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Phone on

“Vibrate”

  Ground Rules

GM Global APQP for Suppliers

Manuel YamadaTel Aviv, Israel

April 12th, 2010

This is your class, feel freeto ask questions at any time!

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• Introductions

• APQP Process and Expectations

• Project Plan

• Customer vs Supplier Monitored APQP

• APQP management in GQTS

• APQP Requirements

•

GM Requirements• Q & A

AGENDA

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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 effectiveIdentify 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

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The goal of a successfulprogram launch and mass

production is to provide:

“Quality @ Rate On Time”

Supplier Responsibility

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GM

Global

APQP

AIAG APQP

ISO/TS 169497.1

Planning of Product Realization

Linkages of the ISO/TS 16949:2002, AIAG

APQP and Global Supplier Quality Manual

Background

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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

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GM-1927

Global SupplierQuality Manual is

the General MotorsCommon Global APQP

Manual

GM’s commondirection for thedevelopment andimplementation of anAPQP plan

Download fromGMSupplyPower 

Global APQP

Advanced Product Quality Planning

Worldwide Purchasing

November 2000

General Motors Corporation

GM

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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 Qual i ty Pow er 

• Select L ibrary 

• Select Suppl ier Qual i ty 

• Select APQP Manual & Documents 

GM 1927 Documents and Forms

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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

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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

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GM Global APQP Monitoring

• Customer Monitored – SQE Responsibilities• Assure quality @ rate on time

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

Project Plan

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

GM’s upper management, as appropriate

• Participate in the remaining Supplier GateReview 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 KeyDeliverables 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 qualityplanning 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 qualityplanning process with all sub-tier suppliers

• Responsible for meeting quality, timing andcapacity requirements

• Provide parts for all GM build events• Present tasks and deliverables of APQP

Workbook internally in a management review andsubmit the results to GM

• Notify SQE when quality issues arise that mightaffect program timing

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

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There is an inverse relationship –

Customer monitoring means moreresponsibility for the SQE

Supplier monitoring means more

responsibility for the Supplier

Customer Monitored APQP vs

Supplier Monitored APQP

Global APQP

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Global APQP Tasks changed as following:

01-Commodity Key Stakeholders Mtg

02-Technical Reviews

03-Supplier Eligibility04-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

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Corporate Planning sets time frames

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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 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)

GM Global APQP

Combination of the Best Processes

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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   G   R  -   1

   G   R  -   2

   G   R  -   3

   G   R  -   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

4Supplier GateReviews

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

 

AIAG

APQP

Pilot / Pre-LaunchPrototype Launch /

Feedback, Assessment and Corrective Action

Production

Product Design and Development

Planning

Process Design and DevelopmentProduct and Process Validation

 

ProductionInitial -TR

 

Initial-TR

 

Initial-TR

Update Risk

 

Structure

Vehicle

Integration

Vehicle

Validation

Vehicle

MVBs SOPMVBns

 

Letter 2 Letter 3 Letter 4

UpdateDFMEA RPN Reduction

Prototype

 

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Key points

Introduce and establish Key Stakeholder ownership, identifyprogram-specific strategies in the Engineering & AdvancePurchasing Sourcing Process (E&APSP) and ensure that the RFQ-package contains all information needed to receive comparablequotes.

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

Identify suppliers that will require Quality Business Case actionplans 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 thatthey are be included in the Request For Quotation package(suppliers must be capable to meet those specific requirements ifavailable).

1. Commodity Key Stakeholders Meeting (CKSM)

http://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xls

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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 anysuppliers to be sourced with not Green status

1. Commodity Key Stakeholders Meeting (CKSM)

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Supplier Quality Statement of Requirements 

Please sign, date and return page 5 of this document w ith your bid p ackage 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 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 their certification attainment plan with their quote for f urther 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 epresentative

Supplier Quality SOR

• Supplier Quality has a Global

Statement of Requirements thatapplies to all suppliers.

• SOR Included in the GM RFQ.

• Supplier Quotations to GMmust include a signed copy of

the SOR, indicating compliance to

these requirements.

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2. Technical ReviewsReview manufacturability, timing, design, manufacturing

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

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

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Technical Review Checklist

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Risk

Assessment

CustomerMonitored APQP

or

SupplierMonitored APQP

Risk Assessment

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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 andSQE (this is required prior to signing the Sourcing

Recommendation form).

- Initial APQP Open issues list

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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 andtrack 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-OffMeeting) 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)

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Key points

Intended as a Readiness Review of the supplier’s abilityto 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

http://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xls

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4. Gate Review

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Key Deliverables

The Key Deliverable documents (see chart) are to be uploadedinto GQTS. All other APQP documents and forms (referenced inthe GM Global APQP Supplier Status Summary WorkbookGM1927-34) are to be retained at the supplier location.

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

4. Gate Reviews

http://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xls

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Key Deliverables

4. Gate Reviews

Gate

Deadline

Time from

SORP in

weeks)

GVDP 5.0 timingreference

Review KeyDeliverables

Form/Document

ALLGM Global APQP Supplier Status Summary

WorkbookGM1927-34

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

-78Initiated after CVER

and completed 5

weeks after IVER

Gate 2PFMEA Check list GM1927-37RPN Reduction Summary GM1927-21

Subcontractor Status GM1927-25

-52Completed 10 weeks

 prior Matching 1 GAGate 3

Supplier ADV Plan (ADVP&R) showing

execution statusGM1829

QSB Audit (Compliance) or Greenfield Checklist

(Complete)

GM1927-30

GM1927-31

Run @ Rate Capacity Workbook GM1927-35

-35Completed 3 weeks

 prior PPV MRD Gate 4

Dimensional Report GM1927-32

PPAP Worksheet (if not fully approved) GM1411GP12 Audit GM1927-33

-15Completed 1 week

 prior MVBs MRDPPAP PPAP Approval

-8Run @

Rate

Run @ Rate Execution R@R Module

PCPA GM1927-16

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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

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Who toContact?

GM1927-17

List the Key

Positionsneeded to

Manage New

Programs

 

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

ContactPaint

Engineer 

2nd

 Shift

Contact

Current

SQE

3rd

 Shift

Contact

Sub-

Contractor 

GM AND SUPPLIER PROGRAM CONTACTS

APQP Kick Off Meeting

G t i

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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

G t R i # 3

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On-tracking timing chart, PFD/PFMEA/PCP, Qualityimprovement 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

G t R i # 4

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

Dimensional Report

PPAP Worksheet (if not fully approved)

GP12 Audit

Conduct Supplier Launch Day assessment

Gate Review # 4

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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:

G t R i D li

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Global APQP for SQEs

Gate Review Delivery

G t R i D li

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Gate Review Delivery

5 Ti i Ch t / O I

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5. Timing Charts / Open Issues

Key points

Supplier timing chart match GM master timingrequirement / MRD requirement

Supplier shall understand the logic consequence for

each activity and milestone

Supplier timing shall have high confidence of timingachievability

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 Ti i Ch t

http://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xls

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APQP Timing Chart

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APQP Ti i Ch t

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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/inventorybuild up plan

APQP Timing Chart

APQP Timing Chart

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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

http://localhost/var/www/apps/conversion/02%20HSR&A/00%20GD/Timinghttp://localhost/var/www/apps/conversion/tmp/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://localhost/var/www/apps/conversion/tmp/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://localhost/var/www/apps/conversion/tmp/Iris_APQP%20T3/HSR&A/M&E/GM%20M&E%20SCHEDULE_070305.xlshttp://localhost/var/www/apps/conversion/tmp/Iris_APQP%20T3/HSR&A/M&E/GM%20M&E%20SCHEDULE_070305.xlshttp://localhost/var/www/apps/conversion/tmp/Iris_APQP%20T3/HSR&A/Subcontractor/Subcontractor_Prog_Status_Matrix_070305.xlshttp://localhost/var/www/apps/conversion/tmp/Iris_APQP%20T3/HSR&A/Subcontractor/Subcontractor_Prog_Status_Matrix_070305.xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Subcontractor/Subcontractor_Prog_Status_Matrix_070305.xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Subcontractor/Subcontractor_Prog_Status_Matrix_070305.xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Subcontractor/Subcontractor_Prog_Status_Matrix_070305.xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Subcontractor/Subcontractor_Prog_Status_Matrix_070305.xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Subcontractor/Subcontractor_Prog_Status_Matrix_070305.xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Subcontractor/Subcontractor_Prog_Status_Matrix_070305.xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Subcontractor/Subcontractor_Prog_Status_Matrix_070305.xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Subcontractor/Subcontractor_Prog_Status_Matrix_070305.xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Subcontractor/Subcontractor_Prog_Status_Matrix_070305.xlshttp://localhost/var/www/apps/conversion/tmp/Iris_APQP%20T3/HSR&A/Subcontractor/Subcontractor_Prog_Status_Matrix_070305.xlshttp://localhost/var/www/apps/conversion/tmp/Iris_APQP%20T3/HSR&A/M&E/GM%20M&E%20SCHEDULE_070305.xlshttp://localhost/var/www/apps/conversion/tmp/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://localhost/var/www/apps/conversion/02%20HSR&A/00%20GD/Timinghttp://localhost/var/www/apps/conversion/02%20HSR&A/00%20GD/Timinghttp://localhost/var/www/apps/conversion/02%20HSR&A/00%20GD/Timing

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Open Issue List

6 QSB (Quality Systems Basics)

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•

Supplier is requested to work in QSBimplementation from the beginning of the

 program development (Gate Review # 1)

•

Action plan for implementation to be updatedon a regular basis according to the actions

taken based on the plan dates

6. QSB (Quality Systems Basics)

APQP QSB Task must becompliant by Gate Review # 4

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7 Flow Chart

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7. Flow Chart

Inspection

Rework

Scrap

Packaging

Shipping

KCC

Example: Initial process flow chart

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Example: Initial process flow chart

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

9 Design Review

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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/specand 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

Example: KPC/PQC and corresponding control method

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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

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Example: BOM

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Example: BOM

10 Tooling & Equipment Reviews

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10. Tooling & Equipment Reviews

Purpose:

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

• designed to the latest drawing change level

• built

• certifiedso as to produce:

• quality parts

• at rate

• according to GM program requirements

11 Gage Development and Approval

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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 ensuregage accuracy.

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

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

•Verify that it is properly identified as GM property.

11. Gage Development and ApprovalPurpose:

To design, build and certify gages according to latest GD&T

release and per GM requirements.

11. Gage Development and Approval

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Supplier Responsibility:

Design, build, certify gage dimensionally (including a third partycertification), perform complete AIAG MSA (GR&R and Biasstudy) and meet all requirements established by GM1925. A lean

gage (pull ahead CMM holding fixture) should be available forfirst IVER build.

11. Gage Development and Approval

12 PFMEA

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12. PFMEA

TOP 5 RPN Reduction Plan (Correct RPN value) !

IT’S A LIVING DOCUMENT!

Top RPN Reduction Plan

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Top RPN Reduction Plan

13. Control Plan

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13. Control Plan

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

Control Plan

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SQE shall define PCPA schedule andfrequency 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

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14. GP 12

Prototype

Pre-Launch (GP-12)

Production: shall be validated by Pre-launch PCP

Establish a Containment Plan during Start-upand acceleration that will Quickly IdentifyQuality Issues at the Supplier’s Facility; i.e., aPre-Launch Control Plan

GP-12

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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 inControlled Shipping Level 2.

GP 12

Duration of GP-12

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GP-12 must be implemented for a period of timeor quantity of parts as specified by the customer oruntil the Production Control Plan has beenvalidated, whichever is longer.

If time or quantity is not specified, GP-12 willremain in effect through acceleration or aminimum of 2 weeks, whichever is longer.

15. PPAP

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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 andbulk materials

Production Part Approval Process

15. PPAP

PPAP

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Applies to all internal and externalsupplier sites of production and service

parts unless otherwise specified by theauthorized customer representative

Applicability

PPAP

PPAP

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Supplier Production Trial Run

PPAP pre-production

PPAP SPR

PPAP is not one day job

PPAP

Key points

Supplier Production Trial Run

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- Supplier has to proof their process stability before PPAPproduction

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

- Make sure KPC and KCC are clearly identified andcommunicated 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 anyactions required before going to next step

- Verify GM engineering approval status and possible designchange status

pp

Significant Production Run

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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

  ulk material samples shall be taken from “steady state”

operation

g

Customer Notification

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The organization shall notify the authorized

customer representative SQE of any planned changesto design, process, or site

Upon notification and approval, and after changeimplementation, submission is required unless

otherwise specified

PPAP Submission levels

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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

(cons idered the default level)

Level 2 - Warrant with product samples

Level 1 - Warrant only

All required information shall be available or included in thesubmission (levels 2-4) regardless of submission level!

16. Run @ Rate GP – 9

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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

@

Run @ Rate GP – 9

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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 Approval Decisions

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Fail

Pending PPAP

Pass (FULL PPAP)

17. Lessons Learned

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Key points

SQE shall review Lessons learned from the everybeginning 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 continuousimprovement

http://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xlshttp://c/00%20IRIS/APQP%20APO/Iris_APQP%20T3/HSR&A/Tooling/GM%20TOOL&MOLD%20LIST(070405).xls

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Gl b l APQP f SQE

Driving GM to be the BEST!!!

Thank You