A Guide to Proper Understanding and Implementation

GP 12

Contents

• What is GP-12?• Why GP-12• When to establish GP-12• Pre-Launch Control Plan• Ingredients of a good Pre-Launch Control Plan• GP-12 Area Set-Up• GP-12 Deliverables• Documentation Needs for GP-12• What we know works• How to make the Process Robust• Exit Criteria• Recommended Criteria• Exit Certificate

What is GP 12 ?

• GP-12 • Early Production Containment Proc edure

– A procedure to ens ure quick problem identification, broadcast and resolution during the early stages of start-up and acceleration

– A procedure to protec t Customer Assy Plant during the c rucial phases of Launch

– A procedure that es tablishes clear understanding between Customer and supplier during the initial phases of a program launch

Why GP 12?

• To contain quality problems during start-up before it reaches Customer assembly plant

• To provide a method for immediate problem resolution during start-up

• To help suppliers bring their processes under control and make them stable

• To enhance the Production Control Plan with feedback from the Pre Launch Control Plan

When to establish GP 12?

• During ALL pre-production Phases!!• During the early stages of production builds• After all tool moves and major changes to tools• GP 12 should not be used for carry over concerns ; they should be

addressed using the Controlled Shipping Procedure

(3) Key Elements Required to Establish GP12

• Pre-Launch Control Plan (PCP)– IT IS NOT A SUBSTITUTE FOR THE PRODUCTION CONTROL PLAN,

BUT IS OVER AND ABOVE THE PRODUCTION CONTROL PLAN AND IS USED TO VALIDATE IT

– A SIGNIFICANT ENHANCEMENT TO THE SUPPLIER’S PRODUCTION CONROL PLAN

• GP 12 Area Setup (separate from prod.)• Boundary Samples/Pics for appearance items (good and bad

examples)

Pre-Launch Control Plan

• Should take into account all known critical conditions of the part• Should take into account most of the potential causes of failure /

concern as identified in the PFMEA• Should identify additional controls, inspection audits and testing

to identify non conformances during production• Should use the format as identified in the APQP manual

Ingredients of a good Pre-launch Control Plan

• Identifies increased frequency of checking• Increased inspection & control items• Verification of label accuracy• Enhanced process controls using error proof ing

GP 12 Area Setup

• It is recommended that GP 12 area be off - line in a clearly marked & quarantined area

• GP 12 inspectors should not be the same as production inspectors

• GP 12 area should be set at the maximum possible distance from repair/rework area

• Use optimum lighting• When possible utilize work tables that put components in vehicle

position

http://www.pdfcomplete.com/cms/hppl/tabid/108/Default.aspx?r=q8b3uige22

GP 12 Deliverables

• Pre-launch Control plan (PCP)• GP 12 area established• Ship the exact agreed upon quantity • Meet all quality expectation as outlined in the print or as

communicated by the customer during Pre-launch control plan approval

GP 12 Deliverables

• Make sure each container has a green dot (1inch diam.) signed by senior management

• Close all PRR issued by the assembly plant• Meet all Ppk requirement• Have a proven Stable process• Be able to demonstrate that the process is robust and has

rendered the GP 12 area non value added

Documentation Needs for GP 12

• Pre-launch control plan• Pictures, Corrective and Preventive Action documentation,

Communication between shift documentation, Quality Alert • Agreed upon inspection criteria, data points and frequency of

checking• Boundary Sample availability

Documentation Needs for GP 12

• Agreed upon exit criteria– Requires these signatures : Supplier, Plant Quality

Nominee• Documentation to enhance inspection criteria, data points and

frequency of checking if needed • GP 12 exit certificate

What we know Works

• Empower People• Management Involvement• More employee responsibility• Focus on results• Focus on shared effort and clear communication• Make steady progress• Focus on the process and not on inspection

How to make the process Robust

• Define the inspection criteria, data points and frequency of checking before start

• Define exit criteria before start of GP 12• Exit criteria should reflect good statistical parameters eg. SPC

chart showing process under control, Cpk, Ppk, etc. and not quantity of good parts

• Update the data points and frequency of checking to reflect reality at the Customer Assy.

Exit Criteria

• Meet process capability requirements per recommended criteria or similar

• Meet all deliverables identified before• Apply for Exit Certificate along with all data to back up exit claim

Exit Certificate

GP 12 Exit Certificate

Part Number(s): Part Name: Supplier: Duns Code:

Exit Criteria 1. Customer Assembly Plant at full acceleration 2. Enhanced Control Plan Exists 3. Part at saleable Interim status 4. All PRR’s pertaining to the supplier process closed 5. Supplier has process under control and process is stable 6. Supplier has met all Ppk and Cpk requirements as outlined in Table 1 and 2 or

equivalent 7. Supplier has met all deliverables as outlined in the “Agreed Upon Exit Criteria” Upon meeting all the above mentioned criteria the supplier shall be issued this certificate. This certificate allows the supplier to exit GP 12 requirements. However, the supplier shall maintain all required controls in place to warranty good quality parts to Customer. Signatures:

FIAT