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QUALITY PROCEDURE
Issue Date: 02/25/2002 NO: GQP-050 Page 1 of
4
Revision Date: 7/29/03
(Revisions in Red Italics)
Approval: Signature on file at Headquarters

FOREIGN MATERIAL CONTROLS

1. Purpose
1.1 To establish the minimum requirements and to log best practices for a foreign
material reduction process across GM Powertrain.

2. Responsibility
2.1 The plant Quality Systems Manager and/or Production Manager are responsible for
implementing this procedure at their site.

3. Scope
3.1 Foreign material shall be defined as: 1) sediment and 2) extra parts. This
procedure covers all assemblies, subassemblies, and components at GMPT engine,
transmission, and & component plants. Note: Casting Plants are defined in section
7.0 of this Procedure. Foreign material is referred to as Retained material.

4. Sediment Evaluation Requirements

4.1 GMPT plants shall have site-specific procedures and/or work instructions for
performing foreign material evaluations. (Refer to Engineering Standards
procedure #GMN6752 for minimum compliance requirements for sediment labs.)
NOTE: Casting plants do not require sediment labs in their plants due to the
nature of their business.

4.2 GMPT site leadership shall review sediment data to determine corrective actions
needed, at a minimum, monthly. Analysis may consist of reviewing SPC charts,
pareto charts, SPQRC data, sufficiency plans, or other plant metrics as
determined by the site.

4.3 Sediment-related customer complaints shall require corrective action. The Fast
Response system or PRTS shall be utilized for corrective action.

4.4 Cleanliness Level notes: may appear on Part Print drawings for current product
and will appear on Part Print Drawings for New Programs (July 2003 and later).
Refer to addendum GQP-050a section 4.5 for detail.

4.5 Sediment data Requirements: GMPT Plants shall post their sediment data to
the Powertrain Website as prescribed by their specific CPIT requirements.
 GQP-050 Foreign Material Controls Page 2 of 4

5.0 Sediment Reduction Process Controls

5.1 Washer Fluid/Deburr Operations
Application:
Applies to all product component washer/debur processes.
Purpose:
To define the minimum controls required to maintain washer integrity.
Minimum Requirements:
Each manufacturing site shall define in local procedures the method and frequency of checks
required to ensure washer/debur processes are functional as intended.

5.2 Metal Working Fluid Controls

Application:
Applies to all product component metal working fluid processes.
Purpose:
To define the minimum controls required to maintain metal working fluid quality.
Minimum Requirements:
Each manufacturing site shall define in local procedures the method and frequency of checks
required to ensure metal working fluid quality and cleanliness.

5.3 Fluid/Air Probe Flush Station Controls

Application:
Applies to all fluid/air probe flush station containing processes.
Purpose:
To define the minimum controls required to insure fluid/air probe flush station functionality.
Minimum Requirements:
Each manufacturing site shall define in local procedures the method and frequency of checks
required to ensure functionality of fluid/air probe flush stations.

5.4 Dunnage & Part Storage Systems

Application:
Applies to all dunnage and part storage systems.
Purpose:
To define the minimum controls required to reduce sediment caused by dunnage or part
storage in GMPT assemblies.
Minimum Requirements:
Each manufacturing site shall define in local procedures the method to verify materials and
processes involved in part storage and transport to minimize and/or eliminate sediment on
components.
 GQP-050 Foreign Material Controls Page 3 of 4

5.5 Part Handling Process Controls

Application:
Applies to all finished components and assemblies.
Purpose:
. To define the minimum controls to maintain part handling cleanliness.
Minimum Requirements:
Each site shall define in local procedures the method of checks and minimum requirements to
ensure parts handling cleanliness. This may be confirmed via the manufacturing site’s Layered
Audit process.

5.6 Purchased Part Requirements:

Application:
Applies to all Purchased Parts.
Purpose:
To define the minimum controls to monitor and reduce sediment on purchased parts that have
been deemed critical to product performance by the respective PET/CPIT Teams
Minimum Requirements:
Each site shall define in local procedures which purchased parts are to be monitored to ensure
ongoing sediment control and/or reduction. The respective CPIT Teams shall determine the
best method(s) to establish this system. Refer to GM Supply Power Bulletin #4249. Copy in
addendum GQP-050a. NOTE: The respective PET/CPIT teams determine continuous
improvement requirements.

6. Extra Parts Reduction Process Controls

Minimum Requirements:
Each Manufacturing Site shall include in their Layered Audit System the verification of
process controls used to either eliminate or reduce extra parts. (e.g., rollovers, correct
use of masks, magnetic socket functionality, etc.). When the primary process is not
functioning, site leadership shall implement an alternative/back-up method to minimize
risk. The alternative process must be documented (e.g., PPCR, Reaction Plan, Back-up
Work Instructions, etc.)

Transmission and Engine Plants shall keep record of pulls whose failures are due to
extra parts.
 GQP-050 Foreign Material Controls Page 4 of 4

7. Foundries – “As Cast” Shipped Requirements

Application:
Applies to all product shipped from castings.
Purpose:
To define the minimum controls required to maintain the retain-material standards.
Minimum Requirements:
Each casting plant shall define in local procedures the method and frequency of checks
required to ensure as cast product meets retain-material specifications. If the casting plant is
responsible for finish machining, Sections 5 and 6 also apply to the facility as required by the
customer.

8. Sediment Survey.
Sediment Survey available in addendum GQP-050a

9. Records
9.1 Record retention defined in local procedures.

This copy is provided for reference only. Contact GM for the latest revision
of this document.