FORD W-CMS PDF

This Standard defines the requirements for manufacturing of metal cast components with process-specific minimum control plan expectations which include the process characteristics, measuring systems, control points/methods, product testing and and best practices for casting manufacturing processes and related product testing.

The objective of this Standard is to define the requirements and to encourage Best Practices which will assure a quality part as well as promoting continuous improvement relative to quality and productivity including:

A. Drive elimination of systemic casting failure modes.

B. Provide a close-loop lessons learned repository.

C. Ensure manufacturing feasibility of the process to meet product specifications per GPDS timing.

D. Create global common casting manufacturing site assessment tool.

E. Deliver robust control plans to assure the process is in control with proper reactions plans to minimize variability.

The application of this Standard is:

A. All casting supplier within the Ford supply base shall meet the process requirements of this standard.

B. Identifying focus areas of improvement for existing casting suppliers

C. Utilizing advanced engineering and manufacturing process development computer aided engineering

D. Qualifying casting suppliers using the specific casting controls checklist

E. Defining the casting controls plan expectations which include the process characteristics, measuring systems, control points/methods, product testing and sharing best practices.

This Standard is applicable to the following material types and processes:

• Aluminum - High Pressure Die Casting

• Aluminum - Permanent (Semi) Molding

• Aluminum - Sand Casting (Green sand and precision sand cast)

• Aluminum - Squeeze Casting

• Ductile iron - Green sand

• Ductile iron – Shell Molding

• Gray iron - Green sand

• Investment Casting

• Magnesium - High Pressure Die Casting

• Zinc - Hot Chamber Die Casting

CAUTION: APPROPRIATE PRECAUTIONS MUST BE TAKEN RELATIVE TO HEALTH AND SAFETY AND ENVIRONMENTAL HAZARDS. FORD FACILITIES SHALL CONTACT THE APPROPRIATE FORD MOTOR COMPANY HEALTH AND SAFETY AND ENVIRONMENTAL ACTIVITIES FOR SPECIFIC INFORMATION REGARDING SUCH PRECAUTIONS.

These monitoring and control tests are required to keep casting processes and processing equipment under control to produce parts that will meet Product Engineering requirements and functional tests. Regularly scheduled maintenance as well as equipment operating responsibilities of the production operator is not included.

The emphasis on process control is to provide indications that the process is stable or is drifting out of control or actually is out of control before part quality is adversely affected. It is expected that such process monitoring will be of value in maintaining process stability and in bringing a process back into control.

The responsible outside supplier or Company plant or division shall consider requirements for each individual part and decide whether the minimum requirements of this general Standard is adequate or whether they should prepare a more specific or detailed local process control standard for the individual part.

Exceptions to this Standard and alternative plans for control of casting processes may be used provided they afford adequate protection of a process currently proven to be stable and capable, and have the concurrence of the affected Ford Supplier Technical Assistant (STA) and/or Quality Planning Team and are documented in a control plan.