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Characteristics
Designation
System
KCDS Pyramid
KPC
PQC
Functional Checks,
Verification/Traceability,
Safety Compliance and
Component Handling
1A GM KCDS Process
2A Summary of Levels of Care vs. Cost
4A Characteristic Definition
7A Three Stages of KCDS
8A GM Mandated Parts & Components: Product Identification & Verification
8B General Application Guidelines: Product Id, Traceability & Verification
9A Product Characteristic Pyramid
9B Relationship between KPC/PQC and KCC
10A KCDS KCC Worksheet
10B KPC/PQC/KCC Fishbone Diagram
12A Part and Characteristic Action Steps Chart
1.3 KCDS also sets forth the methods and requirements for communication of parts requiring
additional care and Special Characteristics requiring extra care throughout General
Motors and its supplier community
1.4 The Key Characteristic Designation System Reference Manual is referenced in Quality
System requirements ISO-9000, QS-9000 and the other elements of AIAG/ASQ 7-Pack.
Figure 1A
Functional
Check
Parts Requiring
Traceability
Additional Care
Safety /
Part Level
Compliance
Remaining Parts
Require
Standard Care
Standard
Standard Care
Characteristics
2.0 Purpose
3rd Revision: March 2003
Date printed: 08/22/2015
GM 1805 QN
2.1 Employees are responsible for ensuring that GM products are designed, produced, and
delivered to meet the Voice of the Customer and to comply with applicable government
standards and regulations.
A. As a means of exercising this responsibility and achieving conformance to other
customer requirements, the implementation of KCDS in the organization
requires that the use of Standard Care and Additional or Extra Care be
designed into the Quality Systems.
B. Standard Care describes the usual and customary practices that are applied in
the manufacturing and/or assembly environment to ensure specification and
print requirements are consistently met. Usual and Customary Care
encompasses all of the basic methods and systems necessary to ensure that
the product meet the Voice of the Customer based on loss function and safety/
compliance requirements with government regulations.
2.2 The Key Characteristic Designation System will aid in the economical manufacture of
quality products by:
A. Establishing and managing a uniform system of identifying, documenting and
communicating parts requiring Additional Care and Special Characteristics that
require Extra Care. This is done to ensure consistency and compliance to
customer requirements and government regulations within General Motors and
its supplier community.
B. Supporting the reduction and maintenance/control of variation in the
manufacturing and/or assembly process.
C. Supporting the development of robust designs.
2.3 Many parts require additional levels of checks and documentation. The following are part
level checks and documentation that are over and above Standard Care:
A. Functional Checks are controls used by manufacturing and/or assembly plants
to ensure that parts, sub-systems, systems or completed vehicles comply with
requirements that are subject to, or have an effect on Federal Motor Vehicle
Safety Standard (FMVSS), critical performance objectives, customer
satisfaction, State Statutes, various Regional Compliance procedures and/or
Corporate Policies.
B. Product Traceability identifies and verifies individual parts for correct usage by
scanning individual major components for traceability associated with each
vehicle. Other parts/components supplied in labeled containers are traced to
groups of vehicles. This manual is intended to ensure that parts/ components
that must be verified and traced consistently by GM and its suppliers.
Traceability is a key tool in identifying parts related to vehicles involved in
campaign research.
C. Safety/Compliance parts may need Additional Care to ensure the products
safety and/or compliance with governmental regulations.
D. Component Handling Best Practices identifies assembly and handling
requirements that are necessary in addition to standard handling practices.
E. Any part having a safety and/or compliance relationship must comply with
governmental regulations and may require Functional Checks, Product
Traceability or Component Handling.
2.4 When we unnecessarily require Additional Care on parts, we add to the product's cost
without increasing its value.
2.5 All products, and the processes that are used to make them, have characteristics (or
features) that meet requirements.
A. Special Characteristics (Key Product Characteristics (KPC) and Product Quality
Characteristics (PQC)) require Extra Care because excessive variation could
Functional Checks,
Component Handling and
Summary of the KCDS Pyramid
All Parts and Safety / Compliance
Level of Care Product Identification,
Characteristics Parts
Verification and
Traceability Parts
Extra Care KPC & PQC, containment & KPC & PQC, containment PQC, containment &
$$$ KPC
documentation & documentation documentation
+ +
PQC Traceability, Component
Safety/ Compliance,
Handling and /or Functional
Additional Care $$ Checks, containment &
containment &
documentation
documentation
Functional Checks,
+ +
Verification/Traceability, Safety
+
Standard Care (parts Compliance
Requires and Component
standard care Requires standard care Requires standard care
As CARE Increases,
and characteristics) $ COST increases
Handling
$$
4.0 Definitions
4.1 Part Level
4.4 Variable data data that is continuous and measurable relative to the specifications on a
continuous scale such as millimeters, kilograms, etc.
4.5 Attribute data data for characteristics measured with and resulting from correct part or
incorrect part, present or not present, etc., and is generally synonymous with
conformance or nonconformance and when designated as a special product characteristic
an attribute control method shall be used.
6.0 Levels of Care are intended to define the requirements in the manufacturing and
assembly environment needed to ensure economical manufacture of quality products.
These requirements must be described in local quality procedures, business unit
procedures and other quality procedures. The relationship between part and
characteristic levels of care is described below:
Level of Care
Part Level
Product Safety/Compliance Additional Care
Functional Checks Additional Care
Product Traceability Additional Care
Component Handling Additional Care
Characteristic Level
Key Product Characteristics Extra Care
Product Quality Characteristics Extra Care
6.1 Standard Care describes the usual and customary practices that are applied in the
manufacturing and/or assembly environment to ensure requirements are consistently met.
Standard Care encompasses all of the basic methods and systems necessary to ensure
that the product meets the Voice of the Customer and safety/ compliance requirements
with government regulations. These practices should be described in the local
procedures, business unit procedures and other quality procedures. Standard Care is
typically interpreted to mean that the basic quality system should describe the
fundamental administrative, product, and process practices and systems. Standard Care
requires that the production system be designed to manufacture products that meet
requirements, as well as protect our customers from any nonconforming material.
A. Standard Care
6.2 Additional Care is required in the manufacturing and or assembly process. It is a set of
methods/controls employed to ensure processes are producing parts which meet
customer requirements for Safety/ Compliance, Functional Checks, Product Traceability
and Component Handling.
A. A Process Flow Diagram and a Process Control Plan describe each process.
Quality is focused on meeting customer requirements.
B. Safety/Compliance level of care includes those parts, that may affect the safety
of the product or compliance with any government standards or regulations.
These parts require ongoing controls in manufacturing.
a. If the product does not meet the requirements, local and corporate
procedures regarding containment and documentation should be
followed.
b. Communication, problem resolution, and disposition should follow
various regional requirements.
c. Specific documentation retention requirements apply to all
Safety/Compliance parts.
C. Functional Checks are focused on ensuring the reliability, consistency of
operations as intended and customer satisfaction through in-line checks and
audits. If the product does not meet the requirements, local and corporate
procedures regarding containment and documentation should be followed.
D. Product Traceability is focused on ensuring that parts requiring traceability are
properly identified and verified in the manufacturing/assembly process. The
process needs to be error proofed to ensure the necessary data is captured
and stored. If the product and/or process does not meet the requirements, the
organization shall follow local and corporate procedures regarding containment
and documentation.
6.3 Extra Care applies to Special Characteristics. It defines the level of care required for
managing and controlling variation in manufacturing and/or assembly.
A. If manufacturing and/or assembly variation with Standard Care is likely to have
significant impact to the customer, based on the loss function, then Extra Care
must be used to ensure customer satisfaction.
B. If the characteristic is designated as a Key Product Characteristic, variation
shall be reduced.
- Variation reduction is not required during the period when you are proving
stability. Refer to Section 2.7.
C. If the characteristic is designated as a Product Quality Characteristic, variation
shall be maintained/controlled at a designated level above Standard Care.
D. Controls should be applied at the process characteristic level (KCC).
Figure 7A summarizes the concept behind KCDS. It displays the three stages of the system within
the Global Vehicle Development Process.
T2 Characteristics
and
Identify Parts Process Control Plans
requiring
Structure additional care
T2 and Controls are
Characteristics implemented
requiring extra Identify Process
Containment &
care Controls for items
documentation
Integration identified in
conducted per
Stage 1
T2 Corp
Procedures
Figure 7A
A. Performance checks can be developed for any component or system that has a
designed operation or function.
Product ID,
Component Description Traceability &
Verification
Powertrain modules including GMPT Quality
Engines, Transmissions, Transfer System
1
Cases and other Powertrain
modules
Electronic Control Modules that are Required by GMEC
able to transmit and receive serial NOA NOA-001 Rev A
2
data information on a serial data Dec 19, 2000 & GM-
bus (i.e., class 2, GMLAN) W4710
Corporate mandate
4 Safety & Theft Passive Sensors
to be complied
Those required to
comply with some
5 Computer generated Labels specific International,
Federal & State
Rules & Regulations
Table 8B
Product ID,
Component Description Traceability &
Verification
Sequenced Modules or sub
assemblies with or without Risk Assessment,
1 traceable components in the above Warranty & PFMEA,
table. Also Traced using Supplier & Business Case
databases
Risk Assessment,
High Warranty and Hardy
2 Warranty & PFMEA,
Perennials
& Business Case
Risk Assessment,
3 J.D. Power and Quality Issues Warranty & PFMEA,
& Business Case
Tier-1& 2 major & minor Module Risk Assessment,
4 and sub-assemblies suppliers and Warranty & PFMEA,
Multiple Suppliers & Business Case
9.1 Product characteristics are classified into three categories to focus our resources on the
characteristics that significantly affect customer satisfaction and operational effectiveness.
9.2 The KCDS Pyramid (Figure 9A) ranks product characteristics from the lowest (Standard)
to the highest (Key).
{
Key Product Characteristics Drawing
Reduce
Variation Special
Characteristics
Product Quality Characteristics
Spec
Maintain
USUAL AND
STANDARD CUSTOMARY CARE
(no symbol) (STANDARD CARE)
Figure 9A
Although all product characteristics are important, the Key Product Characteristics are the
highest priority. They are shown at the top of the Product Characteristic Pyramid above in Figure
9A.
MATERIAL EQUIPMENT
KCC KCC
PEOPLE KPC/PQC
METHODS AND
SYSTEMS ENVIRONMENT
CAUSE EFFECT
Figure 9B
Figure 9B shows the relationship between a Key Product Characteristic (KPC) / Product Quality Characteristic
(PQC) and its Key Control Characteristics (KCC). Many factors can affect a KPC and PQC. For example,
changes in the material, equipment, and methods and systems that are used to make a product can change its
characteristics.
9.3 Although not preferred, Key Product Characteristics and Product Quality Characteristics
can be monitored directly without determining the Key Control Characteristics (KCCs).
Ongoing control of the KPC / PQC is required. Once KCCs are defined and in place,
product checks for the KPC / PQC should be reduced to a product or process verification /
validation level.
10.2The following is intended to help the team determine appropriate KPC/PQCs and KCCs.
Data and Engineering judgment are required to arrive at the best list with which to begin.
Both discussion and trials help establish confidence in choices.
A. The Design Failure Mode Effects Analysis and Process Failure Mode Effects
Analysis (DFMEA & PFMEA) describes a systemized group of activities
intended to:
a. Recognize and evaluate the potential failure modes and causes
associated with the designing and manufacturing of a product
b. Identify actions that could eliminate or reduce the chance of the
potential failure occurring
c. Document the failure modes of the processes.
B. The Process Flow Diagram defines and describes the product's intended
processing environment and identifies the process parameters (control
characteristics). Developing and analyzing the Process Flow Diagram helps
plan how to control the process by showing how the process affects the
KPC/PQC.
12.2The KCDS Team includes the full range of activities from design and manufacturing
engineering, supplier development, and the internal and outside supplier communities.
The team is an outgrowth of the Concurrent (Simultaneous) Engineering Team or Product
Development Team.
12.3The principal goal of the KCDS team is the selection of all Parts requiring Additional Care
and Special Characteristics and their related process controls for a given part, sub-
system, system or vehicle by program.
Perform Design
Product
Define Process Engineering
Identify Special
Characteristics Supplier/
C Material
and parts requiring
O additional care
Management
N
T
I
N Record special
U Feedback to the characteristics and
Design and Process part requirements
O
U
S
I
M
Drawings Product
P Specifications
R
O
V Global Vehicle Development Process Product
E Stage 2 Product and Manufacturing Process
Development
M Quality
Design Validation and Construction
E Manufacturing System
N * Identify Process
* Perform Process Manufacturing
T
Engineering
P Generate:
Customer / Product
R Supplier Process Flow Engineering
O Input / Diagram
Process Control
C Process Plan Record
KPCs
E
S
S Manufacturing /
Generate
Instructions & Assembly
Control
Records
A. The team begins its activity during the Portfolio Stage of the Global Vehicle
Development Process in team meetings.
B. Define the measurement criteria (e.g., Specific Checkpoints, Sampling
Frequency, etc.) for each part requiring additional care.
C. Identify the parts requiring additional care and record details of the methods of
control.
D. Identify sources of variation of KCC for each KPC/PQC and record details of
the methods of controlling KCC on the Process Control Plan
E. Complete and review the Process Flow Diagram and the Process Control Plan
with appropriate details and distribute accordingly.
F. Review, as a team, the parts identified as requiring additional care and
KPC/PQCs and revising them as necessary for continuous improvement.
a. Delete from the Engineering Documents all unnecessary/ redundant
parts requiring additional care and KPC/PQC per Design Standards.
G. Obtain process capability data on each KPC/PQC at prototype MRD (Material
Required Dates) from actual prototype parts and analyze.
H. These objectives and activities are best accomplished in team meetings that
are held on a scheduled basis during the product/process development and
validation stages.
I. The Engineering Release Center clearly communicates whether the
requirements are the responsibility of the supplier, manufacturing plant or
assembly plant.
J. Consider requirements of attaching parts and mating surfaces.
K. To be effective, team members must come to these meetings equipped with the
necessary information. It is recommended that team members bring as many
items to meetings as possible in order to meet the objectives of the team in a
timely and accurate manner.
14.0Composition of the Team The list of members of the team is intended to be functional in
nature and actual membership or titles of the people varies widely from group to group. Some
members of the team are required on an as needed basis.
14.2KCDS Engineer
14.4Manufacturing Engineer
14.5Manufacturing/Assembly Representative
14.7Dimensional Management
14.8Service Engineer
15.2Supplier Quality
A. Details of past PR/Rs (Problem Reporting and Resolution) of the supplier and
its quality performance
B. Existing Process Control Plans of similar parts
C. Suggested list of parts requiring additional care, KPC/PQC, the related KCC
D. List of Quality Related Concerns for similar parts/suppliers
E. Plant profile of supplier and its organization chart
F. Information on manufacturing/assembly process operations, etc
G. Details of quality & reliability plans/requirements/goals, etc
H. Process capability/reliability data, etc
I. Details of field problems/failures, etc
J. Dimensional Control Management data
15.3Manufacturing Engineering
A. Process Flow Diagram (actual or preliminary)
B. Process Control Plan (actual or preliminary)
C. Suggested list of parts requiring additional care, KPC/PQC, the related KCC
D. Part Prints/Drawings, if applicable
E. A sample of a similar part
F. Process Failure Mode Effect Analysis (actual or preliminary)
G. Details of continuous quality improvement plan for the program
H. Statistical Process Control and Process Capability Data on current production
I. Timing chart for tooling/gauging, etc
J. Measurement System Analysis, if available
15.6KCDS Engineering
A. KCDS (Training) presentation materials
B. Examples of KPC/PQC the related KCC, parts requiring additional care and
Process Control Plans
C. Variation Simulation Modeling
D. Quality Function Deployment data (requirements), where applicable
E. Vehicle Technical Specifications (VTS)
F. Manufacturing Technical Specifications (MTS)
15.7Buyer
A. Part/Supplier listings
B. Cost objective/concerns on cost related issues
C. Status on early sourcing of suppliers
D. Information regarding profile of the supplier, if sourcing is completed
17.0Reference Section
Global KCDS Web Address
http://gmna1.gm.com/vic/sepm/kcds/
EN-04-W-VDP7070, KCDS (Key Characteristics Designation System) Process: Identify, Document and Communicate
Product Characteristics, Functional Checks, Safety/Compliance and Product Identification, Verification and Traceability