Procedure Number: FAP 03-111 FAF 03-111-2 - Special Characteristics Communication Agreement for Externally Supplied Content Issue

ial Characteristics Communication Agreement for Externally Supplied Content Issue Date: March 2023

FAF03-111-2 v2.2 March 2023

Special Characteristics Communication and Agreement - External OPTIONAL: SCCAF Draft Vers: Date:

PFMEA & Special SCCAF Handbook via Global Phased PPAPOnly

(Suppliers - Web
- SiteSee SCCAF Section
DFMEA & Potential Special Type ONLY in Type ONLY in
Characteristics Yellow Boxes
Characteristics
Agreement
Green Boxes
Accessible through Ford
Supplier Portal).
Special Characteristics for:
Lead / Support roles and timing
Ford PD engineer / Supplier Supplier / Ford PD SCCAF Global FMA Website (Ford Internal Only) 2021 B123 MCA John Doe Inc. - Pleasantville Plant - USA BC3Q-6153-A
for each stage
SCCAF Handbook (Ford Internal Only)
Approval Signature Name e-mail Address Approval Date

Model Year & Program Ford LEA D & R Engineer

Code:
2021 B123 MCA Part / System Number: BC3Q-6153-A
Approval / Date:

Engineering Release Ford STA Engineer

Supplier Name / Plant: John Doe Inc. - Pleasantville Plant - USA
Number: Approval / Date:

Ford Craftsmanship
Supplier GSDB Code: A1234 Design Lead: Ford
Approval / Date:

Supplier Plant Quality Manager

Part / System Name: Ring - Oil Control Ford Customer Plant: Saarlouis Assembly Plant - Germany
Approval / Date:

CPSC: 050505 DFMEA Reference: 2021 B123 - Oil Control Note: Approvals may be obtained by a physical signature or electronic sign-off. Recommended: Use DocuSign (Some Country Restrictions for External Approval)
to obtain signatures as it will provide electronic evidence to store with the completed SCCAF & SCCAF Assessment.
(See SCCAF Webpage for DocuSign help & DocuSign Country Restrictions).

Key: From DFMEA: From PFMEA:

For Special Characteristic definitions refer
to Ford FMEA Handbook. YC Sev 9,10 : Potential CC. CC Sev 9,10 (Part) : Critical Characteristic. OS Sev 9,10 (Process) : Operator Safety.
-- SC
Sev 5-8 and may require special control to
DFMEA : Global FMA Website (Ford Internal Only) YS SC Sev 5-8 & Occ 4-10 (Part) : Significant Characteristic. HI Sev 5-8 & Occ 4-10 (Process) : High Impact Characteristic.
maintain process capability : Potential SC.
NotHI
Applicable Not applicable
Special Characteristic Totals: YC YS CC SC - OS HI
Note 1: Automatic calculation of totals (for guidance only).
Note 2: Count of SC may be less than count of YS 4 6 4 4 2 0 0
Special Characteristics Communication and Agreement for all UN content required to support UN design and development is required by UNV2. The remaining UN content not required to support UN design and development is required by <PA>.
Special Characteristics Communication and Agreement for all UP content is required by UPV2.
Where Specification & Tolerance differ in SCCAF to latest released data, released data is Master. Note: Process Control Plan should be crosschecked to released data at creation and at each new data release.

DFMEA PFMEA
DFMEA PFMEA
No. Characteristic Description Specification & Tolerance Process Control Method
Class Class
Material Certification per batch with material usage controls at manufacturing
1 Sheet Steel Material Properties WSS-M1A365-A21 YC CC
stations

Material Certification per batch with material usage controls at manufacturing

2 Sheet Steel Material Thickness 1.8 mm Thickness to ESBAU5-1N260-A YC CC
stations

100% torque control

3 Motor Crank Nut Torque 25Nm ± 2Nm YC CC
DC nut runner with Interlock

CMM
4 Mounting hole diameter 2.5mm +0.0mm, -0.03mm YS -
PPk=3.45

X:345 Y:150 Z:68

5 Mounting hole position YS SC 100 % go / no go fixture
Positional tolerance Ø1.6mm

6 Bush Push In Force 8kN to 12kN YS SC 100% in process with load cell

Vernier Caliper
7 Wire Diameter Ø 12.7mm ± 0.2mm YS -
PFMEA Occurrence = 3
E-Coat/Powder coat as per WSS-M2P177-C2
8 Surface Coating (Corrosion Protection) YS SC Paint Thickness Ultrasound Tester with SPC
paint thickness min. 20 µm - max. 35 µm

9 Alternator voltage 14.4 - 14.6 V with requested voltage of 14.5V YS SC 100% EOL voltage tester

Carpet Surface : WSS-M8P16-B.

Material Properties Material Certification per batch with material usage controls at manufacturing
10 Foam Underlay : WSS-M99P32-D1 YC CC
(Flammability - FMVSS 302) stations
Insulator : WSS-M99P32-D1
11
12
13
14
15
16

Global PD Quality
Page 1 of 6
GIS1 Item Number: 27.60 Version ??
GIS2 Classification: Confidential
Procedure Number: FAP 03-111 FAF 03-111-2 - Special Characteristics Communication Agreement for Externally Supplied Content Issue Date: March 2023

FAF03-111-2 v2.2 March 2023

Special Characteristics Communication and Agreement - External OPTIONAL: SCCAF Draft Vers: Date:

PFMEA & Special SCCAF Handbook via Global Phased PPAPOnly

(Suppliers - Web
- SiteSee SCCAF Section
DFMEA & Potential Special Type ONLY in Type ONLY in
Characteristics Yellow Boxes
Characteristics
Agreement
Green Boxes
Accessible through Ford
Supplier Portal).
Special Characteristics for:
Lead / Support roles and timing
Ford PD engineer / Supplier Supplier / Ford PD SCCAF Global FMA Website (Ford Internal Only) 2021 B123 MCA John Doe Inc. - Pleasantville Plant - USA BC3Q-6153-A
for each stage
SCCAF Handbook (Ford Internal Only)
Approval Signature Name e-mail Address Approval Date

Model Year & Program Ford LEA D & R Engineer

Code:
2021 B123 MCA Part / System Number: BC3Q-6153-A
Approval / Date:

Engineering Release Ford STA Engineer

Supplier Name / Plant: John Doe Inc. - Pleasantville Plant - USA
Number: Approval / Date:

Ford Craftsmanship
Supplier GSDB Code: A1234 Design Lead: Ford
Approval / Date:

Supplier Plant Quality Manager

Part / System Name: Ring - Oil Control Ford Customer Plant: Saarlouis Assembly Plant - Germany
Approval / Date:

CPSC: 050505 DFMEA Reference: 2021 B123 - Oil Control Note: Approvals may be obtained by a physical signature or electronic sign-off. Recommended: Use DocuSign (Some Country Restrictions for External Approval)
to obtain signatures as it will provide electronic evidence to store with the completed SCCAF & SCCAF Assessment.
(See SCCAF Webpage for DocuSign help & DocuSign Country Restrictions).

Key: From DFMEA: From PFMEA:

For Special Characteristic definitions refer
to Ford FMEA Handbook. YC Sev 9,10 : Potential CC. CC Sev 9,10 (Part) : Critical Characteristic. OS Sev 9,10 (Process) : Operator Safety.
-- SC
Sev 5-8 and may require special control to
DFMEA : Global FMA Website (Ford Internal Only) YS SC Sev 5-8 & Occ 4-10 (Part) : Significant Characteristic. HI Sev 5-8 & Occ 4-10 (Process) : High Impact Characteristic.
maintain process capability : Potential SC.
NotHI
Applicable Not applicable
Special Characteristic Totals: YC YS CC SC - OS HI
Note 1: Automatic calculation of totals (for guidance only).
Note 2: Count of SC may be less than count of YS 4 6 4 4 2 0 0
Special Characteristics Communication and Agreement for all UN content required to support UN design and development is required by UNV2. The remaining UN content not required to support UN design and development is required by <PA>.
Special Characteristics Communication and Agreement for all UP content is required by UPV2.
Where Specification & Tolerance differ in SCCAF to latest released data, released data is Master. Note: Process Control Plan should be crosschecked to released data at creation and at each new data release.

DFMEA PFMEA
DFMEA PFMEA
No. Characteristic Description Specification & Tolerance Process Control Method
Class Class
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44

Global PD Quality
Page 2 of 6
GIS1 Item Number: 27.60 Version ??
GIS2 Classification: Confidential
Procedure Number: FAP 03-111 FAF 03-111-2 - Special Characteristics Communication Agreement for Externally Supplied Content Issue Date: March 2023

FAF03-111-2 v2.2 March 2023

Special Characteristics Communication and Agreement - External OPTIONAL: SCCAF Draft Vers: Date:

PFMEA & Special SCCAF Handbook via Global Phased PPAPOnly

(Suppliers - Web
- SiteSee SCCAF Section
DFMEA & Potential Special Type ONLY in Type ONLY in
Characteristics Yellow Boxes
Characteristics
Agreement
Green Boxes
Accessible through Ford
Supplier Portal).
Special Characteristics for:
Lead / Support roles and timing
Ford PD engineer / Supplier Supplier / Ford PD SCCAF Global FMA Website (Ford Internal Only) 2021 B123 MCA John Doe Inc. - Pleasantville Plant - USA BC3Q-6153-A
for each stage
SCCAF Handbook (Ford Internal Only)
Approval Signature Name e-mail Address Approval Date

Model Year & Program Ford LEA D & R Engineer

Code:
2021 B123 MCA Part / System Number: BC3Q-6153-A
Approval / Date:

Engineering Release Ford STA Engineer

Supplier Name / Plant: John Doe Inc. - Pleasantville Plant - USA
Number: Approval / Date:

Ford Craftsmanship
Supplier GSDB Code: A1234 Design Lead: Ford
Approval / Date:

Supplier Plant Quality Manager

Part / System Name: Ring - Oil Control Ford Customer Plant: Saarlouis Assembly Plant - Germany
Approval / Date:

CPSC: 050505 DFMEA Reference: 2021 B123 - Oil Control Note: Approvals may be obtained by a physical signature or electronic sign-off. Recommended: Use DocuSign (Some Country Restrictions for External Approval)
to obtain signatures as it will provide electronic evidence to store with the completed SCCAF & SCCAF Assessment.
(See SCCAF Webpage for DocuSign help & DocuSign Country Restrictions).

Key: From DFMEA: From PFMEA:

For Special Characteristic definitions refer
to Ford FMEA Handbook. YC Sev 9,10 : Potential CC. CC Sev 9,10 (Part) : Critical Characteristic. OS Sev 9,10 (Process) : Operator Safety.
-- SC
Sev 5-8 and may require special control to
DFMEA : Global FMA Website (Ford Internal Only) YS SC Sev 5-8 & Occ 4-10 (Part) : Significant Characteristic. HI Sev 5-8 & Occ 4-10 (Process) : High Impact Characteristic.
maintain process capability : Potential SC.
NotHI
Applicable Not applicable
Special Characteristic Totals: YC YS CC SC - OS HI
Note 1: Automatic calculation of totals (for guidance only).
Note 2: Count of SC may be less than count of YS 4 6 4 4 2 0 0
Special Characteristics Communication and Agreement for all UN content required to support UN design and development is required by UNV2. The remaining UN content not required to support UN design and development is required by <PA>.
Special Characteristics Communication and Agreement for all UP content is required by UPV2.
Where Specification & Tolerance differ in SCCAF to latest released data, released data is Master. Note: Process Control Plan should be crosschecked to released data at creation and at each new data release.

DFMEA PFMEA
DFMEA PFMEA
No. Characteristic Description Specification & Tolerance Process Control Method
Class Class
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72

Global PD Quality
Page 3 of 6
GIS1 Item Number: 27.60 Version ??
GIS2 Classification: Confidential
Procedure Number: FAP 03-111 FAF 03-111-2 - Special Characteristics Communication Agreement for Externally Supplied Content Issue Date: March 2023

FAF03-111-2 v2.2 March 2023

Special Characteristics Communication and Agreement - External OPTIONAL: SCCAF Draft Vers: Date:

PFMEA & Special SCCAF Handbook via Global Phased PPAPOnly

(Suppliers - Web
- SiteSee SCCAF Section
DFMEA & Potential Special Type ONLY in Type ONLY in
Characteristics Yellow Boxes
Characteristics
Agreement
Green Boxes
Accessible through Ford
Supplier Portal).
Special Characteristics for:
Lead / Support roles and timing
Ford PD engineer / Supplier Supplier / Ford PD SCCAF Global FMA Website (Ford Internal Only) 2021 B123 MCA John Doe Inc. - Pleasantville Plant - USA BC3Q-6153-A
for each stage
SCCAF Handbook (Ford Internal Only)
Approval Signature Name e-mail Address Approval Date

Model Year & Program Ford LEA D & R Engineer

Code:
2021 B123 MCA Part / System Number: BC3Q-6153-A
Approval / Date:

Engineering Release Ford STA Engineer

Supplier Name / Plant: John Doe Inc. - Pleasantville Plant - USA
Number: Approval / Date:

Ford Craftsmanship
Supplier GSDB Code: A1234 Design Lead: Ford
Approval / Date:

Supplier Plant Quality Manager

Part / System Name: Ring - Oil Control Ford Customer Plant: Saarlouis Assembly Plant - Germany
Approval / Date:

CPSC: 050505 DFMEA Reference: 2021 B123 - Oil Control Note: Approvals may be obtained by a physical signature or electronic sign-off. Recommended: Use DocuSign (Some Country Restrictions for External Approval)
to obtain signatures as it will provide electronic evidence to store with the completed SCCAF & SCCAF Assessment.
(See SCCAF Webpage for DocuSign help & DocuSign Country Restrictions).

Key: From DFMEA: From PFMEA:

For Special Characteristic definitions refer
to Ford FMEA Handbook. YC Sev 9,10 : Potential CC. CC Sev 9,10 (Part) : Critical Characteristic. OS Sev 9,10 (Process) : Operator Safety.
-- SC
Sev 5-8 and may require special control to
DFMEA : Global FMA Website (Ford Internal Only) YS SC Sev 5-8 & Occ 4-10 (Part) : Significant Characteristic. HI Sev 5-8 & Occ 4-10 (Process) : High Impact Characteristic.
maintain process capability : Potential SC.
NotHI
Applicable Not applicable
Special Characteristic Totals: YC YS CC SC - OS HI
Note 1: Automatic calculation of totals (for guidance only).
Note 2: Count of SC may be less than count of YS 4 6 4 4 2 0 0
Special Characteristics Communication and Agreement for all UN content required to support UN design and development is required by UNV2. The remaining UN content not required to support UN design and development is required by <PA>.
Special Characteristics Communication and Agreement for all UP content is required by UPV2.
Where Specification & Tolerance differ in SCCAF to latest released data, released data is Master. Note: Process Control Plan should be crosschecked to released data at creation and at each new data release.

DFMEA PFMEA
DFMEA PFMEA
No. Characteristic Description Specification & Tolerance Process Control Method
Class Class
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100

Global PD Quality
Page 4 of 6
GIS1 Item Number: 27.60 Version ??
GIS2 Classification: Confidential
 Issue Date: March 2023
Procedure Number: FAP 03-111 FAF 03-111-2 - Special Characteristics Communication Agreement for Externally Supplied Content

PD optionally initiates the process where non YC-YS information for consideration by
Manufacturing PFMEA Information Transfer Sheet (Optional Form) manufacturing is identified by entering the additional information in the LHS.
For additional consideration of Non YS or YC characteristics. Once initiated by PD the full form must be completed with Manufacturing response
(RHS) to complete SCCAF Process (see p22 SCCAF Handbook).

Model Year &

2021 B123 MCA
Program Name:
John Doe Inc. - Pleasantville
Part / System Name: Ring - Oil Control Supplier Name / Plant Ford D & R Engineer: 0
Plant - USA
Part / System
BC3Q-6153-A Supplier GSDB Code: A1234 STA Engineer 0
Number:
Ford Customer Supplier Plant Quality
Saarlouis Assembly Plant - Germany 0
Plant Manager

Required Information to be transferred to PFMEA Failure

Included
No. Excluding YS or YC Design Characteristics. Mode Manufacturing Response
in PFMEA
(Lessons learnt / Quality History) Severity
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25

Global PD Quality Page 5 of 6

GIS1 Item Number: 27.60 Version ???
GIS2 Classification: Confidential
 Special Characteristics Communication & Agreement Form
Introduction and Background
This form serves the following purpose:
Internal Ford procedure FAP03-111 requires that the agreement of product and process special characteristics be documented.

SCCAF FAP Ford Automotive Procedure.

FAP03-111 Selection, Identification, and Control of Special Characteristics
(Internal Ford Only)
Table showing when an update to a SCCAF is required due to Design or Process Changes with the required documents
FAA03-111-E - SCCAF Updates
to be updated.

SCCAF - Webpage www.fma.ford.com (Internal Ford Only) Link SCCAF Webpage that contains all the information for SCCAF Completion.

SCCAF Handbook Global Phased PPAP Website Detailed help file on all aspects of SCCAF Process - Approved by STA and available to share with Suppliers.

SCCAF External Reference Guide Global Phased PPAP Website Detailed help file on all aspects of SCCAF Process - Approved by STA and available to share with Suppliers.

SCCAF Handbook (Internal Ford Only) Link Detailed help file on all aspects of SCCAF Process - Approved by STA and available to share with Suppliers.

SCCAF External Reference Guide (Internal Ford Only) Link Detailed help file on all aspects of SCCAF Process - Approved by STA and available to share with Suppliers.

SCCAF Storage (Internal Ford Only) Link Help file showing how to create, store and publish SCCAFs in FEDE, for existing programs using Global FMA Tracker.

SCCAF Storage - FMA Plan in FEDE (Internal Ford Only) Link Help file showing how to create, store and publish SCCAFs in FEDE, for new programs using FMA Plan in FEDE.

Internal SCCAF Form (Internal Ford Only) Link Special Characteristics Communication and Agreement (Internal Ford Manufactured and Assembled Content).

SCCAF Assessment for External SCCAF Only (Internal Ford Only) Link File to help assess the quality of completed External SCCAF.

SCCAF Assessment Training (Internal Ford Only) Link Training material on completion of SCCAF Assessment.

Example - PFMEA Info Transfer Sheet (Internal Ford Only) Link Example of a completed PFMEA Info Transfer Sheet for reference.

Link Help file on how to complete the electronic sign off process for SCCAF documents using DocuSign.
SCCAF Approval with DocuSign
Help file on using pre-created SCCAF Templates within DocuSign that automatically generates the required fields
Link
selected for approval and places them on the SCCAF.

Special Characteristics Table (Internal Ford Only) Link FAA03-111-B - Special Characteristics Classification Table - showing linkage between DFMEA & PFMEA Class.

DFMEA - Webpage (www.fma.ford.com) (Internal Ford Only) Link DFMEA Webpage that contains all the information for DFMEA Completion.

Acronyms Used
SCCAF Special Characteristics Communication & Agreement Form.
· Form used in the process for Ford Automotive Procedure FAP-03-111 - Selection, Identification, and Control of Special Characteristics.
FMA Failure Mode Avoidance.
· A set of analytical tools to do Engineering in a disciplined manner and document it for use in the future.
LVEA Lead Vehicle Engineering Activity.
· LVEA is the region responsible for overall delivery of the vehicle or platform.
· May be the same or different from the LEA.
LEA Lead Engineering Activity.
· LEA is the engineering activity (functional) that has lead for the design of a particular system or component.
· May be the same or different from the LVEA.
· LEA is responsible to ensure the process is completed by the specific Suppliers for the relevant system or component.
STA Supplier Technical Assistance.
· Lead in the selection and development of Ford's global supply base to achieve the highest manufacturing capability in support of world class customer satisfaction and safety.
SREA Supplier Request for Engineering Approval.
· Ford’s process for handling and approving post-Job #1 process or design changes initiated by Suppliers.
FMEA Failure Mode & Effects Analysis.
· Recognize and evaluate the potential failure of a product or process and its effects.
· Identify actions which could eliminate or reduce the chance of the potential failure occurring.
· Document the process.
DFMEA Design Failure Mode & Effects Analysis.
· A FMEA that is focused on the design of a product.
PFMEA Process Failure Mode & Effects Analysis.
· A FMEA that is focused on the manufacturing/assembly process.
YC Critical Characteristic.
· Are product or process characteristics that can affect compliance with government regulations and/or safe vehicle and/or product function.
· Require specific manufacturing, assembly, shipping and/or monitoring action to prevent shipment of non-conforming product and the inclusion in the Control Plan.
SC Significant Characteristics.
· Those product, process, and test requirements that are important for customer satisfaction. Significant Characteristics require Quality Planning actions that must be addressed in a Control Plan.
OS Operator Safety Characteristics.
· Operator safety characteristics (OS): Operator Safety Characteristics are related to process parameters or product characteristics that may adversely affect the safety of the operator or compliance with governmental regulations.
HI High Impact Characteristic.
· High Impact Characteristics are related to process parameters or product characteristics that can adversely affect the operation of the process or subsequent operations, but that do not adversely impact customer satisfaction.
PCP Process Control Plan.
· Control Plans are written descriptions of the systems used to control and minimize product and process variation.
· Specify the process monitoring and Process Control Methods (i.e. Special Controls) used to control Special Characteristics.
KPIV Key Process Input Variable.
· Characteristic of a process that determine the performance level of a higher-level key process output variable.
NTEI New Tool End Item.
· The parts on a new model year product that have changed since the previous model year.
Ppk Process Capability (Ppk).
· Is a measure of how well the process output meets the customer requirements. It takes into account both the spread & centering of the data. Assumptions include rational sampling plan, stability, control & the appropriate data distribution.
GSDB Global Supplier Database.
· Companies that conduct business with Ford have a 4 or 5-character GSDB Parent Code this is used to identify the company for purchasing and other Supplier related activities.
JV Ford Joint Venture.
· Ford partnership such as Changan Ford (CAF) which is a joint venture for vehicle production based in Chongqing, China.