FPA For Stamping and Body

Procedure No.
VOPQUG-055
Ford Product Audit (FPA) for Stamping and Body

Vehicle Operations Procedure - Global
Page 1 of 12 Revision Date: 20060411
1. PURPOSE
The purpose of this procedure is to outline the basic principles of the FPA evaluation process utilized on
prototype, Job #1, and production parts/bodies within Stamping, Clinching and Body systems.
This procedure applies to Engineering, Staff and/or V.O. plant FPA assessment quality personnel.
2. ORGANIZATIONS AFFECTED
Vehicle Operations Quality Office
Stamping Engineering
Body Construction Engineering
Vehicle Operations Integrated Stamping & Assembly Plants
New Model Programs
Vehicle Operations Assembly Plants
Vehicle Operations Stamping Plants
3. FORMS USED
None
4. REFERENCES & ATTACHMENTS
This procedure can be found in the EKB in folder:

https://www.ekbbooks.ford.com/ekbbooks/bookmark.html?objectId=0b000c518074589b
Attachments
Customer Concern Rating System (CCRS)

Exhibit 1
Surface Classification FPA
Exhibit 2
FPA Stone Specification
Exhibit 3
Stamping/Clinching Write-Up Sheet (example)
Exhibit 4
BIW Write-Up Sheet (EU only)
Exhibit 5
BIW Write-Up Sheet (NA only)
Exhibit 5a
Audit-Box Illumination
Exhibit 6
Vehicle Operations Procedure (VOP) Printed copies are uncontrolled

Procedure No. VOPQUG-055

References
VOPQUN-001 Time and Data Management (N.A. only)

VOPQUE-600 Time and Data Management (E.U. only)
VOPQUG-004 Product Containment and Preventive Action
VOPQUN-247 Ford Consumer Product Audit (FCPA) (NA only)
VOPQUE-625 Ford Consumer Product Audit (FCPA) (EU only)
FAP01-016 Document/Data and Record Control
GIS1 Global Information Standard 1
5. DEFINITIONS
BIW - Body-in-White
CCRS - Customer Concern Rating System
Clinch Items - Assembled parts including inners
ES - Engineering Specification
FPA - Ford Product Audit (in-process audit)
GIS1 - Global Information Standard #1
PSW - Part Submission Warrant
VOQO - Vehicle Operations Quality Office
6. EXCLUSIONS
None
7. PROCEDURE
7.1. FPA Overview
The application of the FPA process for specific operations is the responsibility of the local Plant Quality
Manager.
The FPA process is applied to:
7.1.1. Skin Panels (Panel FPA)
Skin panel stampings/visible clinch items and Sub-assemblies at tool construction source, at PSW,
and regular production. Recommended frequency is beginning of press runs for surfaces,
periphery curvature and Trade Marks, considering draw panels only if production representative
black tooling is available. Additionally, periodic FPA during press runs at a frequency determined


locally are recommended. EU only: Sub-Assemblies/ Clinched Items evaluation is part of the BIW
Audit process or may be conducted separately.
7.1.2. Body-in White (Body FPA)
For surface, closure panel fits, openings, visible welds, sealer, adhesive, Trade Marks.
The prime intent of the FPA is to identify manufacturing imperfections, early indicators for
stamping/clinching and potential customer complaints. The objective is to drive and effect
containment action and concern resolutions to avoid recurrence promoting continuous improvement
in quality levels of sheet metal and Body-In-White.
It is expected that the auditors operate as trained observers/critical customer and will find more
deficiencies, especially in craftsmanship aspects (fit and finish) as compared with external customer
feedback (TGW / Warranty). Therefore FPA is not a tool to predict warranty or TGW numbers. In this
context Gap and Flushness tolerances are measured if the visual review shows discrepancies (EU
only). Dirt on unpainted surface panels is counted (NA only). Any other specifications, tolerances
and process capabilities will be ignored and will not be the basis for the FPA quality standard. No
other measurements will be taken. The FPA Audit tool is applied to passenger and commercial
vehicles in the same way.
There is only one aligned quality standard, endorsed by senior Vehicle Operations Quality Office
management. Vehicle Operations Quality Office's NA and EU are responsible for setting and
maintaining this standard across all affected plants within their responsibility. The FPA assessment
process is a one person audit process.
7.2. Utilization of the FPA function
7.2.1 It should be utilized within New Model Development: During the product development pre-Job
#1 build phases (CP through to Job#1) to identify early build concerns.
7.2.2 It shall be utilized during Production: From Job#1 and ongoing through the daily monitoring of
regular plant new production panels/bodies(NA: only panels), reported monthly at the Control
Plant and/or Matching Fixture Meetings.
7.3. Assessment Sample
FPA products must be selected randomly where the product has been given final "OK" for shipment to the
next customer.
Audit Scope: (This is determined locally for sample frequency and responsible personnel).
Stamping Plant responsible personnel (determined locally) can perform:
1. Skin Panel (Outer Exterior Panels before Sub-Assembly)


2. Sub-Assembly (Clinch Item) audits
Body Plant Personnel can perform:
1. Body-in-White
2. Skin Panel
3. Sub-Assembly (Clinch Item) audits
Audit Time (approximate)
EU : Skin Panels 60 minutes

NA : Skin Panels 60 minutes - Additional time is required for very large panels (e.g. full-size van body
panels.)
EU : Clinch Items (assembled parts including inner panels) 60 minutes

NA : Clinch Items (assembled parts including inner panels) 60 minutes - Additional time is required for
very large panels (e.g. full-size van body panels.)
Body-in-White: 150 minutes (Note: "Stoning" inspection for "C" concerns is not required for Body-In-
White FPA )
7.3.1. Sample Sizes
- Skin Panels minimum of 1 per production press run. Additional FPA inspections during press runs
may be conducted at a frequency determined locally based on part size, duration of production run
or other constraints.
- Clinch Items (assembled parts including inner panels) minimum of 1 per production press run
(NA only). Additional FPA inspections during press runs may be conducted at a frequency
determined locally based on part size, duration of production run or other constraints.
(NA only) Assembly Plant Body-in-White units a minimum of one BIW sample per month rotating
among the various models supporting the monthly Sheet Metal Control Plant Meetings.
(EU only) Body in White units 2 vehicle per day. Production sample composition should reflect
the operations derivative mix of body styles for each vehicle line produced, over time.
7.3.2 Targets
No A or B1 concerns on:
- Skin panels and Sub-assemblies (Clinch items)
- Body-in-White units
New model development vehicle mix will be determined by the availability of the units from the
advance build program and launch team (recommend each body style is evaluated at each major
build phase).


All sample panels / units should have exterior surfaces clean for the visual inspection.
7.4. Teams/Personnel
Summary
The FPA assessment must only be carried out using competent personnel. Any personnel performing
specific FPA assigned tasks must be qualified on the basis of education, training and/or experience, as
required in line with FPA Auditor qualification. Stamping and Body Plant Management are responsible to
select the FPA auditors. Basic attributes may include - good physical condition, communication skills,
computer skills, team member experience, integrity, overall product knowledge/automotive experience
and a customer focus. The Auditors need to be familiar with the vehicle, its parts and function, and
concern modes. In addition, auditors must be capable to assess sensory items demanding touch and
sight.
Auditor Calibration / Auditor Certification
EU only:
VOQO trains, calibrates and certifies key persons for Skin Panels and BIW Audits to act as a S.P.o.C.
(Single Point of Contact) within every plant. VOQO certifies the S.P.o.C. FPA Plant Auditors yearly. The
S.P.o.C. will train and certify further FPA Plant Auditors as needed. Certified Plant Auditors have to be
recertified by the Plant S.P.o.C. yearly. The S.P.o.C. has to inform VOQO about new auditors and has to
train and certify them within 4 weeks. A copy of the certificate has to be sent to VOQO.
NA only: Trained FPA auditors within the Stamping Business Unit may train / calibrate additional auditors
at the discretion of the local Quality Management.
Auditor Responsibility
The auditor's prime function is to assess the product as a critical customer/trained observer against the
set quality standards related to skin panels, clinch items, body-in-white. Each concern is to be captured
(nature and location) and classified. Summarizing of concerns, with a few exceptions, is not permitted
(see Section F). The auditor is not responsible for assigning complaints against the most responsible
area. Assigning concerns is to be performed by the local Management. Furthermore, auditors must not
repair or assemble any condition during course of the audit.
Verification Audits
VO Quality Office will verify audit process and results on a regular basis.
7.5. Assessment Location/Facilities & Basic Requirements
The FPA assessment process can be done in various locations such as the stamping plants, division pilot
plant facilities, body shop area or other Company/Affiliate locations.


7.5.1. Light Tunnel/Audit Crib or Audit Room
For the surface quality assessment the parts, components, bodies will be located under intensified
illumination (show room condition) to maintain reproducible conditions throughout all audit areas and
to consistently evaluate panel surface quality. The facility may have dimming capability.
(NA only) - For assessing bodies, the light source should be at a height of approx. 3.0 m (9 ft),
angled to ensure good illumination at roof and sides. Illumination at roof/hood should be
approximately 2000 lux (daylight tubes are recommended). 2000 lux is also recommended for
panels/parts.
(EU only) - Illumination for the individual audit area (approximately 6m x 3m) needs to be 2000 lux at
1,5 meter height, horizontally measured and 1000 lux at 1m height vertically measured (see Exhibit
6). It is recommended that tubes are angled to ensure that vertical panels are illuminated correctly.
7.5.2. Body/Panel FPA Quality Assessment:
A-concerns: In Paint FCPA (EU only) or Full FCPA verified, visual Concerns. Or concerns where any
kind of assembly risk could be expected
B-concerns: Tactile inspection with special gloves (thin weight)
C-concerns: Visual inspection by stoning (only applied on Skin Panel and Sub-assembly Audits)
(NA only) Medium India Stones (Modern Abrasive Part # UTR25M250MMI or MT125) should be
used for Sheet Metal surface assessment (Exhibit 3). Two sizes of stones are recommended. The
large stone should be used for the majority of the surface. The smaller stone should be used only if
the surface curvature and crown cannot be properly evaluated with the large stone. Flat tool steel
similar in size to the stones may be used to evaluate aluminium or SMC (plastic) body panels.
Engineering scales (1/2x6) can be used instead of stones to evaluate reverses and sweeps on
both steel and aluminium panels.
(EU only) DIN ISO 525 Form 9020 thrihedron Stone should be used for Sheet Metal surface
assessment (Exhibit 3 Photos). Two sizes of stones are recommended. The large stone should be
used for the majority of the surface. The smaller stone should be used only if the surface curvature
and crown cannot be properly evaluated with the large stone.
For the acceptance of tools/dies with PSW, the FPA methodology shall be applied by the consumer
and / or the construction source. Tools / Dies can be sold by the Tool shop after having "A" concerns
and "B1" concerns corrected (other "B" concerns and "C" concerns may be left for continuous
improvement after homeline tryout).
7.6. FPA Evaluation Process


7.6.1. Concern Classification
General scoring will be in line with Customer Concern Rating System (CCRS), Exhibit 1. The prime
criterion in this assessment is the outgoing product quality level and not the production capability.
Scoring remains unchanged despite whether a concern can be fixed in process (no acceptance
standards allowed).
7.6.1.1. A-Concerns
A-Concerns are unacceptable to customers and will cause complaints (in-house/externally)
and/or reflect a severe deviation from the Vehicle Operations quality standard/specification
and noticeable by untrained customers and/or issue might cause subsequent concerns during
the assembly process or functional concerns (e.g. water leak, electrical system malfunction,
trim installation, etc.). A-Concerns require immediate containment action and in-system
purging (see Section G-Containment Program). Irrespective of affected zone, A-Concerns on
skin panel surfaces are scored with 90 demerit points. A-Concerns are directly visible
concerns seen from an oblique angle. Generally, A-concerns are easy to feel as well.
7.6.1.2. B-Concerns
B-Concerns are annoying and disturbing issues to customers, with complaints expected (in-
house/externally). For all B-Concerns, documented corrective actions (tool/ process
optimization) have to be initiated and followed-up. In agreement with the in-plant customer,
bodies/panels with B-surface concerns may be passed to the subsequent area, however,
audit scoring remains unchanged. B-Concerns are items, which are detected after tactile
inspection with gloves B-Concerns can be verified and visualized by stoning for presentation
purposes to make it easier to visualize for the participants.
7.6.1.3. C-Concerns (only Skin Panels and Sub-assemblies):

C-Concerns will be noticed by trained observer/customer in-house/externally and may require
improvement (on sheet metal panels, under this category fall all those imperfections visible
after 'stoning'). If, however, defects require rework in subsequent processes, they may be
reclassified as B-Concerns
7.6.2. Surface Classification (Exhibit 2)
Zone I All directly visible outer/inner surfaces

Zone II All not directly visible surfaces (e.g. openings, inner door panels)
Zone III All areas covered with trim parts (inner/outer areas) or looked at occasionally during
customer duty cycle.
7.6.3. Severity Ranking
For sheet metal, scoring is predetermined on individual checklists (Exhibits 4 & 5) in line with
CCRS, Exhibit 1.
7.6.4. Assessment Criteria


7.6.4.1. Body/Panel
All skin panels, closure panels, openings and other areas are to be evaluated for
imperfections and fit. Different concern natures are counted as single concerns and may not
be summarized on a panel/component. Same concern natures on a panel/component can be
summarized if caused by the same process in the same area of the panel. A decision if a
concern nature is the same on a panel/component is down to the FPA training, conducted by
VOQO, and discussions with the local process/tooling management.
A-level concerns are to be scored independently of zone classification (above). B-and C-level
concerns are judged in line with zone criteria. Outer panel surfaces which will be covered by
parts are considered one severity grade less. All inner panel surfaces covered with trim parts
may be ignored (except potential assembly risks).
NA only: Outer panel surfaces that will be covered by parts are considered one severity grade
less. Generally, inner panel surfaces covered with trim parts may be ignored unless the
concern affects fit / function of the trim covering.
7.6.4.2. Weld Spots and Seams are to be inspected and called in case:
Spot weld burned through (visual impairment) (A concern)
Considerable impairment of general appearance (B concern)
o Welding stud / screw / pin is missing (A concern)

o Weld seam burned through in several places (strong visual impairment)
(A concern)
o Weld seam is missing (A concern)
o Pointed, sharp edged weld residue - possibly resulting in injury / manufacturing
complications / part damages. (A concern)
o Welding stud / screw / pin is welded on insufficiently (A/B concern)
o Pulled in too deeply or uneven appearance (B concern)
o Weld seam burned through (visual impairment). (A/B concern depend on area)
o Severe Weld Splatter remains in the area of the weld location / spot (splatter
formation, wire, meat hooks) - corrosion risk. (B concern / injury risk A)
o Weld seam is incomplete or interrupted in a small area (B concern)
7.6.4.3. Sealer application needs to be inspected and called in case:
(Complaints describing position, shape or appearance of the surface of sealants. Glue or

sealant is spread or worked untidily or shows visual defects after having been finished.)
Sealant is missing completely (A concern)

Unacceptable surface unevenness/irregularity (A concern)
Not well spread, partly missing, damaged, peels off partly (A/B concern)
Glue/sealant at unintended location, clearly visible (A/B concern)
Open blister (A/B concern)
Several small blisters (B concern)


Low quantity of small blisters (C concern)

Slight surface unevenness/irregularity (C concern)
7.6.4.4. Ford Trade Mark Execution:
Trade Mark execution is to be audited based on the master reference sample/Drawing

Specification that needs to be available to the auditor. Concerns to the surface of the panel
that are caused due to the Trade Mark imprint need to be scored separately (e.g. Distortions).
A-Concerns:Trade Mark Missing or strongly deviating to Master Sample

B-Concern:Partially Stamped/Uneven/Wrong position (horizontal/vertical
misalignment),Visual Impairment
C-Concern:Low Visual Impairment (only applied on Skin Panel and Sub-assembly audits)
7.6.4.5. Assessment Criteria
EU only: Gap and Flushness will only be measured if an imperfection has been detected
during the visual inspection. Scores for BIW fit calls (taper or calliper's required) must be
available to the auditor at latest issue level:
Out-of-Specification +/- 0.5mm to 0.9mm = B (30 points)

Out-of-Specification +/- 1.0mm plus = A (90 points)
NA only: Scores for Stamping Die Process Dirt concerns on unpainted surface panels which
are only visible after stoning (Score is independent of Zones) on skin panels and sub-
assemblies:
1 to 4 pieces of dirt = C (15 points)

5 to 9 pieces of dirt = B (50 points)
10 plus pieces of dirt = A (90 points)
NA only: For hot-dip galvanized exposed steel applications, the dirt due to hot-dip dross
(impurities in the hot dip product during the galvanizing process) is scored differently than
noted above. The number of incidents of this dirt identified after stoning is not considered in
elevating the severity.
In general, the hot-dip dross dirt is much smaller (1.0mm or less) than stamping die process
dirt and more prevalent. After stoning, this dirt always appears as a dark area. In contrast,
the stamping die process dirt appears alternately dark and shiny depending on the viewing
angle. Incidents of the hot-dip dross dirt identified after stoning are not elevated to a "B"
concern unless they are easy to feel with the gloves and are not elevated to an "A" concern
unless they are easy to see and easy to feel before the stone is applied.


7.7. Reports/Documentation
The FPA Procedure (VOPQUG-055) must be available to all evaluators by either hard copy or automated
electronic media (such as the Ford Web).
The Exhibits as listed below must be available to all evaluators by either hard copy or automated
electronic media (such as the Ford Web).
Each master individual FPA Review/Report should be maintained by the Staff and/or Plant vehicle
assessment personnel in a file system which can basically be arranged by a suitable local file structure.
Computer applications are utilized in the assessment process, a master hard drive or disk storage backup
system should be identified for file storage.
FPA Reports/Reviews may be in different formats due to the staff/plant/location and type of reviews done.
(Exhibits 4, 5, and 5a are sample formats that may be used for reporting.)
Results and Reporting
Results will indicate achieved Demerit Point Level by panel/body, covering panels and bodies.
VO Stamping Plants shall control chart the demerit points for all surface panels and react to the data per
VO SPC Manual requirements.
Reporting will be in terms of Demerit Points per panel/body and maintained in trend charts.
Containment Program
Parts/bodies must not leave the respective area with any A or B1 Concerns unless authorized by the local
quality management. All related complaints to be contained in the area prior shipping to next customer.
On new programs, the threshold at Job #1 should not exceed the total number of demerit points as
agreed in the surface acceptance buy-off process among Stamping Plant, Assembly Plant, VO New
Models and VO Stamping Die Processing/Structure/Final Engineering personnel.
The disposition/control of completed FPA units is a decision made by the local quality personnel and units
which require rework may be processed back-through the regular plant buy-off production system before
release to the shipping location.
7.8. Meetings/Actions
The results of the Full Body FPA Audit will be reviewed at the Monthly Control Plant and Matching Fixture
Meetings. These results are to be used to establish priorities of concerns, and implement corrective and
preventive actions at the Assembly Plant Bodyshop and sheet metal supplier locations.
The FPA Staff personnel and/or Launch Management and/or Plant Quality Manager will determine the
need for a meeting and the attendance/logistics to review the results of FPA evaluations.


The FPA report for the location can suffice as a record of the meeting review. The respective Plant Quality
/ Launch Teams will have the responsibility for inputting the concerns into the normal daily plant/program
corrective action system for follow-up and action by the responsible program activities.
8. GENERAL RULES:
None
9. RECORDS
The following records are to be identified on the Documents/Records Matrix of the responsible
department/activity and retained in accordance with the Global Information Standard 1 (GIS1):
Category: Record: Retention:

28.02 (GIS1) FPA Audit Results FPA Superseded or Obsolete + 1
Year
28.02 (GIS1) Summary Reports Superseded or Obsolete + 1
Year
37.01 (GIS1) Training Files Superseded +3, T
10. RECORD OF REVISIONS
Date Description Author Authorized by

20040506 Steve Opaleski
Martin Steinhuser
Martin Steinhuser
20060411 Elimination of stone inspection P. Urcheck Steve Opaleski
requirement for Body-In-White; D. Tempel Martin Steinhuser
Update of Auditor Calibration /
Auditor Certification (EU only);
Establish assessment criteria for
dirt caused by hot-dip galvanized
exposed material (NA only).


Date: Authorized by: Signature:

20060411 Pauline Walsh
Note: or red & italic letters denote area of change from previous version

FPA For Stamping and Body

Caricato da

Informazioni sul documento

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

FPA For Stamping and Body

Caricato da

Copyright:

Formati disponibili

Procedure No.

Ford Product Audit (FPA) for Stamping and Body

Page 1 of 12 Revision Date: 20060411

4. REFERENCES & ATTACHMENTS

This procedure can be found in the EKB in folder:

Customer Concern Rating System (CCRS)

Vehicle Operations Procedure (VOP) Printed copies are uncontrolled

Ford Product Audit (FPA) for Stamping and Body

Page 2 of 12 Revision Date: 20060411

VOPQUN-001 Time and Data Management (N.A. only)

7.1. FPA Overview

The FPA process is applied to:

7.1.1. Skin Panels (Panel FPA)

Vehicle Operations Procedure (VOP) Printed copies are uncontrolled

Ford Product Audit (FPA) for Stamping and Body

Page 3 of 12 Revision Date: 20060411

7.1.2. Body-in White (Body FPA)

7.2. Utilization of the FPA function

7.3. Assessment Sample

Stamping Plant responsible personnel (determined locally) can perform:

1. Skin Panel (Outer Exterior Panels before Sub-Assembly)

Vehicle Operations Procedure (VOP) Printed copies are uncontrolled

Ford Product Audit (FPA) for Stamping and Body

Page 4 of 12 Revision Date: 20060411

2. Sub-Assembly (Clinch Item) audits

Body Plant Personnel can perform:

Audit Time (approximate)

EU : Skin Panels 60 minutes

EU : Clinch Items (assembled parts including inner panels) 60 minutes

7.3.1. Sample Sizes

Vehicle Operations Procedure (VOP) Printed copies are uncontrolled

Ford Product Audit (FPA) for Stamping and Body

Page 5 of 12 Revision Date: 20060411

Auditor Calibration / Auditor Certification

7.5. Assessment Location/Facilities & Basic Requirements

Vehicle Operations Procedure (VOP) Printed copies are uncontrolled

Ford Product Audit (FPA) for Stamping and Body

Page 6 of 12 Revision Date: 20060411

7.5.1. Light Tunnel/Audit Crib or Audit Room

7.5.2. Body/Panel FPA Quality Assessment:

B-concerns: Tactile inspection with special gloves (thin weight)

7.6. FPA Evaluation Process

Vehicle Operations Procedure (VOP) Printed copies are uncontrolled

Ford Product Audit (FPA) for Stamping and Body

Page 7 of 12 Revision Date: 20060411

7.6.1. Concern Classification

7.6.1.3. C-Concerns (only Skin Panels and Sub-assemblies):

7.6.2. Surface Classification (Exhibit 2)

Zone I All directly visible outer/inner surfaces

7.6.3. Severity Ranking

7.6.4. Assessment Criteria

Vehicle Operations Procedure (VOP) Printed copies are uncontrolled

Ford Product Audit (FPA) for Stamping and Body

Page 8 of 12 Revision Date: 20060411

o Welding stud / screw / pin is missing (A concern)

7.6.4.3. Sealer application needs to be inspected and called in case:

(Complaints describing position, shape or appearance of the surface of sealants. Glue or

Sealant is missing completely (A concern)

Vehicle Operations Procedure (VOP) Printed copies are uncontrolled

Ford Product Audit (FPA) for Stamping and Body

Page 9 of 12 Revision Date: 20060411

Low quantity of small blisters (C concern)

7.6.4.4. Ford Trade Mark Execution: