1 supplier program review meeting #1 gm1927-15 apqp kick-off meeting advanced product quality...

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Supplier Program Review Meeting #1

GM1927-15APQP Kick-off Meeting

Advanced Product Quality Planning

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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.

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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

4

Background

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

APQP

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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

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GM 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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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


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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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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

AD

VA

NC

E P

LAN

NIN

G &

PR

EV

EN

TIO

N

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)

PRO

BLEM

RESO

LUTI

ON

GM Global APQP

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 3G M P r e - s o u r c i n g

P l a n a n d D e f i n eP 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 t

A 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 tP 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


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

SQ Global APQP

Combination of the Best Processes

Experience

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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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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


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 3G M P r e - s o u r c i n g

P l a n a n d D e f i n eP 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 t

A 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 tP 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


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


A P Q P T a s k










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



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





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




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

SQ Global APQP

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APQP Project PlanAPQP 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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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


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


A P Q P T a s k










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



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





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




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

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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 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

TODAY

Overview

15

4) Supplier Program Reviews

• 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

Supplier Program Reviews 2,3,4

Task 6

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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

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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

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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

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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

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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

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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

25

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

26

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

27

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

28

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

30

• SQ Requirements

• Program Timing

• Review 1927-14 Checklist

• Open Issues

• Summary

APQP Kick-off Meeting



November 2000


GM

Agenda

31

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

32

• (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 Information Letter

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 prototype

tools, 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 occurrence

prevention /defect outflow detection. PFMEA strategy must strive for zero defects and include any lessons

learned from previous programs.15. ISO/TS 16949 or QS9000

Certification 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

33

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

Program Timing InformationAPQP Timing Chart Date Revised:___________

P ro gram Dates : Alpha__________ Beta _________ 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 dule 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 Charts Submitted

DFMEA

Feas ibility/As s es s ment Letters

- Des ign

- P ro to type

- Capability & Readines s

KCDS / GD&T

- KCDS wo rks ho p

- GD&T Co mple te /Math Drawing

Des ign Review

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

Gage Review

- Des ign

- Build

Meas urement Sys tem R&R

- Certifica tio n

Facility & Layo ut P lan

To o ling/Machinery P lan

P ro ces s Flo w Chart

- P re liminary

- P ro to type

- P ro ductio n

P FMEA Stra tegy

- P re liminary

- P ro to type

- P ro ductio n

RP N Reductio n P lans

P ackaging P lan

Tier 2 Timing P lan

GP -11

P ro ces s Capability Studies

Co ntro l P lan

- P re liminary

-P ro to type

- P ro duc tio n

P P A P s ubm itte d

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

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

Le s s o ns Le a rne d R e v ie ws

S upp lie r D e s igna te d A dd 'l In fo

Target A ctual

P la n t M a na ge r S igna ture :

S upp lie r P ro gra m R e v ie w # 1 D a te :




• 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.

35

APQP 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

Program Contacts

Who to Contact?

GM1927-17List the Key

Positions needed to

Manage New Programs

36

APQP Kick-Off Meeting Checklist

• Review 1927-14 Checklist

• Identify Open Issues- GM responsibility- Supplier Responsibility

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

• Drive all Issues to Closure!

APQP Kick-Off Meeting

The purpose of this meeting is to develop a common understanding between our companies concerning the totalrequirements of the part/material. The sequence of questions in this form follows the AIAG Advanced ProductQuality Planning and GM APQP Manual GM-1927. Its intent is to ensure that advanced product quality planningactivities occur at the appropriate time.

DATE: PROJECT/PROGRAM: SUPPLIER: LOCATION:

DUNS CODE:

PART NO: DESCRIPTION:

Introduction: Present the Common APQP Kick-Off Meeting Overview (Pre-Production Meeting) presentation tothe 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 factorscritical to the customer?

A P Q P O p e n I s s u e sS u p p l i e r /M f g L o c a t i o n : P a r t N u m b e r ( s ) : D u n s N u m b e r : S u p p l i e r C o n t a c t : P r o g r a m ( s ) : G M S Q E C o n t a c t : P a r t N a m e :

* T y p e K e y : S = D e s i g n - S u p p l i e r T = T o o l i n g M = M a n u f a c t u r i n g / P r o c e s s R = P r o d u c t i o n C o n t r o lG = D e s i g n - G M C = C a p a c i t y O = O t h e r : _ _F = F a c i l i t i e s L = L a t e R e l e a s e P = P u r c h a s i n g

I s s u eN o .

I s s u eD a t e

S e v e r i t yI s s u e s

D e s c r i p t i o n a n d / o r S k e t c h

P e r s o nR e s p o n s i b l e

( N a m e )

*T y p e

A c t i o n P l a n&

P r o g r e s s t o P l a n

F o r e c a s tC o m p l e t i o n

D a t eS t a t u s

S t a t u s :2 5 % I s s u e I d e n t i f i e d 7 5 % A c t i o n P l a n I m p l e m e n t e d

5 0 % A c t i o n P l a n P r o p o s e d 1 0 0 % I s s u e R e s o l v e d

S e v e r i t y : 1 - D i r e c t o r S u p p o r t 2 - M a n a g e r / S u p e r v i s o r S u p p o r t

3 - S Q E S u p p o r t

A P Q P O p e n I s s u e s . D O CJ u n e 1 9 9 9

G M - 1 9 2 7 - 5

APQP Open Issues

37

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-Suppliers

38

• 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!!

1 supplier program review meeting #1 gm1927-15 apqp kick-off meeting advanced product quality...

Documents

background apqp

apqp deliverables

gm global apqp gm

parties apqp slide

divisional apqp manuals

common global apqp process

apqp direction establishment

apqp structured method