0010 Ford GDCAP

Design Technical Operations
Global Decorative Components Approval Process
Issue: Version 4.0

Effective Date: 27-Jun-2016 Authorized: S.Bazinski/D.Katers/M.Loss/G.Parvulescu/M.Thomas/ M.Waller
GLOBAL
DECORATIVE
COMPONENT
APPROVAL
PROCESS
(G-DCAP)
Version 4.0

Authorized:
S.Bazinski/D.Katers/M.Loss/G.Parvulescu/
M.Thomas/M.Waller
DTO Date Issued: 27-Jun-2016

GIS1 Item Number: 25.01 Date Revised: 27-Jun-2016
GIS2 Classification: Proprietary i Retention Start Date:
Copyright © 2016 Ford Motor Company. All rights reserved.
Issue: Version 4.0

DESIGN QUALITY MISSION STATEMENT
Drive vehicle appearance quality and harmony to ensure Design Intent

through the optimization of color, texture, gloss and surface quality.

GIS2 Classification: Proprietary ii Retention Start Date:
Issue: Version 4.0

TABLE OF CONTENTS
INTRODUCTION---------------------------------------------------------------------------------------------1-7
Purpose 1
Global Decorative Component Approval Process (G-DCAP) Process Flow Diagram 2
GPDS Program Appearance Approval Milestones 3
Cross Functional Team; Roles and Responsibilities 4-7
SECTION 1 - APPEARANCE APPROVAL PROCESS--------------------------------------------8-18

Appearance Items that Require Approval Sign-off 8
In-Plant Painted Components / Review / Sign-Off 8
1.1 Global Part Appearance Approval Guideline 9
1.2 AAR Component and AAR Sub-System Assembly Reviews 10
1.3 Vehicle Reviews for Mid Cycle Action (MCA) & In Cycle Action (ICA) & C/O parts 10
1.4 Product Development (PD) Fit to Nominal (FtN) 10
1.5 Ok to Texture (OKtT) 10-11
1.6 Final Appearance Approval Report (AAR) 11-12
1.7.1 AAR Document (CFG-1002-F1) 12
1.7.2 Completion Guideline for Ok to Texture and Appearance Approval Document 13
1.7.3 Global Ford Minimum Appearance Standard Label 14
1.7.4 “Color Reference Only” 14
1.8.1 Supplier Part / Raw Materials & MIC Resin Change of Supplier/Source 14-15
1.8.2 SMC Part Evaluation / Documentation / Sign-Off 15
1.9 Special Commodities 16-18
SECTION 2 – GLOBAL COLOR MANAGEMENT SYSTEM (GCMS)-------------------------19
SECTION 3 - TEXTURING GUIDELINES-------------------------------------------------------------19-20

3.1 Acid Etching Texturing (Graining) Guidelines 19
3.2 Electrical Discharge Machining EDM Texturing (Spark Erosion) 20
3.3 Casting Textures (including Slush Molding Process) 20
3.4 Tool / Texture Repair Process 20
SECTION 4 – PART / SYSTEM EVALUATION ACTIVITIES-------------------------------------20-25

4.1 Appearance Evaluation 20-24
4.2 Color Harmony Reviews 24-25
4.3 Mold Flow Sign-off 25
4.4 Design Quality Autoshow / Marketing / Special Review Vehicle Evaluation 25
4.5 Go Further: Ford’s Commitment to Appearance Excellence 25
SECTION 5 – APPENDICES------------------------------------------------------------------------------26-43
APPENDIX A - Sample AAR Forms: a) OK-to-Texture Sign-off, b) Final Appearance Sign-off 26
APPENDIX B - Identifying Color & Appearance Characteristics: Materials / Paint 27
APPENDIX C - Gloss Code Definitions 28
APPENDIX D - Ford Master Procurement 29
APPENDIX E - “Visual Orange Peel Standards” Letter 30
APPENDIX F - Sample Tool Grain Specification (TGSS) Sheets 31-32
APPENDIX G - Material Color / Durability Compliance Cert (MCDCC) 33
APPENDIX H - Master Handling Guidelines 34-37
APPENDIX J - SCCAF Alignment Definitions 38
Single Point Lesson – Chips & Scratches 39
GLOSSARY 40-43
DCAP CHANGE LOG 43

GIS2 Classification: Proprietary iii Retention Start Date:
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INTRODUCTION
PURPOSE
This document describes the requirements by which suppliers of all interior, exterior and underhood decorative
components must comply in order to achieve appearance approval, as described in the Production Part Approval Process
(PPAP) Manual for Ford vehicle programs.
An approved Appearance Approval Report (AAR), obtained from this process, is included in the supplier's Part
Submission Warrant (PSW) package. Q-1 suppliers are NOT exempt.
Appearance Harmony includes a range of Ford processes that ensure customer appearance expectations are met or
exceeded. This process manual highlights the roles, responsibilities and actions necessary to achieve appearance
approval (e.g. Mastering, Fit-to-Nominal, Vehicle Operations Pre-Texture Sign-off, Grain Mapping, and Ok-to-Texture).
This Global Decorative Component Approval Process (G-DCAP) ensures the Design Intent and Appearance Harmony
by establishing the Minimum Acceptance Standards to achieve the highest possible quality for maximum Customer
Satisfaction.

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Global Decorative Component Approval Process (G-DCAP)

Process Flow Diagram

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GPDS PROGRAM APPEARANCE APPROVAL MILESTONES

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CROSS FUNCTIONAL TEAM - ROLES AND RESPONSIBILITIES

DESIGN QUALITY (DQ)
 Supports Color and Material Design (CMD) and Design Studio with lessons learned & feasibility assessments.
 Attends and contributes to the Color Harmony Team.
 Supports development of the Production Direction Letter (PDL) with CMD and Program Management.
 Conducts virtual texture mapping / part and texture mark up with supplier (and D&R for BTPS Parts)- captured on
CAD (Tool Grain Specification Sheet-TGSS), and 1st off parts. Supports Tier1 activities with approved graining source
and cross-functional team.
 Conducts appearance approval (Ok-to-Texture /AAR) for interior, exterior, underhood components and assemblies,
captured on the AAR document.
 Advises Program Management (Color Harmony Team Leader) and Supplier Technical Assistance (STA) of potential
Appearance Approval concerns.
 The DQ Color Management Analyst (CMA) establishes the program AAR tracking matrix and delivers progress
reports to Program Management through the Color Harmony Team for their presentation to the Launch Management
Meetings (LMM) and Stakeholder Meetings.
 Supports part sign-offs for the final Mold Flow Analysis performed by PD CAE. Ford D&R, Tier 1/ Molder,
Craftsmanship and the Tool source will also sign-off the Mold Flow Part Analysis.
 Global Programs – It is mandatory that the lead region DQ must communicate and inform other regions of any
regionally directed color, grain or gloss differences to meet global design intent. It is also mandatory that the lead
region DQ send AAR equivalent part samples to all the other affected regions for globally alignment of color, grain
and gloss. (DQ supervisor to reconcile concurrent AAR part approvals on a part by part basis).
COLOR & MATERIAL DESIGN (CMD)

 Establishes the design intent for color, material, texture and gloss,
 Leads the Program Definition Approval event, where the teams reach consensus on color, texture, gloss and finishes
for all vehicle lines.
 C&M Mastering (CMM) will sign the color portion of the Material Color / Durability Compliance Certification (MCDCC)
for approval to proceed to test (requires 95% color match to master).
 Designers are responsible for providing the Program Teams with a summary of all appearance decisions made.
 Supports DQ in evaluation of Color/Texture approvals (FSA)
TIER1 SUPPLIER and TIER 1 BUILD TO PRINT SUPPLIER (BTPS)

 Manages the timing function of their decorative components (including Tier 2/3 suppliers) for appearance approval
submissions. For example: Fit-to-Nominal (FtN), Ok-to-Texture (OKtT), and AAR timing.
 Attends and contributes to the Color Harmony Team.

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 Provides parting (split) line locations and Feasibility assessment to Craftsmanship in accordance with surface
development criteria prior to tool kick off.
 Provides a list of raw materials, including supplier name, contact information and material specification to the Color
Harmony Team Leader – Program Management.
 Provides their STA site engineer with any raw material changes by them or their sub tiers (Tier 2 plus – e.g. Tier 3, 4
etc.). which may require re-AAR approval. An SREA (Supplier Request Engineering Approval) may be required by
PD Engineering (D&R) to perform this action. STA must notify DQ if any parts need to be re-evaluated for re-AAR.
 Involves and manages their Tier 2 plus supplier(s), Grainer, Tool maker(s) and Raw Material Supplier(s) (regardless
of sourcing direction) - throughout the appearance approval process.
 BTPS - If applicable, provides Tool design, sharing this data with Design Quality Group for review (PRIOR to Tool
Kick-Off) for all appearance parts. (Check with the D&R engineer responsible for specific details).
 BTPS - If applicable, supplies CAD Data with Minimum Draft Requirements and components for texture mapping,
and supports the nominated texture source throughout the graining process. (Check with the D&R engineer for
specific details).
 BTPS - If applicable, Supports the virtual texture mapping activity, and captures this information on the Tool Grain
Specification Sheets (TGSS), for all appearance parts, with component sections and draft analysis.
 Supplies all AAR required documents.
 Maintains all AAR forms & parts / assemblies for the active life of part / assembly.
 Upon request, will ship signed-off “AAR Equivalent” parts to other DQ regional representatives for reference on
subsequent program launches.
 All Tiered suppliers must use the signed-off AAR part (as a tool) and compare it visually (for color, texture, gloss and
quality) during their normal production volumes (freq. determined by STA and the Tier 1/2/3/4 etc.) to ensure ongoing
quality compliance is being met.
 Tier1 updates TGSS file (refer to ESOW Design feasibility attachment 06).
TEXTURE SOURCE
 Provides a Single Point of Contact (SPOC), and travels to tool maker and supplier’s production plant when required.
 Ensures the texture is technically feasible.
 Supports DQ and all Tier1 and Tier2/3 suppliers regarding the texture mapping strategy.
 Ensures the texture is applied per the texture mapping strategy, and will be blended across the components.
 Analyzes the draft analysis, the tool draft angles, marks up parts, and photographs them.
 Establishes the virtual texture mapping, and captures all required information on the Tool Grain Specification Sheet
(TGSS).
 No texturing activities are allowed without the approved AAR / OK-to-Texture (OKtT) document signed by DQ.
 Supports the Toolmaker and Suppliers with post-grain activities.

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PD ENGINEERING / CRAFTSMANSHIP
 PD Engineering establishes the program TCB (Trim Coordination Build) and FtN (Fit to Nominal) tracking matrix.
 Conducts Fit to Nominal review for all appearance components.
 Signs off on the appearance part as meeting the required PROD. DEV. (PD) FIT to NOMINAL (on CFG-1002-F AAR
form).
VEHICLE OPERATIONS (VO)

 VO provides approval for all end item components requiring grain. VO Pre-Grain Sign-off is required on the AAR
form (CFG-1002-F) for all End Item components which require grain.
 PIA parts within the End Item component does not require VO to sign the Pre-grain portion in the AAR form. This
signature block can be left blank.
 The TCB1 event in VOPGOG-227 provides the mechanism for pre-grain approval. This VOPGOG-227 is a global
process.
 Design Quality does not own the VO Pre-Grain Sign-off process but we act as the gatekeepers for the VO Pre-Grain
signoff.
DESIGN & RELEASE (D&R) ENGINEER

 Coordinates and guides the Tier1 from the development phase to the Production Part Approval Process (PPAP).
 D&R responsible for starting the TGSS process and signing the TGSS form.
o Please refer to ESOW Design Feasibility attachment 06 for D&R responsibilities to TGSS
 Writes the Alert for unapproved parts, which requires Assembly Plant approval prior to shipping. The Alert is a WERS
document used to authorize the shipment of parts temporarily, until the part receives AAR by DQ.
 Participates and signs off on OK-to-Texture part mark-up reviews.
o FAP as required
 Responsible for identification / resolution of part and timing issues for appearance items (i.e. incomplete or missing
MCDCC, molding issues, etc.) and will report this information to Program Management.
SUPPLIER TECHNICAL ASSISTANCE (STA)

 Conducts Supplier PPAP (Production Part Approval Process) for all Appearance Items.
 Supports Vehicle reviews for MCA and ICA for new and carry over part alignment as required. (See also Section 1.3
vehicle reviews for MCA, ICA, & C/O)
 STA supports OKtT/AAR process & reviews (FAP/FOE)

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Program Management
 Leads the Color Harmony Team process.
 Issues the Color and Material Product Direction Letter (PDL) at 18 MBJ1.
o The C&M PDL will be released through GCMS after July 2016 for all future programs.
o Any important information (e.g. material specifications) not readily available and outlined in the initial C&M
PDL release will be the responsibility of the PDL writer to obtain and update the PDL as soon as possible.
 Presents AAR status provided by DQ as part of program review presentation i.e. OKTB scorecard or specific
management review material.
o Design Quality will support with AAR status and technical information when required.
 Color Harmony Team Leader (Program Management) to complete “Color Harmony / Graining Status” in New Models
OK-To-Buy Scorecard.
o Design Quality will provide support with AAR status and technical information to PM.
 LQOS 310: Plant Color Harmony Review - Color Launch.
o Any CTG mismatches determined unacceptable by the Design Quality Representative and the assembly
plant representatives should be entered into AIMS by the affected VO ME launch representative.

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SECTION 1 - APPEARANCE APPROVAL PROCESS
APPEARANCE ITEMS THAT REQUIRE APPROVAL SIGN OFF

 New parts in all colors.
 Carry-over parts in new colors
 Material change*
 Material source change*.
 Capacity Tooling / Tool change*
 Manufacturing location change*
 Or as determined by Ford DQ.
*NOTE: The approved item will have written in the comment section of the AAR and
Label “Reference the original AAR samples for color.”
IN-PLANT PAINTED COMPONENT SURFACE EVALUATION / DOCUMENTATION SIGN-OFF

The following process steps are required for AAR sign-off, on decorative components that are supplied unpainted, for in-
plant paint finishing. The steps are designed to ensure that parts represent production-level appearance when reviewed
for appearance sign-off.
1. The Tier 1 supplier will notify the appropriate Design Quality Representative and Design & Release Engineer when
parts are intended for in-plant paint operation. The Tier 1 supplier is responsible for scheduling the review meeting.
2. The following items should be submitted by the supplier to the Design Quality representative:
 An unpainted part for review - 1 part from each cavity

 A part painted in high-gloss black (or DARKEST production color) and high-gloss white, (or LIGHTEST color) -
1 part from each cavity- using the Ford production paint system.
 If corrective actions are required, suppliers will correct and resubmit painted parts to DQ for final approval.
 The supplier must retain all documentation per PPAP requirements.
 Should the component receive a “Rejected for Surface” evaluation, the supplier will provide a corrective action
work plan and planned resubmission date. Rejected / marked-up parts must be included in the next approval
review.
 FOR COLOR SUBMISSIONS: Refer to Section 4 of the GDCAP manual (Part/System Evaluation Activities)

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1.1 GLOBAL PART APPEARANCE APPROVAL GUIDELINE
Global Parts: Multiple Regional supplier manufacturing sites; same part, new tool and location
 OK to Texture (OKtT) and AAR will be approved by regional DQ representative assigned to

the launch site Assembly plant.
MULTIPLE
SUPPLIER
MANUFACT. APPROVED BY REGIONAL DQ
SIDE:C/O REGIONAL DQ UPDATES
DESIGN; NEW REP. TRENDING CHART
TOOL
One supplier manufacturing site; parts will be shipped to multiple regions for final assembly
 OK to Texture (OKtT) and AAR will be approved by the DQ representative assigned to the
lead Assembly plant.
APPROVED BY DQ IF COLOR IS
MULTIPLE REP. ASSIGNED UNIQUE FOR ONE LEAD DQ
ONE SUPPLIER
REGIONS FOR TO LEAD PLANT REGION, UPDATES
MANUFACT.SITE
FINAL ASSEMBLY REGIONAL DQ TRENDING CHART
APPROVES AAR
Unique Parts: Part is unique to vehicle assembly region.
 OK-to-Texture (OKtT) and AAR will be approved by regional DQ representative assigned to

the launch site Assembly plant.
PART USED APPROVED BY

FOR SPECIFIC REGIONAL DQ
REGION REP.
Global Color: Lead Launch Region and Annual Color Change Notification
 New colors will be approved by lead region per program, and Color Trending data will be
entered into the Global Design Quality Color Trending Database.
 Lead Launch Region will sign-off AAR parts, and will send AAR-equivalent parts to share with
follow-on regions.
SUPPLIER CONTACTS DQ LEAD LAUNCH REGION DQ LEAD LAUNCH REGION DQ REP.

REP. TO DETERMINE REP. REVIEWS/APPROVES STICKERS AND WILL APPROVE (AAR-
WHO IS COLOR LEAD (BY PARTS. AAR SIGNED & EQUIVALENT) PARTS.TO FOLLOW-ON
PROGRAM / REGION) PARTS STICKERED. DQ REP. REGION DQ REP.
UPDATES COLOR TRENDING.
Each respective DQ representative noted above is responsible for updating the color trending chart after initial trending
position is defined (located in Global DQ website).

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1.2 AAR Component and AAR Sub-System Assembly Reviews

 Program assigned DQ is responsible to ensure assembled AAR sub-systems have equivalent AAR components
installed as part of the “system review process”.
o E.g. Supplier A has a component bezel for a headlamp switch which is signed off for AAR. Supplier B brings
in a sub-assembly with supplier A’s component part (this part must be equivalent to the AAR signed off
component) before the DQ can sign-off the sub-system assembly for AAR. It’s the responsibility of the DQ
person to ensure this process is followed.
1.3 VEHICLE REVIEWS for Mid CYCLE ACTION (MCA) and IN CYCLE ACTION (ICA), NEW
and C/O PARTS; C/O PARTS IN GENERAL (Review C/O parts next to new parts regardless of program scale
or size)
 Objective – Ensure carry over parts and new (adjacent) parts are aligned for Design Intent – Color, Texture,
Gloss and Quality
 DQ will conduct complete current model vehicle reviews at <PTC> for future MCA and ICA programs only. DQ
will use the FC5 new surface parts release information from EMM when making this assessment to determine
which parts are new. DQ will publish any concerns to the CHT Leader – Program Management for disposition
and follow-up.
1.4 PRODUCTION DEVELOPMENT (PD) FIT-TO-NOMINAL (FtN)

 FtN is led by the PD Craftsmanship Engineer
 The FtN event will occur at the Trim Coordination Build TCB1 Event. Ref. to Process VOPGOG-227
o In some cases, parts may be approved at the TCB0 Event
 Prod. Dev. (PD) Fit to Nominal signature is required on all components and end items (assemblies)
 Parts requiring grain need FtN approval (before DQ grain approval) & ungrained parts require FtN approval
before final AAR
 FNA - PD – Interior parts will be signed off by the FtN Engineer
 Electrical Engineering (EESE), Exterior, Lamps, Chassis and Powertrain parts will be signed off by the D&R
Engineer. (FNA Only);
 PD Craftsmanship Engineer in FOE/FAP/FSA is responsible for all FtN sign-offs.
 Design Quality does not own the FtN process but acts as the gatekeepers for the PD FtN signoff process.
1.5 OK-TO-TEXTURE (OKtT)

The following procedures are mandatory for the OK-TO-TEXTURE (APPEARANCE EVALUATION) /sign-off process:
 PD Engineering Fit-to-Nominal (FtN) is assessed as “Proceed”, “Correct & Proceed”, “Correct, Proceed & Resubmit.
 VO Pre-Texture Sign-Off is assessed as “OK-to-Proceed” (end items to plant only).
 Grain Mapping is completed. Marked up parts are signed by DQ.
 All TGSS are completed and signed prior to Ok to Texture.

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 On submission for OK-to-Texture, the Supplier submits at least one (1) part from each cavity in black or the darkest
production color, with a completed AAR form.
 The appropriate DQ representative reviews all parts for design intent, i.e. surface, finish, parting lines, flow lines, gate
location, etc. If necessary, the representative will give direction by marking areas on the part requiring improvements.
 Parts will be signed off using the AAR form, and assigned one of the following designations:
o Correct and Proceed– Supplier corrects all deficiencies noted and proceeds to texture the tool.
o Correct and Resubmit – Supplier corrects all deficiencies noted and resubmits parts for approval.
o Approved to Etch/Tool/EDM – Supplier should immediately proceed to texture the tool.
 The supplier retains the OK-to-Texture AAR form and returns it with any marked-up pre-textured parts, when
submitting for final AAR evaluation/sign-off.
 The Supplier must provide approved documentation as a reference for texture accuracy (i.e. TGSS, marked up parts,
photographs, etc.).
 If the part is not approved to texture (i.e. “Correct and Resubmit”), the supplier will, within five (5) days of
review, provide a corrective action work plan and planned resubmission date.
1.6 FINAL APPEARANCE APPROVAL REPORT (AAR)

The following procedures are mandatory for the FINAL APPEARANCE EVALUATION /sign-off process:
 The Supplier retains the pre-texture/OK-to-Texture AAR form and returns it with any marked-up pre-textured parts
when submitting for post-texture appearance evaluation/sign-off.
 AAR will be given only on Run-at-Rate (R@R) production parts produced at the final production location, using
production materials and processes.
 Rejected parts must be included in the next approval review.
 The Supplier must provide an APPROVED Material Color / Durability Compliance Certification (MCDCC) sheet for
the final surface materials, as viewed by the customer. This MCDCC must be submitted with a completed AAR.
 Design Quality (DQ) does not own the MCDCC process but we act as the gatekeepers for the Materials Engineering
process. (See form in APPENDIX). This is required before DQ signs final AAR.
 The Supplier must provide their masters (texture, color, SM, etc.) for the review.
 The Supplier submits parts for surface, color, texture, and gloss approval from every cavity of new or modified tooling,
using the Job #1 intended process from their production tool facilities, in the darkest program color to the appropriate
DQ representative.
 DQ approves the additional program colors from a single cavity. This cavity number must be documented on the
AAR. Parts are identified and tagged with the Global Ford Minimum Appearance Standard label.
 The approved parts are provided for the appropriate Ford Incoming Receiving area(s) and also for the Tier1
Supplier(s). They are retained by the supplier for their active life, and are made available for review upon request by
Ford. Additional approved parts are available upon request for sub-Tier suppliers.
 Lost AAR samples require a new appearance approval and will be brought to the attention of Ford STA.

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 The signed AAR form and stickered part, reflecting the MINIMUM appearance standard, must be retained by
Tier1 supplier; the signed AAR form must be submitted with the PSW to Ford STA.
 Supplier submits a copy of approved AAR to DQ Color Management Analyst (CMA) for update entry into the Global
Color Management System (GCMS) AAR Tracker.
1.7.1 AAR Form CFG- 1002-F1

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1.7.2 COMPLETION GUIDELINE FOR OK-TO-TEXTURE AND FINAL APPEARANCE

APPROVAL REPORTS (For samples, see Appendix A)
1. Mandatory, Component Part Number: Engineering released part number.
2. Mandatory, Drawing/Assy. Number: Use the number of the drawing on which the part is shown if different from
the part number.
3. Application: Enter the model year(s) and vehicle or other program on which the part is used.
4. Mandatory, Part Name: Use the finished part name on the part drawing.
5. Buyer Code: Enter the code for specific buyer of part
6. Level: Engineering Change Level
7. Date: E/C date for this submission
8. Mandatory, Supplier Name: Supplier responsible for submission (include sub supplier if applicable).
9. Mandatory, Manufacturing Location: Location where part was manufactured or assembled.
10. Mandatory, Supplier Code: Customer-assigned code for supplier location where the part was manufactured or
assembled.
11. Mandatory, Reason for Submission: Check box or boxes explaining the reason for this submission.
12. Mandatory, Supplier Sourcing & Texture Information: Tool Source, Type of Tool Steel, No. of Tools, No. of
Cavities, Texture type, Texture source, Gloss Code, Material, Material Specification, Paint Specification,
Performance Specification, Material Color / Durability Compliance Certification Form (MCDCC) Y/N (Yes or No),
Painter if painting is outsourced. All related Specifications are available through Ford Materials Engineering.
13. Mandatory, Pre-Texture Evaluation: To be completed by Ford Design Quality (DQ) Representative.
14. Mandatory, Color Suffix: Use alphanumeric or numeric color identification.
15. Tri-stimulus Data: List numerical (colorimeter) data of submission part as compared to the MASTER. (NOTE:
according to FLTM BI 109-02: optional).
16. Master Number: Enter Master Identification Number.
17. Master Date: Enter the date on which the Master was approved.
18. Mandatory, Material Type: Identify first surface finish and substrate (i.e. paint/ABS).
19. Mandatory, Material Source: Identify first surface and substrate suppliers. Example; Basell/Dow.
20. Mandatory, Color Evaluation, Hue, Value, Chroma, Metallic Brilliance & Gloss: Visual assessment by Ford DQ,
using ISO and Ford Equivalent Terminology. refer to FLTM BI 109-01/2, FLTM BI 110-01
21. Mandatory, Color Shipping Suffix: Color part number suffix or color number.
22. Mandatory, Part Disposition: To be determined by Ford DQ Representative (approved or rejected).
23. Comments: General comments by the supplier or Ford DQ Representative (optional).
24. Mandatory, Ford V.O. Representative Signature & Date: Ford approval signature.
25. Mandatory, Ford PD Engineering (Fit to Nominal) Representative Signature & Date: Ford approval signature.
26. Mandatory, Supplier Signature, Phone No. & Date: Supplier certification that the document information is
accurate and meets all requirements specified.
27. Mandatory, Ford Design Quality Representative Signature & Date: Ford approval signature.

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1.7.3 GLOBAL FORD MINIMUM APPEARANCE STANDARD LABEL

A Minimum Appearance Standard label will be signed and permanently attached to all approved appearance items. The
Label should be attached directly to the approved AAR component. If the approved AAR component is too small to attach
a label, a permanent alternative method may be used.
(FAP): Consult your DQ Rep/Supervisor for additional clarification regarding local operating procedures for AAR part
sign-off.
All appearance items / production parts shipped to the assembly plant must meet or exceed the approved
minimum appearance AAR standard component.
The Global Ford Minimum Appearance Standard label is available from your DQ representative.
1.7.4 COLOR REFERENCE ONLY

Under certain rare circumstances, an appearance item may be used exclusively for color comparison. These items are
not to be used to judge surface quality, orange peel, texture or any other appearance attribute except color. Such
parts are not considered acceptable for AAR or PSW (no sticker will be applied to this part). The appearance part will
be marked with indelible media by the DQ representative stating: ““For Color Reference Only-Resubmit for Final
AAR”.
The AAR for this part will NOT be signed by the DQ representative, nor will an appearance sign off sticker be
affixed to the part. To avoid confusion, the supplier should retain this Color Reference part, and include it in future
appearance reviews, until the part in question has achieved full AAR appearance approval
1.8.1 SUPPLIER PART / RAW MATERIALS

Tiered Suppliers (Tier 1,2,3,4 etc.) suppliers are required to document any part or raw materials changes (via SREA)
during normal production where the part does not meet the minimum appearance standard AAR signed off part). The
Tiered supplier is required to review these changes with their STA site engineer for appropriate disposition.

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MIC Resin Change of Supplier/Source

The following appearance approval process applies to all MIC material resin changes where the colorant remains
unchanged and the resin material stays the same (Ford Material Spec & Performance).
 The supplier will be required to submit samples from one tool (all cavities) representing each program color and
texture as directed by Ford Design Quality. The Ford Design Quality Rep. is responsible to select which tools
shall be reviewed. The Ford Design Quality Rep reserves the right to request any additional tools affected to be
brought in for review as necessary.
 A completed MCDCC sheet will also be required.
 Once Ford Design Quality has approved each color and texture the supplier will only need to submit the
completed AAR form and the original AAR sample signed prior to the resin change for all remaining resin change
submissions. Should the original AAR sample not be available (missing) a new sample with the resin change
will be required for sign-off.
Note: Design Quality Representative reserves the right to determine how this will be implemented. If it is not specified
by the DQ rep, full re-AAR is required.
1.8.2 SMC PART EVALUATION / DOCUMENTATION / SIGN-OFF

The following process steps should be adhered to for a supplier to achieve AAR sign-off for decorative components made
from SMC (Sheet Molded Compound). The steps are designed to be iterative and are applicable to achieving OK-to-
Chrome and OK-to-Paint approvals.
1. The SMC supplier will notify the appropriate Design Quality Representative and Design & Release Engineer when
parts are available for review. The Tier 1 supplier is responsible for scheduling the review meeting. The following
items should be submitted by the supplier to the Design Quality representative:
 An unpainted part for review-1 part from each cavity
 A part painted in high-gloss black-1 part from each cavity
2. The supplier will document the review with digital images of marked parts as appropriate/required.
3. If corrective actions are required, suppliers will correct and resubmit their parts to DQ for final approval.
4. The supplier must retain all documentation per PPAP requirements.
5. Should the component receive a “Correct and Resubmit” evaluation, the supplier will provide a resubmission date
within five (5) days of review. Rejected parts must be included in the next approval review.
6. FOR COLOR SUBMISSIONS: Refer to Section 3.1 of the DCAP manual (Part/System Evaluation Activities)
Review committee for SMC parts should include:
 Part supplier representative
 Design Quality representative
 Design and Release engineer
 Toolmaker

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1.9 SPECIAL COMMODITIES
APPEARANCE BOUNDARY BOOKS

Boundary book development must be led by the appropriate Ford Engineering activity, and executed by the Tier1 Supplier,
using the Ford-approved format. Upon completion and approval, the book must be signed by the Tier1, Design Quality,
D&R Engineer and Assembly Plant Incoming Quality (with additional signators on a case-by-case basis). With
concurrence by DQ, the following special commodities (Leather Wrapped Components, Seats, Wrapped Steering Wheels,
Top-Stitched Components) may require an Appearance Boundary Book.
 Tier 1 suppliers, VO Incoming Quality (assembly plant), and sub-tier suppliers (as applicable), will retain copies
of the approved Boundary Books.
 Any follow-up changes to the Boundary Book must be submitted to STA for review and acceptance by the
original approvers.
 Contact your DQ representative for an example of the approved Boundary Book format.
SEATS: Please consult your regional Seat Engineering and DQ Representative for details.
 “Master” Seat – is a physical prototype showing Design Intent; as established by the Ford Design Studio.
 Seat hard plastics are reviewed as individual-tooled items for OKtT and Final AAR sign-off by DQ.
 R@R Seat assemblies require Final AAR sign-off by DQ.
 AAR Signed Off seats must be retained by the Tier 1 supplier for the life of the program.
BADGES/GRAPHICS: All Badges/ Graphics shall be accompanied by a released drawing on a 1 to 1 Mylar or

equivalent (Release Drawing, CAD data reference, etc.)
 Approval from the Ford Graphics department is required for verification of Design Intent.
 For Badges, an appropriate Color Master shall be supplied for final submission. (reference normal AAR)
LABELS: The Tier 1 is responsible to ensure that the affixed labels, and their position, have been approved prior
to Final AAR sign-off. Design Quality has no jurisdiction on the appearance or contents of labels;
Design Quality does not review any labels. Appearance parts with labels must have all the labels
affixed in position during final AAR approval/review.
BLACK CERAMIC (Glass):

An appearance sign-off via AAR of the black ceramic execution involves review of the pattern. The 2D
print (PPT document) is required for AAR. No MCDCC is required for Ceramic Paint.

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LIGHTED COMPONENTS:
DQ will evaluate daytime (unlit condition) appearance criteria only.
The EESE representative will evaluate these components for night-time illumination criteria.
The criteria guideline for the Interior Harmony on Lighted Components IH SDS (Interior Harmony
System Design Specification) is available at:
http://www.requirements.ford.com
The following items are approved in the lighted / illuminated state:
 Color (Chromaticity)
 Intensity (Luminance)
 Uniformity / Evenness
 Legibility (Contrast under different ambient lighting conditions)
WHEELS: Only one sample is required for appearance approval of multiple cavity/tool cast wheels
with a machined surface finish. All subsequent cavities/tools are required to meet the
Minimum Appearance Standard established by the approved cavity/ tool.
The “Road Wheel Defect Criteria Guideline“ is available from your DQ representative.
UNDERHOOD COMPONENTS: Designated Components follow this G-DCAP manual for appearance approval.
VEHICLE PERSONALIZATION (VP)

FNA
The Ford North America Vehicle Personalization Group offers three (3) levels of decorative components (described
below). In all cases, VP Design is responsible for defining appearance intent, surface, and OK-to-Texture. G-DCAP
requirements for VP-sourced parts in North America are administered as follows:
1. PRODUCTION COMPONENTS INSTALLED IN-PLANT (i.e. Feature vehicle / base program parts; wheels,
spoilers, badges, etc.)
 VP supplies copies of AAR, with OK-to-Texture signatures (must align with approved base program texture
source).
 Supplier provides signed-off parts (when requested), and proof (via MCDCC) of Ford approved materials.
2. MOD CENTER / OFF-LINE PLANT- INSTALLED (i.e. Feature vehicles and factory-installed accessories)
 VP supplies copies of AAR, with OK-to-Texture signatures (must align with approved base program texture
source).
 Supplier provides signed-off parts (when requested), and proof (via MCDCC) of Ford approved materials.
 VP mod-center components are subject to Base Program DQ review and sign-off for final color approvals and
color harmony evaluations at the assembly plant.

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3. DEALER-INSTALLED ACCESSORIES (i.e. VP components that are available only from the dealer)
 VP is fully responsible for any VP-designed, dealer-only/dealer-installed component.
 VP must retain AAR, MCDCC and signed-off part for the life the program, in accordance with G-DCAP guidelines,
and make them available to DQ personnel for review if required.
(NOTE: Should the status of a dealer-only part change to Mod Center or Base Program usage, the component will
be subject to Design Quality approval for AAR and PPAP certification).
FOE
Ford of Europe G-DCAP requirements for VP-sourced parts are administered as follows:
1. PRODUCTION COMPONENTS INSTALLED IN-PLANT & MOD CENTER / OFF-LINE PLANT- INSTALLED (i.e.
wheels, spoilers, seat covers etc.)
 VP performs AAR versus Master Panel (Thierry) or Master Part (signed from VP Design)
 Supplier provides signed-off parts (when required), and proof (via MCDCC) of Ford approved materials.
 Base Program DQ will review and approve color harmony (where applicable) at plant level evaluations.
 VP is fully responsible for any dealer-only product.
 Should the status of a dealer-only product change to Mod Center or Base Program usage, see point 1.
FAP
Ford Asia Pacific G-DCAP requirements for VP-sourced parts are administered as follows:
 All decorative components must follow the same GDCAP as the Base Program, i.e. FAP Design Quality will be
responsible for the review and sign-off of ALL (OK-to-Texture and Final) AAR submissions.
 Note: Proof of the completion of Fit-to-Nominal (FtN) and Material Color Durability Compliance Certification
(MCDCC) will be required.
 Supplier Branded Accessory (SBA) does not require AAR.
FSA
Ford South America G-DCAP requirements for VP-sourced parts are administered as follows:
1. PRODUCTION COMPONENTS INSTALLED IN-PLANT & MOD CENTER / OFF-LINE PLANT- INSTALLED (i.e.
wheels, spoilers, seat covers etc.)
 All decorative components must follow the same G-DCAP as the Base Program, i.e. FAP Design Quality will be
responsible for the review and sign-off of ALL (OK-to-Texture and Final) AAR submissions.
 Note: Proof of the completion of Fit-to-Nominal (FtN) and Material Color Durability Compliance Certification
(MCDCC) will be required.
 VP is fully responsible for any dealer-only product.
 Should the status of a dealer-only product change to Mod Center or Base Program usage, see point (1).

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SECTION 2 – GLOBAL COLOR MANAGEMENT SYSTEM (GCMS)
PDL, Mastering, e-AAR Form, Texture Tracking, Metrics, Color System Scorecards, Etc.
 GCMS is an all-inclusive system to globally manage color harmony from start to finish using a variety of modules
as outlined above.
 GCMS is entirely electronic and replaces most of the paperwork currently done for AAR part approvals and
tracking.
 GCMS is being rolled out slowly in 2016 CY and will be fully operational by 2017 CY.
 GCMS Link - https://www.gcms.ford.com/GCMSUiWeb/authenticatePre.do
o Suppliers need to access GCMS through Covisint
 For an overview and training please contact your regional DQ supervisor.
SECTION 3 - TEXTURING GUIDELINES
3.1 ACID ETCHING TEXTURING (GRAINING)

DQ nominates the program texturing source for all interior, exterior, and underhood textures.
Grain Mapping is required to ensure that the nominated graining source, Toolmaker, Tier 1 Supplier, CMD and DQ
representative's expectations are aligned.
Grain Mapping is an exercise, initially on CAD surfaces starting at <AA1> to capture component sections and draft angle
analysis in line with Ford CAD Method ‘SD041-0123_M’ and guidelines ‘SD041-0124_G’. At <VP>, the grain is mapped
on physical parts. This mapping is done in order to understand how the grain will be applied and blended with
consideration to actual tool design geometry, radii, parting lines, and grain direction across mating components.
Once grain mapping is completed:
The Tier1 Supplier, Grainer and Toolmaker capture the agreed direction pictorially and graphically on the TGSS document
which is signed by the Tier 1 Supplier, Toolmaker and Nominated Graining Source.
The Tier 1 Supplier manages the initial TGSS activities on CAD and the nominated graining source manages it
subsequently on physical parts.
The following guidelines should be accomplished to ensure best quality results:

 All texturing and hand engraving (except EDM) are done by the nominated graining source.
 The original nominated graining source is used for capacity or replacement tools and refurbishment activities.
 The grain pattern selection and orientation has to be identical for every molding cavity.
Ford Design Quality reserves the right to use additional grain sources other than the nominated grain source for any
program at their discretion.

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3.2 ELECTRICAL DISCHARGE MACHINING (EDM) TEXTURING; SPARK EROSION

DQ will not specify any “EDM” source for texturing. Suppliers interested in using this process for texturing (Stipple patterns
only) are required to adhere to the following AAR process guidelines:
 The Engineering Release Drawing accompanies EDM submission.
 Design Quality approves all final burn electrodes.
3.3 CASTING TEXTURES (INCLUDING SLUSH MOLDING) PROCESS

The following process shows the stages of surface approval for all parts to be cast with a texture:
 Vinyl ‘Roll Stock’ or alternative textured form – approved by CMD Prior to Model wrapping.
 Die Model/PU hard model – approval by CMD/Studio Designer with assistance of DQ.
 Wrapped Model – approval by the DQ representative with assistance of CMD/ Studio Designer.
 Master Mandrel/Cast part – Final appearance approval sign-off by DQ (see post-grain appearance evaluation)
3.4 TOOL/TEXTURE REPAIR PROCESS

Grain repairs are carried out by the nominated graining source. Design Quality reserves the right to use additional grain
sources other than the nominated grain source for any repair.
Surface damage to a tool may require repairs to the texture of that tool and a subsequent surface approval by DQ. If a
tool is damaged, hand repair or welding should not take place immediately. Photos are emailed to STA, DQ and the
graining source, so assessments can be made. The following two steps occur to receive approval:
 Submission of part showing surface repair before re-texturing (in some cases a digital photo may be acceptable).
 The Tier1 resubmits parts to DQ for surface approval and has to follow the GDCAP process.

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SECTION 4 - PART/SYSTEM EVALUATION ACTIVITIES
4.1 APPEARANCE EVALUATION
NOTE: THE VISUAL ASSESSMENT IN ACCORDANCE WITH THIS METHOD WILL ALWAYS OVERRIDE
NUMERICAL MEASUREMENT DATA AND IS COMPULSORY FOR ANY TYPE OF APPEARANCE APPROVAL.
The Appearance Evaluation is structured into its methods and the recommended tolerances to be applied.
METHODS
The Ford Laboratory Test Methods (FLTM) cover the scope & field of application, definitions, general & equipment
requirements, conditioning & test conditions, measurement procedures, measurement evaluations, reports and
literature advised for the best possible compliance with Ford's procedure. In addition, these build the foundation of the
recommended tolerances to be applied.
 Visual Appearance Evaluation according to FLTM BI 109-01
 Color Measurement of Interiors, according. to FLTM BI 109-02
 Gloss Measurement of Paint Panels according to FLTM BI 110-01
All FLTM’s are available (See DQ or Ford Engineering Representative).
The subjective Visual Appearance Evaluation describes a procedure for visual comparison of a sample's color
against a reference under illuminants of different spectral distribution.
All personnel involved in viewing and evaluating color, should pass both a color vision test, vision acuity and
discrimination test, and be familiar with the color difference rating scheme according to ISO 3668, (see table below).
Table: Color difference rating scheme
A light booth that meets the requirements is the GretagMacbeth SpectraLight III (or latest model, also Master
Equipment).
The sample and reference are assessed at face, flash, flop angle and all intermediate positions at daylight illumination
D65. In addition, assessment in the later post assembly position is recommended. Material metamerism in the sample

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is assessed for the face angle by alternating the illuminant between the different illuminating units (D65, A, F11). Any
observed color difference shall be analyzed by the components according to ISO 3668.
In cases where an approval is not granted, it is recommended, though not necessary, to measure the color difference(s)
and/or the gloss difference(s).
The objective Color Measurement describes an instrumental comparison of a sample's color against a reference by
defining measurement conditions and measurement procedures for the measurement of color of materials.
The evaluator shall be trained on the instrument to be used. Color spectrophotometers meeting the requirements
are
Instrument Solid (uni) Colors Effect Colors

Master Konica Minolta CM-2500c CT Byk mac-I
Secondary Byk Gardner spectro guide X-Rite MA98, 96, 94
All values shall be calculated for D65 illumination and 10° standard observers.
The objective Gloss Measurement of Paint Panels describes three methods for the measurement of the specular
gloss of paints with 20°, 60° and 85° geometries. Depending on the gloss value of the 60° geometry measurement the
suitable measurement geometry shall be recorded in addition to the 60° geometry value to improve differentiation for
paints.
 high-gloss (>70 GU@60°  20° geometry),
 medium-gloss (10 – 70 GU@60°  60° geometry) and
 low-gloss (<10 GU@60°  85° geometry)
The evaluator shall be trained on the instrument to be used. A reflectometer (gloss meter) meeting the requirements
is
 Byk Gardner micro-TRI-gloss S (also Master Instrument).
COLOR CONTROL PROCESS MONITORING
The supplier shall monitor their process to maintain the necessary color position throughout production.
A Quality Control Plan for appearance components must include a visual inspection of Color and Gloss.
Instrument measurements can be included when applicable.
The tolerances that are defined below resemble guidelines for the start of sampling unless otherwise agreed. No
rounding of measurements for comparison to these is permitted.
Measured color deviations in comparison to the respective Final Approval shall be differentiated into three categories:

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Base Tolerances for the Sampling of Components

Metamerism Trend Acceptance
Guidance
Customer Satisfaction Not Acceptable Borderline Acceptable
|E00*| > 0.75 0.5 – 0.75 < 0.5 SOLID
|MD65/A*| > 0.5 0.25 – 0.5 < 0.25
|MD65/F11*| > 0.5 0.25 – 0.5 < 0.25
Table: Base tolerances for the sampling of components
Please Note: The final AAR approval of a decorative component is subject to

visual acceptance in assembled vehicle position.
The range (difference between the largest and the smallest observation in a data set) of measurements taken on 10
consecutive parts in production shall NOT exceed 0.15 CIELAB units in the a*- or b*-axis.
Refined measurement tolerances for specific colors are based on extensive plausibility tests of measured boundaries
for the visual acceptance and feasibility experience. These are determined by FMC Design (Color & Materials), DTO
and/or R&A (Vehicle Interior Technologies) and can be updated and logged any time.
COLOR TRENDING
To ensure World Class color harmony, Ford Design Quality will identify a color trending target/color quadrant for all
interior and exterior colors. All suppliers will be required to maintain the color trending position for all programs. The
latest color trending chart is available from your DQ Representative.
This chart identifies the value (lightness / darkness) and hue trends for all interior and exterior program colors. DQ will
only approve submitted components when the color position is within the Ford specified color quadrant.
ORANGE PEEL
To ensure overall vehicle harmony between painted components, for the visual assessment, Orange Peel Standards
have been established by Ford DQ.
The Minimum Orange Peel acceptance rating is > 7
Those Standards have been approved for usage in evaluating the appearance of painted parts. The set of panels
shows a graduated degree of orange peel (flow) from rough to smooth. Each panel within the set is painted black and
labelled with a corresponding flow rating (orange peel).
These panels are available from:
 ACT Test Panel Technologies | Headquarters - 273 Industrial Drive Hillsdale, MI 49242
The table on the next page is provided for clarification and assistance in meeting the requirements of this specification.

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AAR Supplier Action

Panel Degree of perception Meaning
approved Required
Nr.
No perceptible not detected/detectable Yes None
9/10
Very slightly, i.e. just perceptible detected by experts only Yes None
7/8
Minor adjustment
detected by the most critical
6 Slight, but clearly perceptible No should be made on
customer
next lot of material
5 Moderate detected by many customers No Adjust immediately
4 Considerable detected by most customers No Adjust immediately
detected directly by all
<4 Very major customers and causes No Adjust immediately
customer dissatisfaction
For additional information, please refer to APPENDIX F – FORD Visual Orange Peel
Standards Letter
4.2 COLOR HARMONY REVIEWS
Interior and exterior appearance/color harmony reviews are conducted to ensure overall vehicle harmony. Suppliers may
be required to adjust their component appearance (post AAR sign-off) at the discretion of DQ based on vehicle harmony
reviews.
Normal process adjustments for appearance (constituting minor ratio changes) are allowable to maintain the visual
acceptance criteria to the AAR signed off part.
 Any formula/ingredients changes need to be verified with all stakeholders - primarily Materials Engineering.
These changes may be required to improve the overall vehicle appearance/color harmony and may need to be
verified and approved via SREA. It’s the supplier’s responsibility to outline these to changes to their STA contact
to determine an appropriate action plan.
At the color harmony review (build gateways) – For max calls, Design Quality may require a respray or part resubmission
within 72 hours to validate the visual acceptance criteria of the production part.
During the color harmony review, suppliers may be asked to improve the color position of their previously AAR stickered
component for improved vehicle color harmony. The supplier will then be required to return the adjusted/ improved
component for sign-off/stickering. All previously stickered components, prior to the adjusted date, should be returned to
DQ for destruction.
TT Color Harmony Review Requirements:

Suppliers are required to bring their AAR paperwork and signed-off/stickered part to the TT Color Harmony Review (if
the component has been AAR approved).
PP, MP1, MP2 Color Harmony Review Requirements:
Suppliers will be required to produce their AAR and signed-off/stickered part to resolve any post TT Color Harmony issues
within 24 hours.
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Color Harmony reviews are conducted in accordance with the Launch Quality Operating Systems L-QOS 310 which is
available from your Design Quality Representative.
4.3 Design Quality Mold Flow Signoff

 Design Quality does not own the mold flow sign-off process.
 Design Quality is an active participant with the team of 6 (DQ, D&R, CAE, Craftsmanship, Supplier and Tool
Shop) to sign-off all mold flows (both exterior and interior parts) starting at FC5 and ending at FDJ.
 Issue resolution will occur through the AST, MADF, CADF, Part 2 or Escalation meeting if necessary.
 Hard tools will not be kicked off until DQ has signed off on all mold flows per ESOW & MSOW.
DF7.5.B3 Support and comply with requirements in PPAP. All suppliers, Q1 or non-Q1, must get Design SHARED
Quality Appearance Approval Report (AAR) sign-off. (Ref. PPAP).
 Provide FEA and mold flow analysis to Design Quality prior to tool kick off. Parting line
location, gate location, knit lines, sink marks, and positive locating features must be specified in
accordance with surface development criteria and approved by DQ prior to tool KO.
4.4 Design Quality Auto-Show / Marketing / Special Review Vehicle Evaluation

 Vehicles should be available at least 5 weeks before show or reveal timing.
 Design Quality will audit vehicles for overall color, grain, gloss and quality workmanship.
 Design Quality will identify issues on an excel spreadsheet.
 Design Quality will take pictures of all issues.
 Design Quality will outline the issues identified to the teams managing the corrective actions and make
recommendations on how to correct the quality issues identified.
 It’s the responsibility of the vehicle teams to decide on how and when to correct the issues DQ has identified
4.5 Go Further: Ford’s Commitment to Appearance Excellence

While the AAR process establishes a Minimum Appearance Standard for all decorative components and assemblies, it is the
expectation of the Global Design Quality Group that all Ford Motor Company suppliers strive to exceed the minimum standard.
DQ representatives are empowered to review the appearance quality of Ford vehicles post Job #1, and will notify the
appropriate plant personnel, should they observe substandard appearance harmony or quality of the decorative components
of current product.
Bottom Line: The expectation of continuous excellence does not end with a signed AAR form.

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SECTION 5 – APPENDICES
APPENDIX- A:
SAMPLE APPEARANCE APPROVAL REPORTS
SAMPLE
OK‐to‐TEXTURE
APPEARANCE SIGN‐OFF
SAMPLE
FINAL APPEARANCE
SIGN‐OFF

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APPENDIX- B:
IDENTIFYING COLOR and APPEARANCE CHARACTERISTICS: MATERIAL AND PAINT
Example: Product Material Specification Number – WSS-M4D500-A

MATERIAL SPECIFICATION
The second letter to the right of "M" in the product material number denotes the type of material. Generally, the letters found
in this position represent material as follows:
D Hard Plastics
E Panel board
F Leather, Vinyl (soft) supported or unsupported
G Vinyl Bindings, Welts, or Tape
H Cloth, Carpet, Webbing, or Thread
J Paints or Transfers
P Performance Specifications
“ALPHA CODE”
The Color Alpha Code is 7 or 9 digits (ex. 5B8A03J, 5B8AAAATJ) depending on the designated texture code (see table below).
This Alpha Code is the Corporate Design Code used to describe the Color, Finish, Texture, and Gloss of all Interior, Exterior,
and Underhood Appearance items as per the design intent.
This Color Alpha Code may have seven (7) or nine (9) positions:
1st Position Indicates first model year introduced (i.e."7" stands for 2007)
2nd Position Indicates the color family/specific hue (i.e. red, blue, green, yellow, etc.)
3rd Position Indicates the color lightness (i.e. light, medium light, medium, dark, etc.)
4th Position Indicates the Finish (i.e. metallic, non –metallic, pearl, etc.)
5th & 6th Position Indicates Texture code (new system – the 5th, 6th, 7th& 8th position indicates the texture code)
7th Position Indicates the Gloss if applicable (new system – 9th position indicates the gloss if applicable)
Please note that because some materials such as fabrics do not have a gloss the full alpha code is one digit less / replaced by
an asterisk (*) which results in either a 6 or 8 digit alpha code.
Example:
5B8X8D* = Charcoal Black Airfield Fabric
ZHEXAAGP* = Ebony Black Ambassador Fabric

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APPENDIX- C:
GLOSS CODE DEFINITIONS
Ford Motor Company’s Gloss Code definitions are based on visual assessments.
The following shall serve as a measureable baseline for achieving appearance harmony.
Independent of the color, the gloss code below defines a range in which the gloss value should be, when measuring
according to Ford Laboratory Test Method (FLTM) BI 110-01 on a smooth (e.g. for MIC plastics with SPE – SPI#5
texture), flat surface of production material (e.g. plastics, paints, coatings, etc.).
(Due to the inherent properties of a textured surface a gloss reading may or may not directly correlate to the measured
range below on the final visual approval.)
For AAR sign-off on component parts (with or without texture) the visual assessment by
Design Quality will always override numerical measurement.
Gloss Code Gloss Units @ 60° Gloss Units @ 20°

A > 92
B 76 – 84
C 66 – 74
D 58 – 66
E 47 – 53
F 32 – 38
G 17 – 23
H 7 – 13
J 4–6
K 2–4
N 1.8 – 2.4
R 1.2 – 2.0
L < 2.0 (lowest possible)
X HP (highest possible)
Z non-applicable
Note: Design Quality reserves the right to give specific direction that requires modification to the established
gloss level for Color Harmony purposes.

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APPENDIX- D:
FORD MASTER PROCUREMENT
Color Material Mastering Process

Contact: Allen Brown
21175 Oakwood Blvd.
Dearborn, MI 48124 USA
abrown76@ford.com
Tel: +1 313-322-4459
Color Masters - Exterior & Interior Paint Standards Only:
Contact: ACT Laboratories, Inc.

273 Industrial Dr.
Hillsdale, MI 49242 USA
http://www.acttestpanels.com/home.aspx
Phone: +1 517-439-1485 Fax: +1 517-439-1652
Color Masters - Vinyl, Plastics, Carpet, Body Cloth, Headliners, other trim/fabric materials Master Textures and
Styling Master (SM) Standards:
Contact: Attn: Mastering Dept.

[Please FAX all master requests to +1 313-248-6971]
Master Distribution
21175 Oakwood Blvd.
Dearborn, MI 48123 USA
Ford of Europe (FoE) has an agreement with Thierry to supply Masters.
Contact: Thierry Präzisionslackiertechnik GmbH

Motorstrasse 30
70499 Stuttgart
Germany
Tel.: +49 (0) 711 83 99 74 73

Fax: +49 (0) 711 83 99 74 80
Email: master.samples@thierry-gmbh.de
Web page: www.thierry-gmbh.de

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APPENDIX- E:
FORD Visual Orange Peel Standards Letter

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APPENDIX- F:
Tool Grain Specification Sheet (TGSS) Example

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APPENDIX- F: (continued)
Tool Grain Specification Sheet (TGSS) Example

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APPENDIX-G:
MATERIAL COLOR/DURABILITY COMPLIANCE CERTIFICATION (MCDCC)
WORLDWIDE MATERIALS ENGINEEING PROCEDURE - MEP 13 (PROPOSED)
https://www.lom.ford.com/launchomatic/launch/view.jsp?chronicleId=0900cad980d635eb&docbase=ed
msna1
(Note: Design Quality does not own the MCDCC process but acts as gate keeps to ensure the form is filled out correctly)
MATERIAL COLOR / DURABILITY COMPLIANCE CERTIFICATION (MCDCC)
COLOR & MATERIAL SUPPLIER INFORMATION

MATERIAL SUPPLIER MATERIAL TYPE
PRODUCT ID FORD SPECIFICATION
IF RESIN, IS IT - PRE-COLORED COLOR AT THE PRESS ALPHA CODE / SM / SD
COLORANT SUPPLIER COLOR NAME / DESCRIPTION
INITIAL PROG. / MODEL YR
SUPPLIER REPRESENTATIVE:
(Print and Signature) I CERTIFY THAT THE ABOVE MATERIAL IS INTENDED TO MEET ALL COLOR/MATERIAL REQUIREMENTS. DATE
FORD COLOR & MATERIALS GROUP DISPOSITION

NON PRODUCTION SAMPLE PRODUCTION SAMPLE MASTER SECONDARY SOURCE REFERENCE
ENTERED INTO GCMS YES NO IF NO, EXCEPTION MUST BE NOTED IN REMARKS.
REMARKS:
APPROVED REJECTED
NO VISUAL MATCH REQUIRED COLOR MASTERING REPRESENTATIVE DATE
(Print and Signature)
FORD CORE WHEEL MANAGER SIGNATURE

REQUIRED FOR NEW WHEEL
AND WHEEL TRIM COLORS
(Print and Signature) DATE
SUPPLIER TEST DATA AND CERTIFICATION
(complete all fields that apply)
NOTE: ALL COLOR PROPERTY TESTING PER THE APPLICABLE MATERIAL / PERFORMANCE SPECIFICATION MUST BE COMPLETED FOR SIGN-OFF
FOR RESINS, PROVIDE COLOR CONCENTRATE LETDOWN RATIO
FOR PAINT OR CHROME, PROVIDE SUBSTRATE MATERIAL SUPPLIER NAME & PRODUCT CODE
FORD MATERIAL OR PERFORMANCE SPECIFICATION TESTING WAS PERFORMED TO
COLOR PROPERTY DATA, NOTE PARAGRAPH #'S TESTED (ATTACH ADDITIONAL PAGES AS NEEDED) :
WEATHERING: GRAIN TESTED (AS APPLICABLE): DOES COLORANT CONTAIN HALS?

AATCC RATING PROGRAM GRAIN: YES NO
HALS (Hindered Am ine Light
METHOD USED GRAIN DEPTH:
Stabilizers) IS PROHIBITED IN PC OR
EXPOSURE LEVEL PC/ABS RESINS
SUPPLIER REPRESENTATIVE:
(Print and Signature) I CERTIFY THAT THE MATERIAL DEFINED ABOVE MEETS ALL COLOR AND SPECIFICATION DATE
PROPERTY REQUIREMENTS. (The submission of this data does not preclude part testing)
FORD MATERIALS ENGINEERING DISPOSITION
RESUBMISSION PROMISE DATE:
REMARKS:
MATERIALS ENGINEERING REPRESENTATIVE DATE

APPROVED REJECTED (Print and Signature)
UV DURABILITY NOT REQUIRED DATE ENTERED IN GCMS

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APPENDIX- H:
Master Handling Guidelines
Global Appearance Masters

Storage, Handling and Cleaning Guidelines

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Introduction
This guideline offers a set of criteria designed to assist Design Quality Representatives and suppliers in the appropriate handling,
cleaning, and storage of appearance masters used in the evaluation and appearance approval process, as described in the Ford
Design Quality Global Decorative Component Approval Process (G‐DCAP) Manual.

This guideline is effective April 2, 2014 and replaces all previously issued documents on this subject.

BACKGROUND
Appearance harmony is a significant factor in the new vehicle purchase decision. When color, texture, and gloss are accurately and
consistently executed, potential buyers perceive added value in that product. To ensure that Ford Motor Company vehicles achieve
the highest possible level of appearance harmony, Global Appearance Masters are utilized to assist both the Design Quality
Representative and supplier in establishing and maintaining the Minimum Appearance Standard objective for decorative
components.

DEFINITION: Global Appearance Masters
Global Appearance Masters (“Masters”) are physical visual examples of approved appearance elements, which accurately represent
Ford Motor Company Design Intent for Appearance. These masters cover the following appearance elements:
 COLOR ‐ (paint, vinyl, leather, fabric/textile, and mold‐in‐color plastic) in plaque and master sample form.
 TEXTURE ‐ Derived from both acid‐etch and Electrical Discharge (EDM) methods of tool texturing process.
 GLOSS ‐ As shown on painted gloss master plaques, relating to Ford Alpha‐code gloss levels.
 FINISH ‐ Non‐paint (Plating, In‐Mold Film, and Hydrographic) processes, established as Styling Masters (SM).

Usage of accurate masters ensures that all manufactured appearance parts are produced within Ford quality tolerances.
It is important that up‐to date, pristine masters are used. This guideline will offer various methods of maintaining the quality of
appearance masters over time.

HANDLING
 Handle masters with care to avoid damaging them.
 The wearing of cotton gloves when handling masters should be considered mandatory.
 Ensure that the masters are kept in their respective protective environments when not in use:
o Polypropylene color/ texture and paint masters should be kept in cloth/paper sleeves
o Styling masters should be maintained in plastic sleeves or a styling master booklet (fig.1).
 Avoid prolonged exposure to light when in use.
 Avoid stacking unprotected masters on top of each other (scratching).
 When performing outdoor reviews, avoid leaving masters in direct sunlight or high‐heat.
 If you suspect or observe degradation of masters; check with Design Quality Core group.

Fig.1 Master standard containment examples

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CLEANING
 Clean the masters with microfiber cloth after each review to ensure their longevity.
 Wash master plaques with mild soap, do not rub; Air or blow dry.
 Isopropyl alcohol can also be used to clean oil residue from fingers if gloves aren’t utilized during part reviews.
 Avoid damaging the plaque ID label.

STORAGE
 Store all Masters in a cool, dry, dust‐free area, away from direct and indirect light.
 Masters should be stored and filed in the drawers in alphabetical order by type (color, grain, gloss, etc.).
 Storage in closed file cabinets is highly recommended (Fig.2).
 Reference parts should be wrapped and stored on shelving to avoid damage and degradation (Fig.3).

Recommended Storage Methods

Fig. 2 Closed filing cabinets for master plaques Fig. 3 Reference Parts Storage

MASTER DEGRADATION‐EXAMPLES:

Factors that contribute to the deterioration of masters and hinder the visual standards set by DQ include:

 Fingerprints/Oils and acids from handling.
 Scratches and scuffing from inappropriate handling.
 Exposure to high temperatures.
 Exposure to continuous lighting sources, particularly direct sunlight.

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AUDIT PROCESS FOR MASTERS
 An audit process should be performed Bi‐annually by the core process group to ensure that masters are technically
accurate, and in pristine condition.

 Monitor master color and gloss regularly to insure its accuracy. We recommend that the gloss and L*, a*, b* values be
taken and recorded immediately upon receipt.

 Read your master and compare values to identify any shift in COLOR or GLOSS. If color shifts by more than .3 units, the
master should be replaced.
 If GLOSS shifts more than .5 units, the master should be replaced. Readings for gloss are taken on the smooth low gloss
surface with a certified gloss meter @ 60 degrees.

 Periodically, the Design Quality Specialist should visually compare his master to the supplier’s to ensure that they are
both within the boundary to meet the minimum appearance requirements set for the parts being evaluated.

 When properly handled according to the procedure outlined, master plaques can expect the following shelf‐life:

Exterior Paint Polypropylenes References Styling Masters
Master

Years 10 ‐ 15 4 ‐ 7 10 ‐ 15 15 ‐ 20

 Wherever regions boundary is inaccessible, DQ supervisor should audit the masters.

 Suppliers are responsible to ensure that their masters are representative and valid to design intent.

 Suppliers should visually compare their masters bi‐annually to confirm that they are valid/pristine through their master
provider such as THIERRY, AMERICHEM, ACT etc.

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APPENDIX J:
Generic Special Characteristics Communication and Agreement Form (SCCAF) - Alignment
Definitions
Consult Ford D&R engineer for SCCAF alignment
Color and Texture Mismatch between AAR Part and Master

Tolerance and Specification
• Production parts must be visually assessed to be between the Minimum Appearance Standard signed off AAR part
and the Ford Master Hue Plaque for color / Ford Master Texture Plaque (if the part has texture)
• Production parts must be visually assessed to be in the correct color trend position as defined by Design Quality.
(Obtain this information from your Design Quality Representative.
• A visual part assessment will always override any numerical data. Reference - FLTM BI 109-01/2 and (GDCAP)
Global Decorative Component Approval Process
Gloss level
• Production parts must be visually assessed for gloss. The production part must meet the Minimum Appearance
Standard signed off AAR part for gloss.
• Consult with your Design Quality Representative to determine your production part gloss range relative to the
Minimum Appearance signed off AAR part. Document and add this gloss tolerance range to this SCCAF.
• A visual part assessment will always override any numerical data. Reference - FLTM BI 109-01 / FLTM BI 110-01 and
(GDCAP) Global Decorative Component Approval Process
Parting Line Height

• Production part parting line height (needs to meet the Minimum Appearance Standard signed off AAR part and the
Ford F&F 60 micron (0.060mm) maximum requirement.
Note: Design Quality may (at their discretion) scan the Minimum Appearance Standard signed off AAR part to
determine an absolute parting line height/flash if necessary. The supplier would then be required to meet this absolute
measurement.
Part Quality Issues - Sink Marks (or read thru) / Knit Lines / Gate Blush / Flow Lines / Etc.
• Production part surface imperfections must be no greater than the Minimum Appearance Standard signed off AAR
part.

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GLOSSARY
Alpha Code is the seven or nine character alphanumeric code assigned by CMD to specify color, texture, and gloss of
a part.
Appearance (1) of an object, the collected visual aspects of an object or a scene.

(2) perceived, the visual perception of an object, including size, shape, color, texture, gloss, transparency, opacity, etc.,
separately or integrated. (ASTM E284)
<AA1> Appearance Approval 1

 Interior/Exterior design feasible surfaces approved using full size properties.
 Begin release of production intent surface data.
AAR Appearance Approval Report (CFG-1002-F)
Appearance PSW (Part Submission Warrant)

The overall PSW package, relating to appearance characteristics.
BTPS – Build to Print Supplier

Supplier is responsible to build exactly what is released from the Ford D&R
Corporate Design
The division of Ford Motor Company responsible for complete Class I surface development and delivery (creation to
finish) to support production parts.
Color Value – The "lightness/darkness" dimension of the Munsell color system. Examples: Light, Medium, and Dark.
Customer – is the recipient of the organization's or supplier's product or service.
Decorative Component
Is an appearance item or component of an assembly, which is visible to the customer.
Engineering Statement of Work – ESOW

A document that both the Supplier and Ford agreed to.
<FAA> Final Appearance Approval

 Appearance Approval process of all exterior / interior decorative components.
 Design Intent for Appearance (“Design Intent”) established.

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<FEC> Final Engineering Completion

 Verification Prototype (VP) issues resolved.
 All DV testing completed.
 Meets FAP03-201 requirements.
<FDJ> Final Data Judgment

 Data readiness for VP tooling/build/test.
 VP build dates are established.
Finish – An appearance aspect of a product material. Examples: Metallic, Tweed Print and Transparent.
Gloss – The referenced reflectivity value of the surface of a product material. Angular selectivity of reflectance, involving
surface-reflected light, responsible for the degree to which reflected highlights or images of objects may be seen as
super-imposed on a surface.
Global Product Development System (GPDS) - Ford Motor Company’s global product development process, which is
common to brands. It builds on existing best practices to create a quick, efficient and lean integrated development process.
Global Color Management System (GCMS)

A system which runs the Global Color Harmony Process from start to finish. Modules include Color and Material PDL,
Mastering, e-Apperance Approval Report and Color System Review Scorecards.
www.gcms.ford.com
<LR> Launch Readiness

 Cross functional activities confirm readiness to process to Body Constr/Assy Tooling Trial.
 Final approval to proceed to Tooling Trial.
 Manufacturing/Service Joint Venture/Strategic Alliance Complete (if applicable).
Material Color Durability Compliance Certification (MCDCC)

 This form is used to support the Global C&M Process (AAR), which is part of GPDS. This Process will identify the
program timing associated with the completion of this form.
SCOPE
The Global MCDCC form and procedure will be used for all materials with a color aspect. This includes
painted surfaces, moulded-in-color (MIC) plastic surfaces, chromed or anodized surfaces, all soft trim and
textiles including leather, vinyl and fabrics, etc. The approval of a new color will require that additional
aspects that may affect color durability are verified. The colors will have to be tested on the correct material
and surfaces as for vehicle program production intent. The procedure does not affect Component Product
Verification (PV) testing that comes later when parts are produced from production tooling and the agreed
manufacturing process. Color aspects of parts will continue to be covered in the AAR and signed off by
Global Design Quality (Part of the Global Design Technical Operations Group).

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Macbeth Light (X-Rite) – A standardized color evaluation lighting system, specified by FLTM BO109-01 to compare
production Standards with appearance masters.
"M" Number – A number used to designate the product material used in the production of a part. "M" Numbers are
typically shown on the blueprint and are subsequently matched with alpha codes to designate individual colors.
Examples: M4D83-A (ABS plastic resin molding compound), M1H315-A (Grenoble Body cloth).
<PA > Program Approval

 Program objectives are approved.
 All supplier CPA's are signed.
 Program funding approval.
Program Direction Letter (PDL) – A document issued by the Programme Office containing specific assumptions and
feature information relating to program(s). It is a confidential document that identifies the appearance items with the
Design Intent for color, finish, grain and gloss. It is the "official direction" describing programme content and MUST be
issued to generate Programme Validation.
<PSC> Program Strategy confirmed

 Program Strategic target/guidelines set.
 Compatibility of ABS with Marketing, Finance, Quality, functional targets, hardware selection and verification timing
confirmed.
 Make provisional <PTCC> system decisions (finalized at <PTCC>)
Part Submission Warrant (PSW) – is an industry-standard document required for all newly-tooled or revised products
in which the organization confirms that inspections and tests on production parts show conformance to customer
requirements.
<PEC> Preliminary Engineering Completion

 All 1st pass Design Verification (DV) testing is completed.
 Meets FAP03-201 requirements.
 Re-DV testing plan is agreed.
Process – is a set of interrelated or interacting activities which transforms inputs into outputs.

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Production Part Approval Process (PPAP) – The purpose of production part approval is to determine if all customer
engineering design record and specification requirements are properly understood by the supplier and that the process
has the potential to produce a product meeting these requirements during an actual production run at the quoted
production rate. The PPAP document contains all forms that are part of the process, including the CFG-1002-F used by
DQ for the Appearance and Color PSW evaluation approval of decorative components.
R@R – Run at Rate – Parts produced at R@R meet intended mass production conditions (same tool, machinery, location,
etc.).
Suppliers – are providers of production materials, or production or service parts, assemblies, heat treating, welding,
painting, plating or other finishing services directly to an organization supplying the OEM or other customers requiring
this document.
TGSS – Tool Grain Specification Sheet (see Appendix G)
Texture – the visual or tactile surface characteristics of a tool or part. The visible surface structure depending on the
size and organization of small constituent parts of a material; typically, the surface structure of a woven fabric.
VO – Vehicle Operations
<VP> Verification Prototype

 First drivable VP prototype vehicle build is completed & ready for customer delivery.
Warrant – See Part Submission Warrant
G-DCAP CHANGE LOG
Change Date Author Document Description of Change
Q1/Q2/A D Katers, G-DCAP v4 G-DCAP updated to clarify AAR appearance approval

of S Bazinski, conditions as well as additions to prevent multiple
2016 M Waller, stop ship recurrences. All changes/updates have
M Loss, been agreed upon by Global DQ supervisors.
S McConchie


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Design Technical Operations

Global Decorative Components Approval Process

Issue: Version 4.0

DTO Date Issued: 27-Jun-2016

Issue: Version 4.0

DESIGN QUALITY MISSION STATEMENT

Drive vehicle appearance quality and harmony to ensure Design Intent

DTO Date Issued: 27-Jun-2016

Issue: Version 4.0

SECTION 1 - APPEARANCE APPROVAL PROCESS--------------------------------------------8-18

SECTION 2 – GLOBAL COLOR MANAGEMENT SYSTEM (GCMS)-------------------------19

SECTION 3 - TEXTURING GUIDELINES-------------------------------------------------------------19-20

SECTION 4 – PART / SYSTEM EVALUATION ACTIVITIES-------------------------------------20-25

DTO Date Issued: 27-Jun-2016

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DTO Date Issued: 27-Jun-2016

Issue: Version 4.0

Global Decorative Component Approval Process (G-DCAP)

DTO Date Issued: 27-Jun-2016

Issue: Version 4.0

GPDS PROGRAM APPEARANCE APPROVAL MILESTONES

DTO Date Issued: 27-Jun-2016

Issue: Version 4.0

CROSS FUNCTIONAL TEAM - ROLES AND RESPONSIBILITIES

COLOR & MATERIAL DESIGN (CMD)

TIER1 SUPPLIER and TIER 1 BUILD TO PRINT SUPPLIER (BTPS)

DTO Date Issued: 27-Jun-2016

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DTO Date Issued: 27-Jun-2016

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VEHICLE OPERATIONS (VO)

DESIGN & RELEASE (D&R) ENGINEER

SUPPLIER TECHNICAL ASSISTANCE (STA)

DTO Date Issued: 27-Jun-2016

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DTO Date Issued: 27-Jun-2016

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SECTION 1 - APPEARANCE APPROVAL PROCESS

APPEARANCE ITEMS THAT REQUIRE APPROVAL SIGN OFF

IN-PLANT PAINTED COMPONENT SURFACE EVALUATION / DOCUMENTATION SIGN-OFF

 An unpainted part for review - 1 part from each cavity

DTO Date Issued: 27-Jun-2016

Issue: Version 4.0

1.1 GLOBAL PART APPEARANCE APPROVAL GUIDELINE

 OK to Texture (OKtT) and AAR will be approved by regional DQ representative assigned to

Unique Parts: Part is unique to vehicle assembly region.

 OK-to-Texture (OKtT) and AAR will be approved by regional DQ representative assigned to

PART USED APPROVED BY

SUPPLIER CONTACTS DQ LEAD LAUNCH REGION DQ LEAD LAUNCH REGION DQ REP.

DTO Date Issued: 27-Jun-2016

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1.2 AAR Component and AAR Sub-System Assembly Reviews

1.4 PRODUCTION DEVELOPMENT (PD) FIT-TO-NOMINAL (FtN)

1.5 OK-TO-TEXTURE (OKtT)

DTO Date Issued: 27-Jun-2016

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1.6 FINAL APPEARANCE APPROVAL REPORT (AAR)

DTO Date Issued: 27-Jun-2016

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1.7.1 AAR Form CFG- 1002-F1