier APQP/PPAP Readiness Assessment - Schedule A Deliverable #38 / Schedule B Row #35
Include all special characteristics
When specified by Ford, submit completed process control capability evidence at a weekly frequency from MP1 to MP1 + 90 days
TERMS AND DEFINITIONS
TERMS DEFINITIONS
Characteristic Print specification item to be measured

Specification Specification for the characteristic defined on the design record (print or E.S.)

DFMEA Classification (YS, YC) Classification as identified on the DFMEA as "Potential Critical Characteristic"
(YC) or "Potential Signficant Characteristic" (YS).

FORD STA Page 32 of 34 Date Issued: 14-Jul-2009

Form #: PP-S-F085 Date Revised: 29-Apr-2013
GIS2 Classification: Proprietary Version 5
 APQP/PPAP External Supplier Evidence
PRODUCTION PROCESS CONTROL RESULTS
PFMEA Classification (CC, SC, HI, Other) Instructions
Classification as identified by the PFMEA. Other characteristics are print
On Production Control Plan (Y/N)
Manufacturing Operation Identifier
Pass Through Characteristic (PTC) (Y/N)
Error Proofed (Y/N)
Process Control Method
Characteristic dependent on sub-supplier (Include PTC)
(Y/N)
Study Parameters
Population
requirements that are not identified as Special Characteristics
Is the characteristic contained on the production control plan of the reporting
supplier?
Supplier's Production Manufacturing Operation identifier is a code or number
unique to the operation identified on the process flow chart and process control
plan
A Pass through Characteristic (PTC) is a product characteristic whose fit or
function qualities are not validated, verified or functionally tested within the
manufacturing or assembly process in question (external suppliers and
internally Ford-made parts)
Does the characteristic have an error proof method? This is required for CCs
and Ford identified PTCs.
How are the parts inspected or measured? If the control method is different than
the method identified on the Special Characteristics Agreement then report the
reasons in the Comments / Actions Taken cell.
Does the characteristic control require process control at a sub-supplier? This
applies to all characteristics classifications and include PTCs.
Study parameters refers to the sample size and population where the capability
study data is collected
What is the population (or estimate) size that contains the samples?

Sample Size How many pieces are contained in the inspection results data set?

Gauge R&R Repeatability and reproducibility of the measuring system

% Study Variation Measurement System Standard Deviation as a percentage of Total Observed

Process Standard Deviation (using Standard Deviation)
% Tolerance Measurement Error as a percentage of Tolerance

Demonstrated Method of Stability and Control Identify the method of statistical process control evaluation. Statistical process
control evaluation techniques include X-bar and R, or X-bar and S, or I-MR.
Note: For charting, X-bar and R or X- bar and S, 25 subgroups of 3 to 5 pcs

Evidence: Number of Points Not in Control Report the number of data points not in control. Out of control coniditions occur
when there is data outside the control limits. An out of control condition for the
X-bar chart is defined as 1 point greater or less than 3 standard deviations from
the mean. If more that 1 data point is not in-control then action is required.

Comments / Action Taken Conditional formatting will identify through field transition to clear when
comments for action taken is needed based on demonstration of process
control. Make comments specific to the special characteristic and include
actions taken for out of control process.
Data Reporting The supplier must complete the measurements and report for all special
characteristics.

FORD STA Page 33 of 34 Date Issued: 14-Jul-2009

Form #: PP-S-F085 Date Revised: 29-Apr-2013
GIS2 Classification: Proprietary Version 5
 APQP/PPAP External Supplier Evidence
PRODUCTION PROCESS CONTROL RESULTS
Required When Specified by Ford Motor Company (MP1 to MP1 + 90 Days)
GPDS: MP1 to MP1 + 90 Days
Study
Characteristic Gauge R&R Process Control
Parameters
Characteristic %
DFMEA PFMEA On Pass Through % Demonstrated Evidence:
Number

Manufacturing Error dependent on Study

Classification Classification Production Characteristic Process Control Population Sample Tolerance Method of Number of
Characteristic Specification
(YC, YS) (CC, SC, HI, Control
Operation
(PTC)
Proofed
Method
sub-supplier
Size Size
Variation
(Target Stability and Points Not in Actions Taken
Identifier (Y/N) (Include PTC) (Target
Other) Plan (Y/N) (Y/N) ≤ 10%) Control Control
(Y/N) ≤ 10%)
Air gage is 100%
1 Hole size 10.5 +/- 0.5mm YC CC Y 10 Y Y Air Gage N 300 125 10.54% 9.55% X-bar and R 1
inspection frequency
2 Hardness 80 - 120 BHN YS SC Y 50 Y N Equotip Y 300 30 18.66% 3.33% I-MR 0
Material Yield
3 207 Mpa min YC CC Y 50 Y N tensile bars Y 300 30 2.09% 2.22% X-bar and R 0
Strength
Material Ultimate
4 276 Mpa min YC CC Y 50 Y N tensile bars Y 300 30 3.45% 2.77% Other 0
Tensile Strength
5 Material Elongation 7% min YC CC Y 50 Y N tensile bars Y 300 30 9.09% 4.67% I-MR 0
Load cell is 100%
6 Press - in load UCA min 29 KN YS SC Y 40 Y Y Load cell Y 300 125 2.55% 5.99% X-bar and R 2
inspection frequency

7 UCA Bore diameter 10 ± 0.5 mm YS SC Y 30 N N CMM N 300 125 12.45% 11.11% X-bar and R 0

End Point Containment of suspect

8 UCA Position 0.5 mm max YS SC Y 30 N N CMM N 300 125 18.56% 15.88% 3
Control lot 100% re-inspected

Modified
Control Chart
Air gage is 100%
9 UCA Roundness max 0.5 YS SC Y 30 N N tallyrand N 300 125 21.50% 17.76% for Non 4
inspection frequency
Random
Variation

10 Bushing span 7.36-7.49 mm YS SC Y 30 N N optical comparator N 300 125 4.65% 7.88% X-bar and S 0

FORD STA Date Issued: 14-Jul-2009

Page 34 of 34
Form #: PP-S-F085 Date Revised: 29-Apr-2013
GIS2 Classification: Proprietary Version 5