Phone on

“Vibrate”

Ground Rules

GM Global APQP for Suppliers

Manuel Yamada

Tel Aviv, Israel

April 12th, 2010

This is your class, feel free

to ask questions at any time!

• Introductions

• APQP Process and Expectations

• Project Plan

• Customer vs Supplier Monitored APQP

• APQP management in GQTS

• APQP Requirements

• GM Requirements

• Q & A

AGENDA

Global APQP Vision

• Become more proactive, by moving right side activities to the left

QSB for suppliers upfront after sourcing

Schedule early cross functional blitz audits on high risk suppliers

• Streamline the APQP Process to be more effective

Identify key deliverables for each quality gate during the APQP

process

Track and report the results of the agreed deliverables, not just

PPAP and R@R

The goal of a successful

program launch and mass

production is to provide:

“Quality @ Rate On Time”

Supplier Responsibility

GM

Global

APQP

AIAG APQP

ISO/TS 16949

7.1

Planning of Product Realization

Linkages of the ISO/TS 16949:2002, AIAG

APQP and Global Supplier Quality Manual

Background

Global APQP Team Goals & Results

Identify Quality Indicators

Develop Quality Tasks (17 total)

Develop Global Supplier Quality Manual, GM-1927

Reason: Global Sourcing and “World Vehicles”

GM APQP Global Process

Background

GM-1927

Global Supplier Quality Manual is

the General Motors Common Global APQP

Manual

GM’s common direction for the development and implementation of an APQP plan

Download from GMSupplyPower

Global APQP

Advanced Product Quality Planning

Worldwide Purchasing

November 2000

General Motors Corporation

GM

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

GM 1927 Documents and Forms

Summary Points

• Global APQP driven by ISO TS 16949 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 is shared between Regions

- All Information Available on GMSupplyPower website at

www.gmsupplypower.com

Global APQP

Customer Monitored

SQE – work closely with supplier

Supplier – work closely with GM SQE

Supplier Monitored

SQE – paper/electronic review of supplier

Supplier – keep GM aware

Customer Monitored APQP

Supplier Monitored APQP

Global APQP

GM Global APQP Monitoring

• Customer Monitored – SQE Responsibilities

• Assure quality @ rate on time

• Drive the supplier’s progress in the development of all quality related documents listed on APQP

Project Plan

• Raise issues that might jeopardize a quality part within the program timing – either to supplier’s or

GM’s upper management, as appropriate

• Participate in the remaining Supplier Gate Review meetings

• Adhere to supplier manufacturing site protocol when in the manufacturing facility

• Attend PDT and associated program meetings

• Drive/Enforce the process of supplier’s quality system development

• Apply APQP Workbook Audits and upload all Key Deliverables to GQTS

• Supplier Monitored – SQE Responsibilities

• Monitor the supplier’s adherence to program timing and track open issues addressing

• Customer Monitored – Supplier Responsibilities

• Execute the content and provide updates per the APQP Project Plan

• Implement an advanced product quality planning process with all sub-tier suppliers

• Invite and conduct all remaining Gate Reviews

• Work closely with GM SQE

• Supplier Monitored – Supplier Responsibilities

• Execute the content of the APQP Project Plan

• Implement an advanced product quality planning process with all sub-tier suppliers

• Responsible for meeting quality, timing and capacity requirements

• Provide parts for all GM build events

• Present tasks and deliverables of APQP Workbook internally in a management review and

submit the results to GM

• Notify SQE when quality issues arise that might affect program timing

SQE is the responsible for invite and conduct Gate #1 (Kick-Off Meeting) for all parts on both Customer or Supplier Monitored APQP

There is an inverse relationship –

Customer monitoring means more

responsibility for the SQE

Supplier monitoring means more

responsibility for the Supplier

Customer Monitored APQP vs

Supplier Monitored APQP

Global APQP

Global APQP Tasks changed as following:

01-Commodity Key Stakeholders Mtg

02-Technical Reviews

03-Supplier Eligibility

04-Gate Reviews

05-Timing Charts / Open Issues

06-QSB

07-Flow Chart

08-DFMEA

09-Design Reviews

10-Tooling & Equipment Reviews

11-Gage Development & Approval

12-PFMEA

13-Control Plan

14-GP-12

15-PPAP

16-Run @ Rate

17-Lessons Learned

01-Commodity Sourcing Strategy Mtg

02-Technical Reviews

03-Risk Assessment / Sourcing

04-Supplier Gate Reviews

05-Timing Charts / Open Issues

06-Feasibility / Assessment Letters

07-Flow Chart

08-DFMEA

09-Design Reviews

10-Gage, Tooling and Equipment Reviews

11-GP-11

12-PFMEA

13-Control Plan

14-GP-12

15-PPAP

16-Run @ Rate

17-Lessons Learned

Corporate Planning sets time frames

START OF

PRODUCTION

RUN @ RATE (GP-9)

PRODUCTION PART

APPROVAL (PPAP)

PROTOTYPE SAMPLE

APPROVAL (GP-11)

PRE-PRODUCTION MEETING

ADVANCED PRODUCT

QUALITY PLANNING (APQP)

SOURCING DECISION

POTENTIAL SUPPLIER

ASSESSMENT

GPSC SUPPLIER QUALITY IMPROVEMENT PROCESS

LIFE

OF PART

TIME LINEEARLY 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)

GM Global APQP

Combination of the Best Processes

1. Commodity Sourcing Strategy Meetings

The Commodity Sourcing Strategy Meeting is the responsibility of the Buyer –

Internal GM people only

The first time the SQE becomes “officially” involved in the APQP process

Commodity Sourcing Strategy Meeting is the first task that is tracked by the

APQP Project Plan

APQP Project Plan

GM GVDP

APQP Task

Gate

Reviews

Sourcing

Activities GR

-1

GR

-2

GR

-3

GR

-4

1

Commodity Sourcing

Strategy Mtg GR-1 o------o o

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

3

Risk Assessment /

Sourcing GR-1,3 TR o o o

4

Supplier Gate

Reviews

5

Timing 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 o

6

Feasibility /

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

10

Gage, 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 o

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

14 GP-12 GR-3,4 o 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 o

AIAG

APQP

Pilot / Pre-LaunchPrototype Launch /

Feedback, Assessment and Corrective Action

Production

Product Design and Development

Planning

Process Design and Development

Product 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

Structure

Vehicle

Integration

Vehicle

Validation

Vehicle

MVBs SOPMVBns

Capacity Analysis

Letter 2 Letter 3 Letter 4

Update DFMEA RPN Reduction

DFMEA

Execute Execute

Prototype / RPN Baseline

Prototype

Production / RPN Reduction RPN Reduction

Prototype

Execute

Capacity Analysis

Key points

Introduce and establish Key Stakeholder ownership, identify program-specific strategies in the Engineering & Advance Purchasing Sourcing Process (E&APSP) and ensure that the RFQ-package contains all information needed to receive comparable quotes.

Review potential bidders list proposed by Buyer to restrict Request for Quotation (RFQ) distribution to suppliers that meet GM criteria.

Identify suppliers that will require Quality Business Case action plans and start planning any required audits.

Review the requirements stated in the SQ SOR GM1927-3, and the Part-Specific Quality & Process SOR (if applicable) to ensure that they are be included in the Request For Quotation package (suppliers must be capable to meet those specific requirements if available).

1. Commodity Key Stakeholders Meeting (CKSM)

Available Data for Supplier Performance

- CT Bid List

- PSA/PCPA audit report

- GMSupplyPower (Six Panel Chart and Box Chart)

Supplier Commitment Letter is required for any suppliers to be sourced with not Green status

1. Commodity Key Stakeholders Meeting (CKSM)

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 (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 orpurchasing 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

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.

2. Technical Reviews

Review manufacturability, timing, design, manufacturing

capability, packaging, etc., issues related to a commodity.

NOTE: There may be situations where a TR is not held. SQE

must take responsibility for a review of the Quality info. This

should be done prior to performing the GPSC APQP

Assessment.

Attendees: Buyer, Engineer, SQE, Supplier, Manufacturing

Engineer, Other pertinent organizations

Outcome:

- Identifying suppliers that should not continue in the sourcing

process

- Initial GQSC APQP Assessment signed by the buyer, DRE and

SQE (this is required prior to signing the Sourcing

Recommendation form).

- Initial APQP Open issues list

Technical Review Checklist

Risk Assessment

Customer Monitored APQP

or

Supplier Monitored APQP

Risk Assessment

3. Sourcing Eligibility

For a supplier location to be eligible to receive a new business

award from GM the manufacturing location to be sourced must

either be:

• Green on the GM Creativity Team Bid List (CTBL) for Quality

for the specific commodity, OR

• Have a supporting Quality Business Case (QBC) QUAD report

approved according to the criteria outlined in this task.

Supplier is requested to provide necessary information as

required and support audit requests at short notice.

- Identifying suppliers that should not continue in the sourcing

process

- Initial GQSC APQP Assessment signed by the buyer, DRE and

SQE (this is required prior to signing the Sourcing

Recommendation form).

- Initial APQP Open issues list

109 Part J

4. Gate Reviews

The purpose of the Gate Reviews is to review the progress of all

APQP Tasks as stated on the APQP Project Plan GM1927-1 and

track the status and progress of items listed on the APQP Timing

Chart GM1927-2.

These review meetings are intended as an APQP team review of

the part and process development and to capture the lessons

learned from each build event. The Gate Review #1 (Kick-Off

Meeting) is coordinated by the GM SQE for all APQP parts.

Used to review the progress of items according to the APQP

Project Plan (GM1927-1) and track the status and progress of

items listed on the APQP Timing Chart (GM1927-2)

Key points

Intended as a Readiness Review of the supplier’s ability

to support specific GM build events and achieve both Full

PPAP and R@R according to the program requirements

Coordinated by the SQE

Conducted by the SQE on all parts tracked as

customer-monitored APQP

Conducted internally by the Supplier if the parts are

supplier monitored APQP

Aligned with GM build events

4. Gate Reviews

4. Gate Review

Key Deliverables

The Key Deliverable documents (see chart) are to be uploaded into GQTS. All other APQP documents and forms (referenced in the GM Global APQP Supplier Status Summary Workbook GM1927-34) are to be retained at the supplier location.

The Key Deliverables related to PPAP (e.g. GM1411, Dimensional Report, GM3660), must contain the GQTS PPAP activity code as reference.

4. Gate Reviews

Key Deliverables

4. Gate Reviews

Gate

Deadline

(Time from

SORP in

weeks)

GVDP 5.0 timing

reference Review

Key

Deliverables

Form/

Document

ALL GM Global APQP Supplier Status Summary

Workbook GM1927-34

Within 30 days of

business nomination

advice / contract

Gate 1

QSB Audit (Gap Analysis) or Greenfield

Checklist (Action Plan)

GM1927-30

GM1927-31

Timing Plan GM1927-2

Kick-Off Check list GM1927-14

-78

Initiated after CVER

and completed 5

weeks after IVER

Gate 2

PFMEA Check list GM1927-37

RPN Reduction Summary GM1927-21

Subcontractor Status GM1927-25

-52 Completed 10 weeks

prior Matching 1 GA Gate 3

Supplier ADV Plan (ADVP&R) showing

execution status GM1829

QSB Audit (Compliance) or Greenfield Checklist

(Complete)

GM1927-30

GM1927-31

Run @ Rate Capacity Workbook GM1927-35

-35 Completed 3 weeks

prior PPV MRD Gate 4

Dimensional Report GM1927-32

PPAP Worksheet (if not fully approved) GM1411

GP12 Audit GM1927-33

-15 Completed 1 week

prior MVBs MRD PPAP PPAP Approval

-8 Run @

Rate

Run @ Rate Execution R@R Module

PCPA GM1927-16

Kick off checklist (GM 1927-14)

Program team contact list (GM 1927-17)

APQP Timing chart

APQP open issue list

Initial PFD/PFMEA/PCP

Lessons learned

QSB Audit (Gap Analysis) or Greenfield Checklist (Action Plan)

Major disruption prevention plan

Delivery

Gate Review # 1 - APQP Kick Off Meeting

Who to

Contact?

GM1927-17

List the Key

Positions

needed to

Manage New

Programs

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 SUPPLIER

Position Name Phone (fax,mobile) E-mail Position Name Phone (fax,mobile) E-mail

Advance

SQE

Project

Manager

Buyer Sales Mgr

Design

Engineer

Design

Engineer

VLE PPM Quality

Manager

Proto PE Laboratory

Supv.

Manuf.

Engineer

GM Plant

Rep

GD&T

Readiness

Coord.

Container-

ization

Packaging

Engineer

Reliab.

Engineer

1st Shift

Contact

Paint

Engineer

2nd

Shift

Contact

Current

SQE

3rd

Shift

Contact

Sub-

Contractor

GM AND SUPPLIER PROGRAM CONTACTS

APQP Kick Off Meeting

Updated timing plans

Updated Open Issues

PFMEA checklist

RPN reduction summary

Subcontractor planning

Lessons Learned and best practice review

Major disruption prevention plan

Gate Review # 2

On-tracking timing chart, PFD/PFMEA/PCP, Quality improvement activities, tier supplier improvement status etc

Open issue review – Identify high risk open issues

QSB Audit (Compliance) or Greenfield Checklist (Complete)

Run @ Rate Capacity Workbook

Supplier ADV Plan (ADVP&R) showing execution status

PPAP plan and requirements

Gate Review # 3

Updated timing plans, PFD/PFMEA/PCP, Open Issues, Quality improvement activities, tier supplier improvement status etc

Dimensional Report

PPAP Worksheet (if not fully approved)

GP12 Audit

Conduct Supplier Launch Day assessment

Gate Review # 4

Gate Reviews 2,3,4

• APQP Major/Open Issues List

• APQP Timing Chart Updates

• Progress of Tooling/Fixtures/Gages

• 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

• Identify build issues/concerns

Meeting Subjects Include:

Global APQP for SQEs

Gate Review Delivery

Gate Review Delivery

5. Timing Charts / Open Issues

Key points

Supplier timing chart match GM master timing

requirement / MRD requirement

Supplier shall understand the logic consequence for

each activity and milestone

Supplier timing shall have high confidence of timing

achievability

Supplier shall identify potential risk by this “report

card”, and usage of escalation process

Use updated “Open issue list” as meeting minutes

and program management tool

APQP Timing Chart

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

APQP Timing Chart

Key Elements:

- Data/Sample comparison

- ADVP&R

- Engineering approval

- Material substitution/approval

- Tier supplier plan

- New facility, M&E

- Tooling building

- Gage/fixture building

- FOS

- A-B-C Comparison (GS)

- ETO

- PPAP SPR & Submission

- PTR

- GP12 GP9

- Acceleration and pipeline/inventory build up plan

APQP Timing Chart

APQP Timing Chart breakdown

Tooling list and timing chart

M&E timing chart

Sub-contractor timing chart

People Hiring and Training planning

Green/Brown field building planning

ADVP&R

APQP Timing Chart

Open Issue List

• Supplier is requested to work in QSB

implementation from the beginning of the

program development (Gate Review # 1)

• Action plan for implementation to be updated

on a regular basis according to the actions

taken based on the plan dates

6. QSB (Quality Systems Basics)

APQP QSB Task must be

compliant by Gate Review # 4

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

7. Flow Chart

Inspection

Rework

Scrap

Packaging

Shipping

KCC

Example: Initial process flow chart

Nonconforming part shall be reintroduced into the process stream at or prior to the point of removal

9. Design Review

Purpose: Ensure that the Design has been adequately Defined to Build Tools

and Gauges

Key points

Ensure engineering data is the latest version

Ensure supplier get SOR and engineering spec.

Ensure supplier understand the engineering data/spec and testing method

Review KPC/PQC list and control method

ADVP should be approved by GM

BOM

Material substitution and approval

Minimum validation requirement for salable PPAP

N

OKPC Value KCC Control Method

1 Length

VE:3060±7.5mm Extrusion: Cutting

Aging: Temperature; time

Finishing: End cutting

Extrusion: Automatic

cutting

Aging: PLC

Finishing: 100% DIM

check & SPCWM:3118±7.5mm

2Compr

ession

Load

VE/WM:

10.75mm

8~14N

Mixing: Ingredient quantity

Extrusion: Temperature;

Line speed

Aging: Temperature; time

Mixing: Bar code

Extrusion: PLC

Aging: PLC control

SPC

Example: KPC/PQC and corresponding control method

Example: Supplier DV/PV plan and result

Verify suppliers lab (GP10 Process) and closely follow up the parts bench tests conducted by the supplier

Example: BOM

10. Tooling & Equipment Reviews

Purpose:

To conduct reviews of a Tooling and/or Equipment to ensure that the manufacturing process is:

• designed to the latest drawing change level

• built

• certified

so as to produce:

• quality parts

• at rate

• according to GM program requirements

SQE approve gage per GM 1925 Fixture Standards, including:

•Ensure that any part changes are incorporated into gages.

•Evaluate Coordinate Measuring Machine (CMM) report to ensure gage accuracy.

•Ensure gage instructions (ODS) are available at the manufacturing operation.

•Verify integrity of gage for fit and function and GR&R (reference MSA AIAG).

•Verify that it is properly identified as GM property.

11. Gage Development and Approval

Purpose:

To design, build and certify gages according to latest GD&T release and per GM requirements.

Supplier Responsibility:

Design, build, certify gage dimensionally (including a third party certification), perform complete AIAG MSA (GR&R and Bias study) and meet all requirements established by GM1925. A lean gage (pull ahead CMM holding fixture) should be available for first IVER build.

11. Gage Development and Approval

12. PFMEA

TOP 5 RPN Reduction Plan (Correct RPN value) !

IT’S A LIVING DOCUMENT!

Top RPN Reduction Plan

13. Control Plan

Define the Method being used to Control all KPCs, PQC and KCCs for Parts being Manufactured for

Vehicle Builds.

Prototype Control Plan

Pre-Launch (GP-12) Control Plan

Implementing from the first production part ship to

GM assembly line

Production CP: shall be verified by Pre-launch PCP

SQE shall define PCPA schedule and

frequency based on the risk priority of part and

process (Based on risk assessment)

It’s a living document to address any

change in product/process and reflect

updated control for quality issue

Supplier and SQE shall verify final inspection to

ensure a robust inspection method

Key points

Control Plan

14. GP-12

Prototype

Pre-Launch (GP-12)

Production: shall be validated by Pre-launch PCP

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

GP12 Audit/Verification and take corrective action

Layered Audits by supervisor/Manager

Proactive Controlled Shipping Strategy and Execution

A. Failure to execute GP-12 will result in Controlled Shipping Level 2 and other possible consequences.

B. Shipment of non-conforming material will result in Controlled Shipping Level 2.

GP-12

GP-12 must be implemented for a period of time or quantity of parts as specified by the customer or until the Production Control Plan has been validated, whichever is longer.

If time or quantity is not specified, GP-12 will remain in effect through acceleration or a minimum of 2 weeks, whichever is longer.

Duration of GP-12

Indicates the process can consistently meet the

requirements at production rate

Indicates the supplier’s understanding of the

engineering design record and specifications

requirements

Defines generic requirements for production and

bulk materials

Production Part Approval Process

15. PPAP

Applies to all internal and external supplier sites of production and serviceparts unless otherwise specified by the authorized customer representative

Applicability

PPAP

Supplier Production Trial Run

PPAP pre-production

PPAP SPR

PPAP is not one day job

PPAP

Key points

- Supplier has to proof their process stability before PPAP production

- Walk through the manufacturing process to verify the PFD/PFMEA/Control Plan and error proofing

- Make sure KPC and KCC are clearly identified and communicated at the shop floor

- Make sure operators are properly trained

- Review error proofing application in the process

- Verify the results of the production trial run to determine any actions required before going to next step

- Verify GM engineering approval status and possible design change status

Supplier Production Trial Run

For production parts, product for PPAP shall be taken

from a significant production run:

From 1 to 8 hours of production

To total a minimum of 300 consecutive parts

Produced at the production site, at the production rate, using production tooling, gages, operators, etc.

Each unique manufacturing process shall be represented

Bulk material samples shall be taken from “steady state” operation

Significant Production Run

The organization shall notify the authorized customer representative SQE of any planned changes to design, process, or site

Upon notification and approval, and after change implementation, submission is required unless otherwise specified

Customer Notification

PPAP Submission levels

Level 5 - Warrant, product samples and data for

review at supplier’s location

Level 4 - Warrant and customer requirements

Level 3 - Warrant, product samples and data

(considered the default level)

Level 2 - Warrant with product samples

Level 1 - Warrant only

All required information shall be available or included in the

submission (levels 2-4) regardless of submission level!

Verifies capability

1 Day production at supplier site

= 1 Day usage in GM

Required for all new parts

Must meet: QTC on contract

Five working days per week

16. Run @ Rate GP–9

Begin from program Kick-Off (Initial GP-9)

No later than 8 weeks prior to SORP

Need to verify from time to time

- Tooling/M&E review

- FOS

- PPAP SPR

- After Salable PPAP (According to “Hours per day”)

Key points

Run @ Rate GP–9

Run @ Rate Approval Decisions

Fail

Pending PPAP

Pass (FULL PPAP)

17. Lessons Learned

Key points

SQE shall review Lessons learned from the every

beginning of a program

SQE shall ensure countermeasure in place to prevent

repeating same problem (Error-proofing, 100%

inspection, SPC)

SQE shall share Lessons Learned of similar

part/process with supplier

SQE shall drive supplier to implement Lessons

Learned as a systematic tool for continuous

improvement

Example: Design Lessons learned and best practice to achieve robust design

Global APQP for SQEs

Driving GM to be the BEST!!!

Thank You