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FPDSWhat is FPDS?The vision of the Ford Product Development System is to document the process tasks and deliverables necessary to develop and launch a vehicle.Team events and milestones are defined to communicate progress at various points throughout the product development process.Each process task is related to at least one deliverable and a process description sheet.Currently,there are a total of 1058 tasks and 1249 deliverables in FPDS.The process tasks and deliverables are logically linked to create generic MS Project work plan templates for large(S3-S6)and small scale(S1-S2)programs.FPDS is utilized by the following brands:Ford,Lincoln,Mercury,Jaguar,and Land Rover.Mazda and Volvo each utilize a unique development process.1FPDS1Generalized Process Flow(for reference only)KOPS1/2SISCPHPAPRCCLRLSJ1STCPVehicle Program timing PlanMarket Research(Qual.)Market Research(Quantitative)Mgmt.&Cust.DriveManagement DriveSupplier Sourcing ProcessTarget AgreementsP-Authority ReleaseFunctional Targets DevelopmentPreliminary Eng.Sign-offFinal Eng.Sign-offFMEA/DVP&R CreationVerificationConfirmation100%PSWManuf.StrategyManufacturing Plan&Design(Tools and Equipment)DevelopmentProduction Launch Dev.Appearance ConceptsTheme(s)Dev.Single ThemeSurface Dev.&ReleasePackage ConceptsDevelop Vehicle Package&3D DesignsCP Prototype PhaseAP0&AP1 Prototype PhaseAP2 Prototype PhaseAP3 Prototype PhasePre-Prod.BuildsConfirm Pkg.P/T Commodity DesignP/T Program Specific DesignPowertrain(P/T)CalibrationP/T CertificationDEFINEDESIGNVERIFYLAUNCH Component Sub-system Level System Level Vehicle LevelTarget CascadeDesign Verification2Generalized Process Flow(for Generic FPDS Timing&ScaleabilityKOPS 1/2SISCPHLRPAPRCCLSJ1STCPNotesMilestone(Reviewed by senior Management)Team Event3Generic FPDS Timing&ScaleabiKick-Off(The Beginning of Program Specific Work)Program“Black Book”that contains strategy/customer information,business assumptions,technical requirements/targets,and implementation information compiled and signed-off Program summary(one pager)reviewed and approved in an executive-level meeting4Kick-Off(The Beginning ofPre#1(Mission/Vision&Target Customers Defined)Adequacy of pre resources verified and program staffing plan updated Initial mission,vision,program scope(markets)and primary brands defined Program Attribute Leadership Strategy(PALS)definedPreliminary manufacturing,assembly,reusability,and modularity strategies definedPrelim.brand profiler,mkt.research plan,and customer experience research completedCustomer,corporate,and regulatory requirements definedBenchmark and Ford comparator vehicles identified 5Pre#1(Mission/Vision&TPre#2(Target Ranges Assessed)Adequacy of postresources verified and program staffing plan updatedInitial strategies developed and preliminary target ranges for vehicle attributes assessedPotential vehicle alternatives and assumptions defined Vehicle assembly plant location confirmed and VO cost analysis completed Sourcing workplan completed&sourcing council approval to conduct make/buy studies 6Pre#2(Target Ranges Asse Strategic Intent(Initial Program Direction Established)Adequacy of post resources verified and program staffing plan updated Vehicle Design Specifications(VDS),patible vehicle target ranges,completed Program technology application report completedFinal Product vision and program mission statements confirmed Preliminary Vehicle Program timing Plan(VPP)establishedStrategies such as product,market,manufacturing,assembly,supply,design,service,quality/reliability,craftsmanship and reusability confirmed Implementation readiness for vehicle-architecture technologies achieved7 Strategic Intent(InitialStrategic Confirmation(Team Confirms Strategy/Viability)Adequacy of postresources verified and staffing issues resolved PMT/PAT work plans for current and future milestones updated Affordable business structure updated to reflect compatible targets&assumptions Vehicle Design Spec.(VDS),including compatible vehicle point targets completed Subsystem(level 1)target agreements signed Campaign prevention awareness sessions completedManufacturing and assembly location for each derivative confirmedImplementation Readiness(IR)for new powertrain technology signed-offVehicle/system/subsystem(level 1)targets committedPowertrain line-up selected and powertrain package envelope completedAll suppliers sourced and part of teamInitial Attribute Prototype(AP)plan is completed and VPPtiming plansigned-off 8Strategic Confirmation(Te Proportions&Hardpoints(Vehicle Proportions Frozen)Adequacy of post resources verified and staffing issues resolved Subsystem(level 2)target agreements signedSubsystem(level 2)targets committedMarket research for people/cargo package,vehicle proportions,and styling development completedProportions and selected hardpoint elements frozen;people and cargo package frozen9 Proportions&Hardpoints Program Approval(All Targets Become Objectives)Adequacy of post resources verified and staffing issues resolved PMT/PAT work plans for current and future milestones updated Affordable business structure to reflect compatible objectives&assumptions updated Marketing strategy document(including committed revenue/volume)delivered Manufacturing and assembly plan(includes facilities and tooling inv.)approved Single appearance theme for final development selected Reliability and robustness demonstration plan for priority systems completed Component(&end-item)Design Specifications(CDS)compatible with program objectives End-item/component target agreements signed Program technology application report completed Program specific FMEAs completed Sub-system Level 2&end-item/component Design Verification Plans(DVPs)completed Final Prototype Plan for AP2,AP3,&CP prototype vehicle builds completed Program Parts List(PPL),including service parts,completedAll targets(I.e.function,cost,etc.)become objectives and are compatible10Program Approval(All Targ(ST)Surface Transfer(Interior/Exterior Surface Provided)Adequacy of post(ST)resources verified and staffing issues resolved Design Manufacturing and Assembly Readiness(DMAR)compatibility completed:Interior/Exterior Class IA surfaces transferred to eng./manuf.(+/-0.5 mm)All hardpoints frozen Campaign prevention”Deep Dive”Review(of engineering disciplines)completedPowertrain design(including P/T control system strategy)completed11(ST)Surface Transfer(InterioProduct Readiness(Designs Ready for CP Builds)Adequacy of post resources verified and staffing issues resolved Package compatibility(interference,service,assembly,occupant/cargo)issues resolved Analytical sign-off of vehicle performance versus requirements and specificationsManagement drive&analytical evaluation of attribute performance vs.objectives completedLast Class I surface for major formed parts verified/releasedAll 3-dimensional data is completedFinal launch plan is confirmed and issued 12Product Readiness(Designs(CP)Confirmation Prototype(First CP Vehicle Available)Adequacy of post(CP)resources verified and staffing issues resolved Process FMEA for all or modified processes/tools completed First CP vehicle(available for deliver)completed Final Engineering Release(all end items/components released at“P”(production)authority by 17 MBJ1 For S5 ProgramCampaign prevention“fresh Eyes”completed(12.5 MBJ1 for S5 program)13(CP)Confirmation Prototype(Fi Change Cut-off(Commitment to Job#1 Timing)Adequacy of post resources verified and staffing issues resolved Reliability&robustness for priority systems(including campaignable items)demonstrated Campaign prevention verification“Deep Dive”review(engineering disciplines)completed CP confirmation tests analyzed Design FMEA documents,in support of preliminary engineering sign-off,updated Preliminary Engineering Signoff completed Initial CP durability testing and initial set of road tests completed Known changes from CP containable for 1PP Design is at Job#1 level-no further design changes except”No Builds”Engineering confidence that objectives will be met and assessed Management drive completed Graining/Final Colors approvedSupplier commitment to support 1PPwith PSW partsProduction level P/T calibration availableCP post durability”Fresh Eyes”review completed14 Change Cut-off(Commitmen Launch Readiness(Engineering Sign-Off Complete)Adequacy of post resources verified and staffing issues resolved Production build(1PP)readiness assessment completed 100%PSW parts available for 1PP Final Engineering Signoff including:Functional objectives satisfied and final road tests completed 100%CP durability testing completed Design Certification based on CP lab/rig certification/homologation test results Readiness to proceed to assembly Tool Try-Out(TTO),1PP and Job#1Hard Tooled Functional Build(HTFB)issues resolved All production assembly tools functioned at tool source or in homelineColor/textures/gloss sign-off completed15 Launch Readiness(Enginee Launch Sign-off(Ready to Launch)Vehicle assembly Tool Try-Out(TTO)&1PP vehicle build completedAssembly plant tools&process verification completed including aids&fixtures Ford Consumer Product Audit(FCPA)5 on manufacturing controlled items Full production feasibility assessedCampaign prevention Verification“Fresh Eyes”review of 1PP completed (J1)Job#1 Achieved(Start Production)Integrated Build(IB)completedIn-process&final quality indicators meet program objectives Field Evaluation Unit(FEU)drive completedEmission certification receivedCampaign prevention“Fresh Eyes”of process validation completedCampaign prevention“Fresh Eyes”review of FEU,IB and J1 builds completed16 Launch Sign-off(Ready to
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