1 Supplier Program Review Meeting #1 GM1927-15 APQP Kick-off Meeting (Long Version) Advanced Product Quality Planning

1

Supplier Program Review Meeting #1

GM1927-15APQP Kick-off Meeting (Long Version)

Advanced Product Quality Planning

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• Background - APQP - Global APQP Development

• APQP Project Plan Overview

• APQP Kick-off Meeting- SQ Requirements- Program Timing- Review Checklists- Identify Open Issues

• Summary

Agenda


Worldwide Purchasing

November 2000

General Motors Corporation

GM

3

• Background - APQP - Global APQP Development

• Requirements from Suppliers

• APQP Project Plan- Supplier Responsible Tasks 4 -- 17

• Summary

Agenda

Primary



November 2000


GM

4

Background

DefinitionAdvanced 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

APQP

5

Benefits

• Directs resources• Early identification of required changes• Facilitates avoidance of late changes• Enables delivery of a quality product that meets

program timing at required capacity

Background

APQP

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AIAG Linkage to QS-9000

AIAG--Automotive Industry Action Group

• Standardized reference manuals, procedures, reporting formats and technical nomenclature used by Ford, Chrysler and General Motors

• AIAG APQP manual one of 7 manuals developed; completed June 1994

– Provides general guidelines for development of an advanced product quality plan

QS-9000

• The Harmonization of Ford, Chrysler and General Motors individual Quality System requirements

– Ford--Q-101 Quality System Standards

– Chrysler--Supplier Quality Assurance Manual

– GM--Targets For Excellence

Background

7

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

Background

8

Drivers of a Global Common APQP Process

• Divisions and regions “Fine Tuned” the AIAG APQP process

• Result was different direction for suppliers

– different reporting formats for program updates

– different timing charts for program events

– varying levels of detail required at different times throughout the product development cycle

• Additional variation occurred when SQE’s further “Fine Tuned the requirements and developed unique forms or timing charts etc.

Background

9

Drivers of a Global Common APQP Process

• Global Suppliers and Global Vehicles compounds varying levels of direction

– This resulted in regional variations on the APQP process requirements

APQP

Background

APQP

APQPAPQP

10

General Motors Global APQP

• GM-1927 is the General Motors

Common Global APQP Manual

• GM’s common direction

for the development and

implementation of an

APQP plan

Global APQP Development



November 2000


GM

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Goals of this Common Global Process

• Identify the critical items

• Eliminate unnecessary requirements

• Support the the SQE and Supplier in performing the day-to-day APQP activities

• Eliminate the divisional & regional specific direction


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• Participation by a Global Team:

– GM North America --GM Europe

– GM Asia Pacific --GM Latin America

• Objective:

- Define the minimum product quality planning requirements

necessary to develop and implement an Advanced Product

Quality Plan for a product or service


13

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 GM’s 4 phase program timing and deliverables


14

Benefits

• Common APQP process for GM worldwide

– All GM divisions and regions will use the same process

– Common requirements

– Eliminates the need to keep separate files for programs due to divisional or regional “unique” requirements

• Common forms and charts

• Interactive computer system (GQTS APQP module)

– Facilitates timely communication of requirements and data

– Eliminates manual data storage

• Common direction and “One Voice” from all GM Supplier Quality Engineers regardless of region or division


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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


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Summary Points

• Global APQP driven by QS 9000 and AIAG APQP

• Common Global APQP Process for GM Worldwide- All GM Divisions and Regions will use the Same Process- Common Requirements for Suppliers- Common Forms and Charts

• Common Direction and “One Voice” from all GM Supplier Quality Engineers

• Supports Global SQ Communication Structure- Supplier Program Status will be Shared between Regions- All Information Available on GMSupplyPower website at www.gmsupplypower.com- GQTS APQP Module will Accelerate Global Communication

Primary


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Requirements from Suppliers

• Proactive Conformance to AIAG APQP Requirements and GM Global APQP Tasks

• Develop Detail Plans for Each Part / System- Robust Part Designs - Robust Processes with Error-proofing ZERO DEFECTS

• 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-SuppliersPrimary

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• The APQP Project Plan GM 1927-1, consists of

17 major deliverables/requirements

• These items if completed properly and on time should result in the development of a manufacturing system that is capable of meeting the GM Quality requirements at stated capacity and ship schedules.

Global APQP

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APQP 17 Tasks / Deliverables

- Key Stakeholders Meeting - Gage / Tooling / Equipment

- Technical Review Review

- Risk Assessment / Sourcing - GP-11

- Supplier Program Reviews - PFMEA Strategy

- Timing Charts / Open Issues - Control Plan

- Feasibility / Manufacturing Letters - GP-12

- Flow Chart - PPAP

- DFMEA - Run @ Rate (GP-9)

- Design Review - Lessons Learned

Global APQP

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Manual Contents

• Preface

• Table of Contents

• RASIC

• Explanation of PMI’s

(Process Model Integration)

• PMI’s for 17 Tasks / Deliverables

• Appendices

• Glossary

Global APQP

The 17 Tasks are the Key for Success!



November 2000


GM

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START OF PRODUCTION

RUN @ RATE (GP-9)

PRODUCTION PARTAPPROVAL (PPAP)

PROTOTYPE SAMPLEAPPROVAL (GP-11)

PRE-PRODUCTION MEETING

ADVANCED PRODUCT QUALITY PLANNING (APQP)

SOURCING DECISION

POTENTIAL SUPPLIERASSESSMENT

ADVA

NC

E PL

ANN

ING

& P

REV

ENTI

ON

WWP SUPPLIER QUALITY IMPROVEMENT PROCESS

LIFE OF PART

TIME LINE EARLY PRODUCTION

CONTAINMENT (GP-12)

GLOBAL SOURCING

IMPROVEMENT MEETING

QUALITY WORKSHOP

LEVEL II CONTROLLED SHIPPING

LEVEL I CONTROLLED SHIPPING

SUPPLIER QUALITY PROCESSES & MEASURES (GP-5)

PERFORMANCE MONITORING

CONTINUOUS IMPROVEMENT (GP-8)

PROBLEM

RESOLU

TION

GM Global APQP

Combination of the Best Processes

Experience

Primary

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APQP “At a Glance”

• Shows the linkage of the 17 deliverables to:

– GM’s 4 phase timing

– GM’s Sourcing Process

– 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

APQP Project Plan

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APQP Project Plan

Primary

APQP Project Plan

GM GVDP

Generic

APQP Task Gate

ReviewsSourcingActivities G

R-1

GR

-2

GR

-3

GR

-4

1Commodity Sourcing Strategy Mtg GR-1 o------o o

2 Technical Reviews GR-1 o------o o

3Risk Assessment / Sourcing GR-1,3 TR o o o

4Supplier Gate Reviews

5Timing Charts / Open Issues GR-1,2,3,4 o o o o o o o o o o o o o o o o o o o o o o o o o o o

6Feasibility / Assessment Letters GR-1,2,3,4 o o o o

7 Flow Chart GR-1,2,4 o o o o o o

8 DFMEA GR-1,2,4 o o o o o o o

9 Design Reviews GR-2,3 o o o o

10Gage, Tooling and Equipment Reviews GR-1,2,3,4 o o o o o

11 GP-11 GR-2,3 o o o o

12 PFMEA GR-1,2,3,4 o o o o o o o

13 Control Plan GR-1,2,3,4 o o o o o o

14 GP-12 GR-3,4 o o o

15 PPAP GR-4 o o

16 Run @ Rate (GP-9) GR-1,2,3,4 o o o o o o o

17 Lessons Learned GR-1,2,3,4 o o o o o

AIAG APQP

Pilot / Pre-LaunchPrototype Launch /

Feedback, Assessment and Corrective Action

ProductionProduct Design and Development

Planning

Process Design and DevelopmentProduct and Process Validation

Gage Concept Approval Gage Design Approval Gage Approval/R&R, Tool Completion

KCDS Workshop

Production

Plan

Initial-TR

Initial -TR

Initial-TR

Initial-TR

GD&T

GP-12 & Production

Exit (Platform Discretion)

Initial-TR

Initial-TR

Plan

Update Risk

Prod Concept-TR

Conduct Run@Rate

StructureVehicle

IntegrationVehicle

Validation Vehicle

MVBs SOPMVBns

Alpha Beta Gamma / Proto

Pre-Pilot / Pilot 1

Pilot / Pilot 2

FE1 FE2 FE3 SSF

Capacity Analysis

Letter 2 Letter 3 Letter 4

Update DFMEA RPN Reduction

Execute Execute

Prototype / RPN Baseline

Prototype

Production / RPN Reduction RPN Reduction

Prototype

Execute

Capacity Analysis

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A P Q P P r o j e c t P l a n

4 P h a s e P h a s e 0 P h a s e 1 P h a s e 2 P h a s e 3

G M P r e - s o u r c i n gP l a n a n d D e f i n e

P r o d u c t D e s i g n a n d D e v e l o p m e n tA I A G P r o c e s s D e s i g n a n d D e v e l o p m e n t

P r o d u c t a n d P r o c e s s V a l i d a t i o n

F e e d b a c k , A s s e s s m e n t a n d C o r r e c t i v e A c t i o n

V D P

P r e -s o u r c i ng - 9 6 - 9 2 - 8 8 - 8 4 - 8 0 - 7 6 - 7 2 - 6 8 - 6 4 - 6 0 - 5 6 - 5 2 - 4 8 - 4 4 - 4 0 - 3 6 - 3 2 - 2 8 - 2 4 - 2 0 - 1 6 - 1 2 - 8 - 4 0 4 8 1 2 1 6 2 0 2 4

G e n e r i c A l p h a B e t a P r o t o F E 1 F E 2 F E 3 P P A P P i l o t S S F

A P Q P T a s k

P r o g r am R e v i e

w s PR-1 PR-2 PR-3 PR-4

1 K e y S t a k e h o l d e r ' s M t g P R - 1 o - - - - - - - - - - - - o

2 T e c h n i c a l R e v i e w s P R - 1 o - - - - - - - - o

3 R i s k A s s e s s m e n t P R - 1 , 2 , 3 T R o - - - - - - - - - - - - - - - - - - - - - - - o

4 S u p p l i e r P r o g r a m R e v i e w s o o o o

5 T i m i n g C h a r t s / O p e n I s s u e sP R - 1 , 2 , 3 , 4 o o o o o o o o o o

6 F e a s i b i l i t y L e t t e r s P R - 1 , 2 , 3 , 4 o o o

7 F l o w C h a r t P R - 1 , 2 , 4 o o - - - - - - - - - - - - - - - - o o - - - - - - - - - - - - - - - - - - - - - o

8 D F M E A P R - 1 , 2 , 4 o o o

9 D e s i g n R e v i e w P R - 2 , 3 o o

1 0 G a g e R e v i e w P R - 2 , 3 , 4 o - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - o

1 1 G P - 1 1 P R - 2 , 3 o - - - - - - - - - - - - - - - - - - - - - o

1 2 P F M E A S t r a t e g y P R - 1 , 2 , 3 , 4 o o - - - - - - - - - - - - - - - - o o o - - - - - - - - - - - - - - - - - - - - - o o

1 3 C o n t r o l P l a n P R - 1 , 2 , 3 , 4 oo - - - - -- - - - - - - - - - - o

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

1 4 G P - 1 2 P R - 4 o - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - o

1 5 P P A P P R - 4 o - - - - - - - - - - - - - - - - - - o

1 6 R u n @ R a t e ( G P - 9 ) P R - 1 , 4 o o o - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - o

1 7 L e s s o n s L e a r n e d P R - 1 , 2 , 3 , 4 o o o o o o

P l a c o m p l e t e / s t a

c o n c e p t d e s i g n g a g e a p p r o v a l ,

K C D S

f i n a l

P l a

i n i t i a l -

i n i t i a l -

i n i t i a l -

G D & T

p r o t o t y p e

f i n a l p r o t o t y p e

f i n a l p r o t o t y p e

C o m p l e t e ( P l a t f o r m

i n i t i a l -T R

K i c k - o f f

i n i t i a l -

p l a n

U p d a t e R i s k

StartHereTask 4

APQP Project PlanS

up

plie

r A

cti

viti

es

Supplier Program Reviews

25

Task 4) Supplier Program Reviews

Four Major Program Reviews:

Purpose:

• Ensure Supplier’s Quality Plan is Progressing to Meet GM Program Timing• Provide a Formal Process to Raise Issues for Resolution

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

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

TODAY

Primary

Overview

26

Supplier Program Review #1 (PR#1)

• Conducted after the Sourcing decision:

-- GM SQE coordinates and leads this first review

-- Supplier responsibilities and deliverables are reviewed

• Purpose:

-- Ensure the GM Global APQP requirements and responsibilities are clearly communicated and understood

-- Verify Program timing and deliverables associated with program timing


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• Purpose: (continued)

-- Communicate process that will be used to provide program updates for APQP deliverables

• Supplier Program Reviews - 4

• Timing Chart GM 1927-1

• Program Tracking Chart GM 1927-2

• Feasibility & Manufacturing Assessment Letters - 4 GM 1927-19

-- Confirm APQP program communication channels within and between supplier and GM

• APQP Project Contact List GM 1927-17

28APQP Contact List.doc GM1927-17

Part name: Part number: GM Program: Model Year: Supplier Name: DUNS #: Manufacturing Location Address: Supplier Mfg. Plant Manager: Phone:

GM SUPPLIERPosition Name Phone (fax,mobile) E-mail Position Name Phone (fax,mobile) E-mailAdvanceSQE

ProjectManager

Buyer Sales Mgr

DesignEngineer

DesignEngineer

VLE PPM QualityManager

Proto PE LaboratorySupv.

Manuf.EngineerGM PlantRepGD&T

ReadinessCoord.Container-ization

PackagingEngineer

Reliab.Engineer

1st ShiftContact

PaintEngineer

2nd ShiftContact

CurrentSQE

3rd ShiftContactSub-Contractor

GM AND SUPPLIER PROGRAM CONTACTS

4) Supplier Program Reviews

Program Review #1 (PR#1)

Who to Contact?

GM1927-17List the Key

Positions needed to

Manage New Programs

29


• Review of Pre-Sourcing Quality Requirements

– Review items listed in the “Required Quality Information” letter

GM 1927-4 contained in the RFQ

– Review the “Supplier Quality Statement of Requirements” (SOR) GM 1927-3

• Review page 5 with the appropriate company representative signature

– Overview of the 17 APQP deliverables and explanation of each


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• (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.

Required Quality InformationPlease gather the following information in a binder or envelope marked “Quality” and submit it withyour bid package.If you have any questions relative to the required information, please contact your GM SupplierQuality Engineer for clarification. All information must relate to the manufacturing site that theproduct will be manufactured and must reference the RFQ number and part numbers. Alllisted information is required in your Quote Package.Be prepared to answer questions during the Technical Review Meeting.

Required information ExplanationReferencedocument

Submitted

1. Preliminary timing charts. Highlight any concerns relative to tooling / testing that may impactproviding a quality process/part on time.

GM-1927-2GM-1927-8

2. Review of the manufacturingfacility.

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?3. Preliminary process flow

diagrams.

Include any special assembly techniques, test methods, andcontainment procedures utilized.

4. Location of Engineering andTechnical Support

Where will the engineering and technical support be located? How do they communicate to the manufacturing location?

5. Warranty Risk and RewardPlan.

(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 plan6. Preliminary Control plans Complete with error proofing, and any part traceability techniques7. Organizational chart Emphasis on people that will be involved from quality and program

management.8. Tier 2 plan Proposed component suppliers and the plan to manage these

suppliers (Your in-house resources/expertise, APQP, PPAP, R@Retc.)

9. Capability studies On similar parts that you manufacture for the Automotive Industry,and the tolerances assigned to those parts.

10. Plan to reduce major disruptions PR/R’s and PPM to the Vehicle Assembly Centers.11. Checking fixtures What is included in the tooling price? Describe in detail. GM-1927-912. Outsourcing of prototype

manufacturing (if applicable)

How do you plan to track and maintain responsibility for all prototypetools, part fabrication, and GP-11?

13. Continuous Compliance testing Included in the quote response? Does the manufacturing facility have the test capability on site?

14. Preliminary PFMEA Including potential failures, potential causes, and error occurrenceprevention /defect outflow detection.

PFMEA strategy must strive for zero defects and include any lessonslearned from previous programs.

15. ISO/TS 16949 or QS9000Certification

Proof ofCertification to GM specific requirements If the manufacturing facility does not have certification, submit your

Certification timetable/implementation plan. (Suppliers with newfacilities)

16. Environmental ManagementSystem

Proof of compliance in accordance with ISO14001 and GMrequirements – or --

Plan for achieving compliance by Jan. 2003 (GM required date).17. Operator-training program Describe your operator-training program.

Are critical operations identified?18. Team Feasibility Commitment Required by QS-9000 QS-9000 3rd

Edition 3/98,Section 4.2.3.3


Required Quality Information

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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 RequirementsPlease sign, date and return page 5 of this document with your bid package asrecord of your understanding of these requirements. Powertrain suppliers pleasesign, date and return page 6 also.

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

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

All suppliers to General Motors must be certified to one of these standards and have a currentcertificate available demonstrating compliance to GM supplements. These standards requirean 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 theircertification attainment plan with their quote for further consideration.

3. General Motors Procedures and Reference Documents 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 Weld 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


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4) Supplier Program ReviewsAPQP Timing Chart Date Revised:___________

P ro gram Da te s : Alpha__________ Be ta _________ Gamma/P ro to _________ P ilo t_________ SSF___________

T a s k

S up p lie r R e s p o ns ib le

C o nt a c t

G M R e s p o ns ib le

C o nt a c tA c t ua lS

t a rtLa s t

Up d a t e

R e quire d C o m ple t io n

D a teS c he du le d C o m ple te

S upplie r C o m ple te

GM R e v ie we d

QTR 1 '0 0

QTR 2

'0 0

QTR 3

'0 0

QTR 4

'0 0

A lpha M R D

B e ta M R D

P ro to type / GA M M A M R D

D e s ig n F re e ze D a te

F ina l P P A P S ubm is s io n

R un @ R a te C o m ple te D a te

P ilo t M R D

S ta rt o f S ys te m F ill

AP QP Kicko ff Mtg

Timing Cha rts Submitted

DFM EA

Feas ibility/As s es s ment Le tte rs

- Des ign

- P ro to type

- Capability & Readines s

KCDS / GD&T

- KCDS wo rks ho p

- GD&T Co mple te /Ma th Drawing

Des ign Review

To o l P .O. is s ued by GM

Gage Review

- Des ign

- Build

M eas urement Sys tem R&R

- Ce rtifica tio n

Fac ility & Layo ut P lan

To o ling/M achine ry P lan

P ro ces s F lo w Chart

- P re limina ry

- P ro to type

- P ro duc tio n

P FM EA Stra tegy

- P re limina ry

- P ro to type

- P ro duc tio n

RP N Reduc tio n P lans

P ackaging P lan

Tie r 2 Timing P lan

GP -11

P ro ces s C apability S tudie s

Co ntro l P lan

- P re limina ry

-P ro to type

- P ro duc tio n

P P AP s ubm itte d

R un @ R a te (GP -9) P la n

GP -12 (P re -La unc h C o ntro l P la n)

Le s s o ns Le a rne d R e vie ws

S upplie r De s igna te d Add'l Info

Target Actual

P la nt M a na ge r S igna ture :

S upplie r P ro gra m R e vie w # 1 Da te :




Program Review #1 (PR#1)

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

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

• 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.

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Lessons Learned

• Review Lessons Learned in GM SupplyPower website- Obtain worksheet on major components- Evaluate Lessons for application to new part

• Discuss other Lessons Learned from similar parts

• Objective of this activity is --- Avoid Repeat Issues

COMMODITY CRITERIA CHECK LIST FOR: Axles Supplier:Date:

No. Criteria Description Description of Issue IssueCode

Resolution Status

1.0 DESIGN1.1 Are magnets secure on cover pan? Is there a

method to insure/prevent magnets fromfalling off due to interaction betweenadhesive/oil or flat magnet to round surface?

1.2 Is the shaft stiff enough to prevent the shaftfrom bending relative to the disc brake systemand load conditions?

1.3 Has the drain/fill plug integrity been properlydefined to assure no loss of fluid?

1.4 Has the Front Differential Seal been validatedat low temperatures to avoid cracking?

1.5 Is the swage at the proper diameter to preventpuddle weld leaks at the axle tubes?

1.6 Has a design/method been validated toeliminate noisy axles? (Number 1 WarrantyItem)

2.0 MANUFACTURING2.1 Is there a method to insure that all

threads/holes are present in the yoke?2.2 Is there a method to ensure that brake pads are

not shy, possibly using a weigh station orvision system to monitor this condition?

2.3 Is there a method to verify fluid fill level, i.e.,monitor or weigh stations?

2.4 Has the process or design been error proofedto prevent R/H and L/H caliper from beingreversed and in the proper position?


34


• APQP Major/Open Issues List• APQP Timing Chart Updates• Progress of Tooling/Fixtures/Gages • Supplier Manufacturing Assessment Letters (3 letters)• Lessons Learned • Design Issues• RPN Reduction Plans• AIAG New Equipment Checklist (A-3)• AIAG Process Flow Checklist (A-6)• AIAG PFMEA Checklist (A-7)• AIAG Control Plan Checklist (A-8)• GP-12 Plan

SQEs will Review Documents at Meetings

Meeting Subjects Include:

Suppliers need to be prepared for each

meeting with supporting documents

Primary

Supplier Program Reviews 2,3,4

Task 6

35

Timing Supplier Program Review #2 (PR#2)

• Program Review #2 (PR2) conducted 2 weeks prior to the Beta Prototype Build Review

– Supplier conducts the meeting and reports the status of the deliverables due for this review

• Purpose--Supplier Program Review #2

– Ensure the suppliers manufacturing process is capable of meeting GM’s requirements for the Beta Prototype Build Review (applicable for suppliers providing parts for Beta)

– Communicate issues that have been identified during the preparation for the Beta Build Review.

– Verify program timing for remaining APQP deliverables


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Specific Review Items

• Items designated on the APQP Project Plan GM 1927-1 with a 2 in Program Review column

– Timing Chart GM 1927-2

• Verify timing is on track

• Only require detail on items where timing has slipped

– APQP Open Issues list GM 1927-5

– Feasibility Letter #2- Supplier Manufacturing Assessment of Design

– Flow Chart-should be more detailed than the initial one due at the Technical Review

– DFMEA - status if design responsible, availability of data if GM design responsible

4) Supplier Program Review #2

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Specific Review Items-(continued)

– Control Plan--review and verification of continued development since initial review during

the APQP Kick-Off/Pre-Production meeting

– The same logic that applied to the PFMEA applies here

• If supplier currently produces a similar part, the Control Plan should be very

detailed

• If this is a new process for the supplier the level of detail will not be as complete

– This build event and the Prototype events are where the supplier clearly

identifies where error proofing techniques and audit type controls are

necessary


38

Specific Review Items -(continued)

– PFMEA Strategy--review and verification of continued development since initial

review during the APQP Kick-Off/Pre-Production meeting

– If supplier currently produces a similar part, the PFMEA should be very

detailed

• If this is a new process for the supplier the level of detail will not be

as complete

– Detail of Recommended Actions may not be

identified for all listed Potential Failure Modes

– Recommended Actions may not be completed


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Specific Review Items -(continued)

– Design Review-discussions should be around a KCDS workshop

• GM design responsible-GM leads workshop

• Supplier design responsible- Supplier leads the workshop or appropriate activity to identify the Key Product Characteristics

– Gage, Tooling & Equipment Review

• Gage Concept approval status

• Specific tooling timing-ensure timing is meeting the plan for the program timing

– GP-11--Discussions should take place between the supplier and the GM engineer on

the plan to provide parts for the Prototype build

– plan should include dimensional data requirements and the method of

collection necessary i.e. , CMM holding fixture, what is the serialization

process required etc.


40

Specific Review Items-(continued)

– Lessons Learned -- update of lessons learned identified during the process

to date

• Include design items and manufacturing items

• Items should be tracked back to the DFMEA if supplier is design

responsible

• Track manufacturing items back to PFMEA


41

• Insert a copy of GM 1927-10 and GM 1927--11

– these show overviews of how the Lessons Learned process was developed and should function


42

• Insert copy of GM 1927-12--this is a copy of the ACTUAL Global Lessons Learned criteria check-sheet that was developed for Exterior Mirrors.


43

Timing Supplier Program Review #3 -- (PR#3)

• Program Review #3 (PR3) conducted 2 weeks prior to the Gamma Prototype Build Review


• Purpose--Supplier Program Review #3

– Ensure the suppliers manufacturing process is capable of meeting GM’s requirements for the Prototype review (applicable for suppliers providing parts for Prototype)

– Communicate issues that have been identified during the preparation for the Gamma Prototype Build Review.



44

Specific Review Items (continued)





• These items are candidates for a “Launch Alert”


• What is the status of major items since the last review

– Feasibility Letter #3- Supplier Manufacturing Assessment of Prototype

• Signature required by manufacturing location plant management


45

• Insert a copy of “Supplier Manufacturing Assessment Of Prototype” GM 1927-19 letter 3


46


– Design Review

• KPC’s should have been identified through the KCDS Workshop process

• GD&T discussions should also be completed by the Prototype build event

– Gage/Tooling Review

• Gage Design approval status

• Specific tooling timing

– Require detail on any item where timing has slipped in relation to GM’s program timing


47


– GP-11--confirm the supplier has met the engineering requirements for Pre-

Prototype and Prototype builds

• This should include a review of the dimensional results and any quality issues

identified during the Prototype build

• Ensure the GM engineer is involved to approve any dimensional issues

– PFMEA Strategy--review and verification of continued development

• emphasis on items identified during any and Prototype manufacturing

processes (see Lessons Learned)


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– Control Plan--review and verification of continued development since Supplier Program

Review #2 meeting

• This should include all necessary controls and error proofing techniques

identified during all early build events

– Lessons Learned -- update of lessons learned that were identified during the Prototype

build process

• Include design items and manufacturing items

• These items should be tracked back to the DFMEA if design responsible

• Manufacturing items tracked back to PFMEA


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• Risk Assessment is updated for the current status in

program

– Review of the overall risk associated with the program is

updated by the SQE after Supplier Program Review #3

– This is reported to internal GM Program Management

Risk Assessment

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Timing Supplier Program Review #4 (PR #4)

• Program Review #4 (PR4) conducted 2 weeks prior the the Pilot Build Review


• Purpose Supplier Program Review #4

• “Dress Rehearsal” for PPAP

– Ensure the suppliers manufacturing process is capable of meeting GM’s requirements for the Pilot build.

• Manufacturing process and all support is to be representative of ALL Production systems and processes

– Communicate issues that have been identified since the Prototype Build Review



51

Specific Review Items


• All Quality documentation at this review is to be ready for PPAP submission




• These items are candidates for a “Launch Alert”


– Feasibility Letter #4- Supplier Manufacturing Assessment of Manufacturing Process Capability and Production Readiness

– Flow Chart--Ready for PPAP submission


52

• Insert copy of “Supplier manufacturing Assessment of Manufacturing Process Capability and Production Readinesss”

GM 1927-19 letter 4


53


• All Quality documentation (continued)

– DFMEA--completed if supplier is design responsible

– Gage/Tooling Review

• Gage R&R should be reviewed and acceptable

• Corrective Action plan reviewed if R&R is unacceptable

• Specific tooling timing at this point should be completed to schedule

– Any tooling issue is a “Launch Alert” candidate


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• All Quality documentation (continued)

– PFMEA Strategy--review and verification of evidence that supports RPN

reductions throughout the manufacturing process (see Lessons Learned)

– Control Plan--review and verification of evidence that indicates error

proofing techniques are in place and that all process operation are

controlled

– GP-12--review of the specific controls put in place to prevent defective

parts from reaching the GM manufacturing site

• This is the supplier’s Pre-Launch Control Plan, reference GM

1920


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– Run @ Rate--final details for the Run @ Rate should be confirmed, this

includes those parts designated as Customer or Supplier Monitored

– Confirm with the supplier the quantities required i.e. LCR and Contracted

Tool Capacity

– Lessons Learned -- ensure all lessons learned during the entire APQP process

have been documented in the appropriate quality documents

– DFMEA

• PFMEA

• Control Plans

This documentation is critical for future programs success


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5) Timing Charts / Open Issues

SQE Responsibility:

Purpose:

• Ensure Program Deliverables are Executed on Schedule

• 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

Primary

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6) Manufacturing Assessment Letters

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

Purpose: Supplier Evaluates Manufacturability of the Part

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ABC Company123 Part LaneAnywhere, Michigan 48000(313)777-7777

July 12, 1997

GM Supplier Quality EngineerGM Release EngineerGeneral 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 PPAPcapability requirements. Manufacturing is making a commitment toachieve zero defects as specified in the GM Supplier Quality Statement ofRequirements. There are no concerns to report.

Manufacturing has minor concerns about the design which have beenreported to the design community and are described below. We areconfident that the design will be modified to accommodate our issues andbe manufacturable to GM required quality levels, within PPAP designspecifications, and within PPAP capability requirements. Manufacturingis making a commitment to achieve zero defects as specified in the GM SupplierQuality Statement of Requirements.

Manufacturing has major concerns about the design and we are not confident that we canproduce 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 zerodefects..

Minor concerns about the design .. Confident that designwill be modified..manufacturableto Required Quality Levels…commitment to achieve zerodefects..

Major concerns about design, not confident part can be produced at GM Required Quality Levels…

6) Manufacturing Assessment Letters

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7) Flow Chart

SQE Responsibility:

Purpose:• Provide a Logical Pictorial Representation of the Process Flow that can be used as the Foundation for PFMEA’s. Control Plans, Work Station Layouts, etc.

• 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

Primary

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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

Primary

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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 KPC’s• 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

Primary

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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

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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!

11) GP 11 Prototype

Primary

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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

Primary

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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

Primary

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14) GP 12 Early Production Containment

Purpose:

• Establish a Containment Plan during Start-up and Acceleration that will Quickly Identify Quality Issues at the Supplier’s Facility; i.e., a Pre-Launch Control Plan.

SQE Responsibility:• Provide GP-12 Timing to the Supplier• Review the Supplier’s 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

Primary

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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

Primary

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16) Run at Rate

Purpose: • Verify that the Supplier’s Actual Manufacturing Process is Capable of Producing Parts that Meet:

- GM’s On-going Quality Requirements- Quoted Tool Capacity- GM’s Daily Volume Requirements

SQE Responsibility:• Evaluate the Supplier’s 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

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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

Primary

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• 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

Summary

Let’s Get Going!!

Primary