Supplier Program Review Meeting #1

Advanced Product Quality Planning

APQP Kick-off Meeting
1

GM1927-15

Supplier Program Review Meeting #1

Purpose:
Communicate the process that will be used to provide program updates for APQP Deliverables. Confirm APQP communication Channels between Supplier and GM. Ensure that GM requirements are understood. Understand current program status to ensure conformance to GM Timing. Provide a formal process to raise open issues for resolution. Form joint focus on future steps.
2

Agenda Background
- APQP - Global APQP Development
GM
General Motors Corporation

APQP Project Plan Overview APQP Kick-off Meeting

- SQ Requirements - Program Timing - Review Checklists - Identify Open Issues

Advanced Product Quality Planning

Worldwide Purchasing

Summary
3

November 2000

Background

APQP
Definition:
Advanced Product Quality Planning -- APQP Structured method defines and establishes steps necessary to ensure product meets customer requirements Required for all new parts Responsibility of the supplier

Purpose & Structure:

Communicates the requirements necessary to develop a product quality plan Top Management support by the supplier is key to the success of the any APQP process Requires an environment of trust and cooperation between all parties
4

Background QS- 9000 APQP Direction

Establishment of an Advanced Product Quality Plan
QS-9000 section 4.2.3.1 requires the establishment of an advanced product quality plan AIAG APQP Manual is referenced as the document that should be used Detail of specific deliverables was not clearly defined Separate unique Regional & Divisional requirements developed

Global APQP Development

GM Global APQP
GM

GM-1927 is the General Motors Common Global APQP Manual

General Motors Corporation

GMs common direction for the development and implementation of an APQP plan
Advanced Product Quality Planning
Worldwide Purchasing

November 2000

Global APQP Development

Common Global APQP Process for GM Worldwide
GM-1927 replaces all regional and divisional APQP reference manuals GM-1927 harmonized and standardized the multiple regional and divisional APQP manuals Aligns with the 5 phases within the AIAG APQP manual and provides the detail required to implement an APQP plan Aligns with GMs 4 Phase Program Timing and Deliverables

Global APQP Development

GM 1927 Documents and Forms
Ordering:
Ordering information for all documents and manuals listed or referenced throughout this manual (GM 1927) is contained on page II

Electronic Copies:
This manual and all documents that are part of this manual (this includes any document with a GM 1927 number) can be found through the internet at the GMSupplyPower website The address is www.gmsupplypower.com, then follow these steps: Log in Select Quality Power Select Library Select Supplier Quality Select APQP Manual & Documents
8

o bination of t e Best Pro esses

WWP SUPPLIER QUALITY IMPROVEMENT PROCESS
GLOBAL SOURCING IMPROVEMENT MEETING QUALITY WORKSHOP LEVEL II CONTROLLED SHIPPING LEVEL I CONTROLLED SHIPPING SUPPLIER QUALITY PROCESSES & MEASURES (GP-5) PERFORMANCE MONITORING

TIME LINE
EARLY PRODUCTION CONTAINMENT (GP-12) RUN @ RATE (GP-9) PRODUCTION PART APPROVAL (PPAP) PROTOTYPE SAMPLE APPROVAL (GP-11) PRE-PRODUCTION MEETING

CONTINUOUS IMPROVEMENT (GP-8)

LIFE OF PART

GM Global APQP
Global APQP
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Global APQP Manual Contents

Preface Table of Contents RASIC Explanation of PMIs (Process Model Integration) PMIs for 17 Tasks / Deliverables Appendices Glossary
Advanced Product Quality Planning
Worldwide Purchasing

GM
General Motors Corporation

November 2000

The 17 Tasks are the Key for Success!

10

APQP Project Plan

Global APQP
4 P has e GM P has e P r e -so u r cin g P la n a n d D e fin e P has e 1 P has e 2 P has e

SQ
A PQ P Project Plan
R
-4 0 SSF 4 8 12 1 o o
C o m p le te ( Pla tf o r m

A IA G

-88 -84 -8 B e ta

-7

-72 - 8 - 4 P r o to

-5

-52 -48 -44 -40 F E1 F E2 F E3

- 2

-28 -24 -20 P P AP

-1

-12 -8 P ilo t

PR-2

PR-3

A P QP T a sk 1 K ey S tak eholder's M tg 2 Tec hnic al R eview s

P R -1 P R -1 P R -1, 2,

o ------------o o --------o

R is k A s s es s m ent

TR
K i c k - o ff

o-----------------------o o o o o o o
f in a l

U p d a te R is k

Shows the linkage of the 17 deliverables to: GMs 4 phase timing GMs Sourcing Process

4 S upplier P rogram R eview s

i n i ti a l -

o o o o o o

5 Tim ing C harts /Open Is s ueR -1,2,3,4 P

i n i ti a l -

PR-4

PR-1

P rogra m R e vie ws

o o o o ---------------------o o o

6 F eas ibility Letters 7 F low C hart 8 DFME A 9 D es ign R eview 10 Gage R eview 11 GP -11 12 P F M E A S trategy 13 C ontrol P lan 14 GP -12 15 P P A P 16 R un @ R ate (GP -9) 17 Les s ons Learned

P R -1,2,3,4
i n i ti a l -

p r o to ty p e

P R -1,2,4 P R -1,2,4 P R -2,3 P R -2,3,4 P R -2,3

i n i ti a l -

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K CDS

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G D& T

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c onc ept

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d e s ig n g a g e a p p r o v a l,

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P R -1,2,3,4 P R -1,2,3,4 P R -4 P R -4

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f in a l

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p la n

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Pla

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AIAG APQP 5 phases within the APQP planning process The focus of the APQP Project Plan is on timing of each deliverable Levels of completeness for specific deliverables is clearly identified The required completion of items is tied to the specific GM build event

11

R SR

S QS

S S

S Q

P res ourc in g V DP -9 -92 Ge n e r ic A lp h a

APQP At a Glance
R

P r o d u ct D e sig n a n d D e ve lo p m e n t P r o ce ss D e sig n a n d D e ve lo p m e n t P r o d u ct a n d P r o ce ss V a lid a tio n F e e d b a ck, A sse ssm e n t a n d C o r r e ctive A ctio n

20

24

APQP Project Plan

APQP Project Plan
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GR-1

GR-1 GR-1 GR-1,3

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2 Technical Reviews Risk Assessment / 3 Sourcing Supplier Gate 4 Reviews Timing Charts / 5 Open Issues easi ility / Assessment Letters low Chart
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Update Risk

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Initial-TR

GR-1,2,3,4
Initial-TR

GR-1,2,3,4
Initial -TR

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KCDS Workshop

GD T

Prod Concept-TR

Gage Concept Approval

Gage Design Approval

Gage Approval/R R, Tool Completion

GR-1,2,3,4 GR-2,3
Initial-TR

o o o
Initial-TR

o
Execute

o
Execute

o o o o

11 GP-11 12 PFMEA 13 Control Plan 14 GP-12 15 PPAP 16 Run @ Rate (GP- ) 17 Lessons Learned
x

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Prototype / RPN Baseline

Production / RPN Reduction

GR-1,2,3,4 GR-1,2,3,4
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Prototype

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Plan

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Execute

GP-12 & Production

GR-3,4 GR-4
Plan Capacity Analysis

o o

Capacity Analysis

Conduct Run@Rate

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12

Design Reviews Gage, Tooling and 10 Equipment Reviews

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Prototype

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Production

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Update

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APQP Project Plan

APQP Project Plan
4 Phase
GM

Phase 0
Pre -sourcing Pla n a nd De fine

Phase 1

Phase 2

Phase 3

AIAG

Product De sign a nd De ve lopme nt Proce ss De sign a nd De ve lopme nt Product a nd Proce ss Va lida tion Fe e dba ck, Asse ssme nt a nd Corre ctive Action

Start Here Task 4

VDP Ge ne ric Progra m Re vie ws

Presourcin g

-96 -92 -88 -84 -80 -76 -72 -68 -64 -60 -56 -52 -48 -44 -40 -36 -32 -28 -24 -20 -16 -12
Be ta Proto FE1 FE2 FE3 PPAP Pilot

-8

-4

0
SSF

12

16

20

24

Alpha

PR-2

PR-3

APQP Ta sk

1 Key Stakeholder's Mtg 2 Technical Reviews 3 Risk Assessment

PR-1 PR-1 PR-1, 2, 3

o------------o o--------o TR
Kick-off

Supplier Program Reviews

o-----------------------o
o o o o o o
f inal Update Risk

4 Supplier Program Reviews

initial-

o o o o o o

o o o o---------------------o o o

5 Timing Charts/Open Issue PR-1,2,3,4

initial-

6 Feasibility Letters 7 Flow Chart 8 DFMEA 9 Design Review 10 Gage Review 11 GP-11 12 PFMEA Strategy 13 Control Plan 14 GP-12 15 PPAP 16 Run @ Rate (GP-9) 17 Lessons Learned

PR-1,2,3,4
initial -

prototype

PR-1,2,4 PR-1,2,4 PR-2,3 PR-2,3,4 PR-2,3

initial -

o o
KCDS

o----------------o o
GD&T

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concept Pla

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design complete/sta prototype f inal gage approval,

o-------------------------------------------------------------------------------------------------------------o
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prototype o---------------o

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Complete (Platf orm

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plan

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o

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13

Task 4) Supplier Program Reviews Overview

Purpose:
Ensure Suppliers Quality Plan is Progressing to Meet GM Program Timing Provide a Formal Process to Raise Issues for Resolution

Four Major Program Reviews: TODAY

Pre-Production Meeting (APQP Kickoff) Beta Prototype Build Review Gamma Prototype Build Review Pilot (Final PPAP Submission) Review

Meeting Responsibility:
Pre-Production Meeting is Scheduled by SQE Meetings 2, 3, 4 are Scheduled by Supplier

14

4) Supplier Program Reviews

Supplier Program Reviews 2,3,4

Meeting Subjects Include:
APQP Major/Open Issues List APQP Timing Chart Updates Progress of Tooling/Fixtures/Gages Task 6 Supplier Manufacturing Assessment Letters (3 letters) Lessons Learned Design Issues RPN Reduction Plans Suppliers need to be AIAG New Equipment Checklist (A-3) prepared for each AIAG Process Flow Checklist (A-6) meeting with supporting AIAG PFMEA Checklist (A-7) documents AIAG Control Plan Checklist (A-8) GP-12 Plan

SQEs will Review Documents at Meetings

15

5) Timing Charts / Open Issues

Purpose:
Ensure Program Deliverables are Executed on Schedule

SQE Responsibility:
Review the APQP Timing Chart and APQP Issues List Identify and Communicate Key Timing and Program Issues with GM Management

Supplier Responsibility:
Create and maintain an APQP Timing Chart and Open Issues List Maintain Detail behind Each High Level APQP Chart Review Timing Chart and Issues List at All Program Reviews Identify and Communicate Any Changes to SQE Identify and Communicate Key Timing and Program Issues with SQE

16

6) Manufacturing Assessment Letters

Purpose:
Supplier Evaluates Manufacturability of the Part

Manufacturing Assessments:
Design -- can the Design be Manufactured to Conform to all GM Performance Requirements? Prototype -- using the Intended Production Process, will all Parts Conform to GM Requirements? Process Capability -- will the Production Process Provide Parts that Conform to GM Requirements?

Supplier Responsibility:
Evaluate Feasibility during 3 stages of program development Submit Letters Signed by the Manufacturing Plant Manager
17

6) Manufacturing Assessment Letters

ABC Company 123 Part Lane Anywhere, Michigan 48000 (313)777-7777 July 12, 1997 GM Supplier Quality Engineer GM Release Engineer General Motors Corporation SUPPLIER MANUFACTURING ASSESSMENT OF DESIGN As required by General Motors, ABC Company held a manufacturing review of the Model Year design on date. The review has led us to the following position: (Select one) Manufacturing is confident the design is manufacturable to GM required quality levels, within PPAP design specifications, and within PPAP capability requirements. Manufacturing is making a commitment to achieve zero defects as specified in the GM Supplier Quality Statement of Requirements. There are no concerns to report. Manufacturing has minor concerns about the design which have been reported to the design community and are described below. We are confident that the design will be modified to accommodate our issues and be manufacturable to GM required quality levels, within PPAP design specifications, and within PPAP capability requirements. Manufacturing is making a commitment to achieve zero defects as specified in the GM Supplier Quality Statement of Requirements. Manufacturing has major concerns about the design and we are not confident that we can produce this part at required quality levels. These concerns are described below.

Design Is Manufacturable to GM Required Quality Levels Manufacturing is making a commitment to achieve zero defects..

Minor concerns about the design .. Confident that design will be modified..manufacturable to Required Quality Levels commitment to achieve zero defects.. Major concerns about design, not confident part can be produced at GM Required Quality Levels

18

7) Flow Chart
Purpose:
Provide a Logical Pictorial Representation of the Process Flow that can be used as the Foundation for PFMEAs. Control Plans, Work Station Layouts, etc.

SQE Responsibility:
Review Process Flow Charts at Sourcing (if available), at Prototype, at Production Part Approval and Regular Production Ensure that the Production Version is linked to the PFMEA and Control Plan Ensure that the Flow Chart Includes Inspection and Rework

Supplier Responsibility:
Create Preliminary Process Flow Chart using a Similar Process Create and Maintain the Flow Chart through Prototype and into Production Ensure the Flow Chart is Linked to the PFMEA and Control Plan Communicate any Changes to the SQE

19

8) Design Failure Mode and Effects Analysis

Purpose:
Support the Design Process in Reducing the Risk of Failure

SQE Responsibility: Confirm that a DFMEA has been Completed

Ensure that Supplier has a DFMEA for input to PFMEA Lessons Learned Checklist to Design Owner

Supplier Responsibility: GM Design Responsible

Suppliers must participate in DFMEA Reviews with Product Engineer Share Knowledge and Experience on Similar Designs Recommend Action Plans for Severity, Occurrence, Detection Targets Supplier Design Responsible Lead Cross-functional Team to Develop and Improve FMEA Schedule Review Meetings with GM Product Engineer Develop Action Plans for Severity, Occurrence, Detection Targets Maintain DFMEA for PPAP Submission
20

9) Design Reviews
Purpose:
Ensure that the Design has been adequately Defined to Build Tools and Gauges

SQE Responsibility:
Participate in KCDS Workshop and GD& T Reviews

Participate in Design Reviews addressing changes in Manufacturing Process/

Quality/Timing/ Risk

Supplier Responsibility:
Participate in KCDS Workshop and GD& T & Design Reviews Participate in Defining Measurable KPCs Participate in Defining Appearance Specifications Satisfy all Performance and Material Testing Requirements Ensure that the Manufacturing Process can achieve Tolerances on a Continuing Basis Quality of the Design Directly Impacts Process Design and Process Quality

21

10) Gage, Tooling & Equipment Reviews

Purpose: Ensure that the Manufacturing process is being designed, built and certified to
produce parts with quality at rate according to GM program requirements

SQE Responsibility: Confirm that Gage, Tooling and Equipment Timing is on Schedule to Support
Program Requirements Confirm that the Gauge Agrees with the Functional Part Usage, Complies with GD&T, Includes Measurement of KPCs and is at the Correct Change Level Ensure Gage is Used as Indicated in Process Flow Chart and Control Plan

Supplier Responsibility: Design, Build and Obtain Certification of Gages

Participate in Reviews with General Motors Relative to Design, Build and Certification of the Gage

22

11) GP 11 Prototype
Purpose:
Ensure Part Problems are Identified and Corrected in order to Minimize the Impact of Part Variation upon Design Evaluation, Manufacturing, and Assembly.

Supplier Responsibility:
Adhere to Requirements Specified in GP-11. Ship Parts and Documentation as Specified in GP-11 and the Prototype Purchase Order. Respond to and Resolve Issues Identified in Prototype Build. Revise the Flow Chart, PFMEA, and Control Plan as Problems are Identified throughout GP-11 and the Prototype Build. Update the APQP Open Issues List and APQP Timing Chart as Problems and Changes Occur.

Prototype will act as a Mirror for Problems that will Appear at Pilot = Address Issues Early in Program!
23

12) PFMEA Strategy

Purpose:
Assure Potential Failure Modes of the Process have been Considered and Addressed

SQE Responsibility: Attend initial PFMEA Development Team Meeting

Monitor Progress and Review PFMEA with Supplier

Supplier Responsibility: Initiate PFMEA prior to Sourcing as part of the Quotation to GM

Drive Error Prevention and Detection throughout the Process Prepare PFMEA - Multi-disciplinary team Insure that PFMEA results have been incorporated into Control Plan Revise PFMEA if Process / Material / Manufacturing Location Changes Develop and Implement RPN Reduction Plans

24

13) Control Plans

Purpose:
Define the Method being used to Control all KPCs and KCCs for Parts being Manufactured for Vehicle Builds.

SQE Responsibility:
Verify use of PFMEA & Statistical Data to determine Necessary Controls
Verify Update of Control Plan with Solutions from PFMEA Verify Pre-Launch Issues have been Incorporated into Production Plan

Supplier Responsibility:
Develop Pre-sourcing Control Plan Ensure Control Plan Flows from PFMEA & Process Flow Chart Use Pre-Launch Control Plan to Validate Production Control Plan Update Control Plan

Process Control Plan Audits will be Conducted at Run@ Rate

25

14) GP 12 Early Production Containment

Purpose: Establish a Containment Plan during Start-up and Acceleration that will
Quickly Identify Quality Issues at the Suppliers Facility; i.e., a Pre-Launch Control Plan.

SQE Responsibility:
Provide GP-12 Timing to the Supplier Review the Suppliers Process and Pre-Launch Control Plan Verify that any PR&R, Prototype or Pilot Issues are in Control Verify that the Supplier used PFMEA & Statistical Data to Set Controls

Supplier Responsibility:
Develop the Pre-Launch Control Plan Based on Experience from Prior Issues Implement the Pre-Launch Control Plan Monitor GP 12 Data and Modify Internal Process to Eliminate Issues Monitor Customer Issues and PR&Rs, Update Control Plans
26

15) Production Part Approval Process

Purpose: Determine if All Customer Engineering Design Records & Specifications
Requirements are properly understood by the Supplier and that the Process has the Potential to Produce Product Meeting these Requirements during Production at the Quoted Rate.

SQE Responsibility: Review PPAP Documentation Prior to Submission

- Verify Completion of all 19 Required Items - Many Documents Can be Reviewed in Advance of PPAP Submission Follow-up on PPAP Rejections

Supplier Responsibility:
Produce Parts in the Production Environment Complete all Documents and Test Requirements in Advance of PPAP Date Target for Full PPAP on First Submission
27

16) Run at Rate

Purpose: Verify that the Suppliers Actual Manufacturing Process is Capable
of Producing Parts that Meet:
- GMs On-going Quality Requirements - Quoted Tool Capacity - GMs Daily Volume Requirements

SQE Responsibility: Evaluate the Suppliers Run at Rate Plan

Determine if the Run at Rate should be Customer or Supplier Monitored Participate in Customer Monitored, or Review the Results of Supplier Monitored Confirm Actual Capacity Exceeds Quoted Capacity and GM Daily Requirements Status Run at Rate According to Results

Supplier Responsibility: Develop Run at Rate Plan and Review with SQE
Confirm Quoted Tool Capacity and Duration of Run at Rate Conduct Run at Rate, Complete Worksheets and Forward to SQE
28

17) Lessons Learned

Purpose: Review Experience from Previous Programs and Consider Opportunities to
Improve Performance on New Programs.

SQE Responsibility: Acquire Information about Previous Experiences with Similar Commodities
- Other SQEs, Local or in Other Regions - Product Engineers Share Personal Knowledge and Experience

Verify that the Supplier Applies Lessons Learned in New Process

Supplier Responsibility:
Share Lessons Learned from Similar Commodities Evaluate Lessons Learned from External Sources Incorporate All Applicable Items into Production Process and Tool Designs

29

APQP Kick-off Meeting

Agenda
GM

SQ Requirements

General Motors Corporation

Program Timing Review 1927-14 Checklist Open Issues

Summary

Advanced Product Quality Planning

Worldwide Purchasing

November 2000

30

Supplier Quality SOR

Supplier Quality has a Global Statement of Requirements that applies to all suppliers. SOR Included in the GM RFQ. Supplier Quotations to GM must include a signed copy of the SOR, indicating compliance to these requirements.

Supplier Quality Statement of Requirements

Please sign, date and return page 5 of this document with your bid package as record of your understanding of these requirements. Powertrain suppliers please sign, date and return page 6 also.

1.

All suppliers are expected to supply parts to General Motors with zero defects. Funding is to be identified in the initial quote and subsequent quotes to reflect error occurrence detection (poka yoke, error proofing devices, etc) and defect outflow prevention to customers. Controls implemented at a later date are the financial responsibility of the supplier.

2. ISO/TS 16949 or QS-9000 - Quality System Requirements

y

All suppliers to General Motors must be certified to one of these standards and have a current certificate available demonstrating compliance to GM supplements. These standards require an extensive, formal, audited evaluation of suppliers quality and manufacturing methods. The evaluation is conducted by a third party certified registrar. Suppliers not certified to ISO/TS 16949 or QS-9000, or those suppliers constructing or purchasing facilities to manufacture the parts being quoted, must include an outline of their certification attainment plan with their quote for further consideration.

3. General Motors Procedures and Reference Documents y

Suppliers are to adhere to the requirements contained in the following documents :  Advanced Product Quality Planning & Control Plan Reference Manual (AIAG)  Potential Failure Mode and Effects Analysis (FMEA) Reference Manual (AIAG)  Fundamental Statistical Process Control (SPC) Reference Manual (AIAG)  Measurement Systems Analysis (MSA) Reference Manual (AIAG)  Production Part Approval Process (PPAP) Manual (AIAG)  Key Characteristics Designation System (KCDS) GM-1805QN  GP-5 Supplier Quality Processes and Measurements Procedure. GM-1746  GP-7 Component Verification and Traceability Procedure. GM-1730  GP-8 Continuous Improvement Procedure. GM-1747  GP-9 Run @ Rate. GM-1960  GP-10 Evaluation and Accreditation of Supplier Test Facilities. GM-1796  GP-11 General Procedure for Pre-Prototype and Prototype Material. GM-1820  GP-12 Early Production Containment. GM-1920  GM-Supplier Technical Information GM-1825  Traceability Identifier Requirement TIR-15-300. GM-1731  Supplier Quality W eld Support Manual  Shipping Parts Identification Label Standard. GM-1724  Fixture Standards Requirement GM-1925  Operating Guide for Suppliers of Prototype Material NAO-0065

Signature of Supplier Representative

31

Required Quality Information Letter (GM1927-4 is Included in all GM RFQs. Supplier submits as part of Quote to GM, includes requested documents. Review Supplier Quality Information provided and discuss exceptions. Update APQP Open Issues List for exceptions.
32
Required Quality Information Please gather the following information in a binder or envelope marked Quality and submit it with your bid package. If you have any questions relative to the required information, please contact your GM Supplier Quality Engineer for clarification. All information must relate to the manufacturing site that the product will be manufactured and must reference the RFQ number and part numbers. All listed information is required in your Quote Package. Be prepared to answer questions during the Technical Review Meeting. Referenc Submitted Required information Explanation e documen t
1. Preliminary timing charts. 2. Review of the manufacturing facility. y y y y y 3. Preliminary process flow diagrams. 4. Location of Engineering and Technical Support 5. Warranty Risk and Reward Plan. y y y y y y y y y Highlight any concerns relative to tooling / testing that may impact providing a quality process/part on time. Where is it located? How long has it been in operation? What modifications to the facility would be required to support the RFQ volumes? Has any SQE from General Motors reviewed the facilities? If so, when? Include any special assembly techniques, test methods, and containment procedures utilized. Where will the engineering and technical support be located? How do they communicate to the manufacturing location? (If indicated by the GM buyer as a risk & reward commodity). What plans do you have in place to meet your IPTV targets? Capability studies on similar parts, along with plans for error proofing, data analysis, and record keeping must be included in plan Complete with error proofing, and any part traceability techniques Emphasis on people that will be involved from quality and program management. Proposed component suppliers and the plan to manage these suppliers (Your in-house resources/expertise, APQP, PPAP, R@R etc.) On similar parts that you manufacture for the Automotive Industry, and the tolerances assigned to those parts. PR/Rs and PPM to the Vehicle Assembly Centers. What is included in the tooling price? Describe in detail. How do you plan to track and maintain responsibility for all prototype tools, part fabrication, and GP-11? Included in the quote response? Does the manufacturing facility have the test capability on site? Including potential failures, potential causes, and error occurrence prevention /defect outflow detection. PFMEA strategy must strive for zero defects and include any lessons learned from previous programs. Proof ofCertification to GM specific requirements If the manufacturing facility does not have certification, submit your Certification timetable/implementation plan. (Suppliers with new facilities) Proof of compliance in accordance with ISO14001 and GM requirements or -Plan for achieving compliance by Jan. 2003 (GM required date). Describe your operator-training program. Are critical operations identified? Required by QS-9000 GM-1927-2 GM-1927-8

6. Preliminary Control plans 7. Organizational chart 8. Tier 2 plan

9.

Capability studies

y y y y y y y y

10. Plan to reduce major disruptions 11. Checking fixtures 12. Outsourcing of prototype manufacturing (if applicable) 13. Continuous Compliance testing 14. Preliminary PFMEA

GM-1927-9

15. ISO/TS 16949 or QS9000 Certification

y y

16. Environmental Management System 17. Operator-training program 18. Team Feasibility Commitment

y y y y y

QS-9000 3rd Edition 3/98, Section 4.2.3.3

Lessons Learned
Review Lessons Learned in GM SupplyPower website - Obtain worksheet on major components - Evaluate Lessons for application to new part
COMMODI Y CRI
N o. 1.0
p

RI

C H EC K
n

OR:

C riteria D escriptio
D ESI N
r s q

D escriptio

o f Issue

Issue C ode

1.1

1.5 1.6

2.0

M A N U F A C TU R IN G
Is there a m ethod to insure that all threads/holes are present in the yoke? Is there a m ethod to ensure that brake pads are not shy, possibly using a eigh station or vision system to m onitor this condition? Is there a m ethod to veri y l uid i ll level, i.e., m onitor or eigh stations? H as the process or design been error proo e d to prevent /H and /H caliper r om being reversed and in the proper position?
r r r r s r u s t

2.1 2.2

2.3 2.4

Discuss other Lessons Learned from similar parts Objective of this activity is --- Avoid Repeat Issues
33

rr

1.4

r r

1.3

rr

1.2

re m agnets secure on cover pan? Is there a m ethod to insure/prevent m agnets r om a lling o due to interaction bet een adhesive/oil or l at m agnet to round sur a ce? Is the sha t sti enough to prevent the sha t r om bending relative to the disc brake system and load conditions? H as the drain/ i ll plug integrity been properly de i ned to assure no loss o l uid? H as the F ront D i e rential S eal been validated at lo tem peratures to avoid cracking? Is the s age at the proper diam eter to prevent puddle eld leaks at the ax le tubes? H as a design/m ethod been validated to elim inate noisy ax les? (N um ber 1 W arranty Item )
r r rr s s s r r r

l o

m hl k

ih

x les

Su p p lier: D ate: R eso lutio

ta tus

Program Timing Information

Date Revi ed:____
|
QTR 2 '0 0 QTR 3 '0 0 QTR 4 '0 0 P A __________ B _________ G P
Tas k

A lp h a M R D B e ta M R D P ro t o t y p e / G A M M A M R D D e s ig n F re e z e D a t e

AP QP K C

EA

RP P

yS

P P AP R

GP L S

P la n t

S u p p lie r P ro g ra m S u p p lie r P ro g ra m S u p p lie r P ro g ra m S u p p lie r P ro g ra m

e v ie e v ie e v ie e v ie

34

@R

(G P 9 ) P

(P

a n a g e r S ig n a tu re :

GP

Suppliers complete the form and return it to the SQE - Updates showing progress are forwarded to the SQE - Detailed evaluations are conducted as part of future Program Reviews.

Sy

y &L y

yP

wC y

P P P

EA S

P P P

- GM 1927-2 provides the Minimum list of activities that must be tracked by the supplier

yA

y &R

KC S G & KC S w G & C R

P .O. R

Define Program Timing Elements -Major Program Benchmark Dates are provided by the SQE

F in a l P P A P S u b m is s io n R u n @ R a t e C o m p le t e D a t e P ilo t M R D S t a rt o f S y s t e m F ill ff

yG

R &R

' I f

#1 #2 #3 #4

D a te : D a te : D a te : D a te :

S u p p lie r R e s p o n s ib le C o nt a c t

GM R e s p o n s ib le C o nt a c t

A c t u a lS t a rt

La s t Up d a t e

_________ P _________ SS ___________ R qui d C o m le io n S c h e d u le d S u p p lie r GM D ate C o m le t e C o m p le t e R e v ie we d

QTR 1 '0 0

Target

| |{ ~   ~ x

P P Timing
w

art

~ v

~ ~  ~{ } |{

Actual

Program Contacts
M ND SUPPLIER PRO RAM CONTACTS
Part number: Model ear: DUNS : Phone: GM Phone (fax,mobile) SUPPLIER Phone (fax,mobile)

Proto PE Manuf. Engineer M Plant ep D&T

APQP Contact List.doc

35

Readiness Coord. Containerization Reliab. Engineer Paint Engineer Current SQE

M1927-17 List the Key Positions needed to Manage New Programs

Position d vance SQE Buyer Design Engineer E PPM

Name

Who to Contact?

Part name: M Pr ram: Supplier ame: Manufacturing o cation d dress: Supplier Mfg. Plant Manager:

E-mail

Position Project Manager Sales Mgr Design Engineer Quality Manager Laboratory Supv.

Name

E-mail

Packaging Engineer st Shift Contact 2nd Shift Contact 3rd Shift Contact SubContractor

GM1927-17

APQP Kick-Off Meeting Checklist

APQP Kick-Off Meeting

Review 1927-14 Checklist Identify Open Issues - GM responsibility - Supplier Responsibility

The purpose of this meeting is to develop a common understanding between our companies concerning the total requirements of the part/material. The sequence of questions in this form follows the AIAG Advanced Product Quality Planning and GM APQP Manual GM-1927. Its intent is to ensure that advanced product quality planning activities occur at the appropriate time. DATE: SUPPLIER: PROJECT/PROGRAM: LOCATION: DUNS CODE: DESCRIPTION:

PART NO:

Introduction: Present the Common APQP Kick-Off Meeting Overview (Pre-Production Meeting) presentation to the supplier (reference GM1927-15 Kick-off Meeting Presentation)

AIAG APQP Phase 1.0 related questions Customer Requirements

1. Does the supplier understand the application and intended end use of the part/material, including all factors critical to the customer?

APQP O APQP O
Program(s): Part Name:

II

ey:

Issue No.

Issue Date

Issues Descriptio and/or Sketch

*
Type

Action lan & Progress to Plan

Drive all Issues to Closure!

36

25% Issue Identi ied 50% ction Plan Proposed

75% ction Plan Implemented 100% Issue esolved

PQP pen Issues.D June 1999 -1927-5

Status:

Severity: 1 - Director Support 2 - anager/Supervisor Support 3 - SQE Support

S = Design-Supplier = DesignF = Facilities Severity

T = Tooling = apacity = ate elease

= anu acturing/Process = ther : P = Purchasing erson Responsible (Name)

= Production ontrol

*Type

Add Items to APQP Open Issue List (GM1927-5)

Supplier/ g ocation: Duns Number: Supplier ontact: SQE ontact:

Part Number(s):

Forecast Completion Date

Status

Requirements from Suppliers

Proactive Conformance to AIAG APQP Requirements and GM Global APQP Tasks
Develop Detail Plans for Each Part / System - Robust Part Designs ZERO DEFECTS - Robust Processes with Error-proofing Maintain Program Timing - Design Completion - Prototype Part Delivery - Accurate Sample Submissions and Part Delivery Identify Issues Early in Program and Drive Correction

Document on APQP Open Issues List

Maintain Communication with GM on Program Status and Issues -- Manufacturing Assessment Letters

Expect these Same Requirements from Sub-Suppliers

37

Summary
Proactive Conformance to AIAG APQP Requirements and GM APQP Tasks Supplier Drives Tasks 4 through 17 to Completion Identify Issues Early in Program and Drive Correction
Maintain Communication with GM on Program Status

and Issues
-- Manufacturing Assessment Letters -- Schedule Program Review 2,3,4 with the SQE

Expect these Same Requirements from Sub-Suppliers

Lets Get Going!!

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