GM APQP for SQE

GM Global APQP for Suppliers
Phone on
“Vibrate”
Ground Rules
This is your class, feel free
to ask questions at any time!
Manuel Yamada
Tel Aviv, Israel
April 12th, 2010
AGENDA
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•
•
•
•
•
•
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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
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
Supplier Responsibility
The goal of a successful
program launch and mass
production is to provide:
“Quality @ Rate On Time”
Background
Linkages of the ISO/TS 16949:2002, AIAG
APQP and Global Supplier Quality Manual
GM
Global
APQP
AIAG APQP
ISO/TS 16949
7.1
Planning of Product Realization
Background
GM APQP Global Process

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”
Global APQP
GM-1927
GM
General Motors Corporation
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
Advanced Product Quality Planning
Worldwide Purchasing
November 2000
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:
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•
•
•
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Log in
Select Quality Power
Select Library
Select Supplier Quality
Select APQP Manual & Documents
Global APQP
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 APQP
Supplier Monitored 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
GM Global APQP Monitoring
SQE is the responsible for invite and conduct Gate #1 (Kick-Off Meeting) for all parts on both Customer or
Supplier Monitored APQP
•
Customer Monitored – SQE Responsibilities
• Assure quality @ rate on time
•
• Implement an advanced product quality
planning process with all sub-tier suppliers
of all quality related documents listed on APQP
Project Plan
• Raise issues that might jeopardize a quality part
• Participate in the remaining Supplier Gate
• Execute the content and provide updates per the
APQP Project Plan
• Drive the supplier’s progress in the development
within the program timing – either to supplier’s or
GM’s upper management, as appropriate
Customer Monitored – Supplier Responsibilities
•
• Invite and conduct all remaining Gate Reviews
• Work closely with GM SQE
Supplier Monitored – Supplier Responsibilities
• Adhere to supplier manufacturing site protocol
• Execute the content of the APQP Project Plan
• Implement an advanced product quality
• Attend PDT and associated program meetings
• Drive/Enforce the process of supplier’s quality
• Responsible for meeting quality, timing and
Review meetings
when in the manufacturing facility
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
planning process with all sub-tier suppliers
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
Global APQP
Customer Monitored APQP vs
Supplier Monitored APQP
There is an inverse relationship –
Customer monitoring means more
responsibility for the SQE
Supplier monitoring means more
responsibility for the Supplier
Global APQP Tasks changed as following:
01-Commodity Sourcing Strategy Mtg
01-Commodity Key Stakeholders Mtg
02-Technical Reviews
02-Technical Reviews
03-Risk Assessment / Sourcing
03-Supplier Eligibility
04-Supplier Gate Reviews
04-Gate Reviews
05-Timing Charts / Open Issues
05-Timing Charts / Open Issues
06-Feasibility / Assessment Letters
06-QSB
07-Flow Chart
07-Flow Chart
08-DFMEA
08-DFMEA
09-Design Reviews
09-Design Reviews
10-Gage, Tooling and Equipment Reviews
10-Tooling & Equipment Reviews
11-GP-11
11-Gage Development & Approval
12-PFMEA
12-PFMEA
13-Control Plan
13-Control Plan
14-GP-12
14-GP-12
15-PPAP
15-PPAP
16-Run @ Rate
16-Run @ Rate
17-Lessons Learned
17-Lessons Learned
 Corporate Planning sets time frames
Combination of the Best Processes
GPSC SUPPLIER QUALITY IMPROVEMENT PROCESS
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)
TIME LINE
EARLY PRODUCTION
CONTAINMENT (GP-12)
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
START OF
PRODUCTION
LIFE
OF PART
GM Global APQP
1. Commodity Sourcing Strategy Meetings
APQP Project Plan
Prototype
Pilot / Pre-Launch
Launch /
Production
Planning
Product Design and Development
Process Design and Development
Product and Process Validation
Feedback, Assessment and Corrective Action
2 Technical Reviews
Risk Assessment /
3 Sourcing
Supplier Gate
4 Reviews
Timing Charts /
5 Open Issues
Feasibility /
6 Assessment Letters
GR-1
GR-1
Sourcing
Activities
o------o
o
o------o
o
TR
o
o
o
o
o
o
o
Initial-TR
GR-1,2,3,4
o
o
GR-1,2,4
o
o
o
o
SOP
o
o
GR-2,3
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
Letter 4
o
o
o
o
Update
o
o
Production
o
o
o
RPN Reduction
DFMEA
o
o
o
o
GD&T
o
Prod Concept-TR
o
Letter 3
o
o
GR-1,2,3,4
o
Prototype
o
GR-1,2,4
o
Letter 2
KCDS Workshop
9 Design Reviews
Gage, Tooling and
10 Equipment Reviews
MVBs
Initial-TR
GR-1,2,3,4
DFMEA
8 DFMEA
MVBns
Update Risk
GR-1,3
Initial -TR
7 Flow Chart
Validation
Vehicle
GR-3
Gate
Reviews
GR-1
APQP Task
Commodity Sourcing
1 Strategy Mtg
Integration
Vehicle
GR-2
Structure
Vehicle
GM GVDP
GR-4
AIAG
APQP
o
Gage Concept Approval
o
o
o
o
Gage Design Approval
Gage Approval/R&R, Tool Completion
o
o
Execute
Execute
The Commodity Sourcing Strategy
Meeting is the
responsibility of the Buyer –
11 GP-11
GR-2,3
o
o
o
o
RPN Reduction
Prototype
/ RPN Baseline
 InternalInitial-TR
GM people
only
Production / RPN Reduction
12 PFMEA
GR-1,2,3,4
o
o
o
o
o
o
o
o
 The first
time the SQEPrototype
becomes “officially” involved
GP-12 & Production in the APQP process
Initial-TR
13 Control Plan
GR-1,2,3,4
o
o
o
o
o
o
o
 Commodity
Sourcing Strategy Meeting is thePlanfirst task that
by
the
Initial-TR
Execute is trackedExit
(Platform
Discretion)
14 GP-12
GR-3,4
o
o
o
o
APQP
Project Plan
15 PPAP
GR-4
o
Plan
16 Run @ Rate (GP-9)
GR-1,2,3,4
17 Lessons Learned
GR-1,2,3,4
o
o
o
Capacity Analysis
o
Capacity Analysis
o
o
o
o
o
Conduct Run@Rate
o
o
o
o
o
1. Commodity Key Stakeholders Meeting (CKSM)
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 RFQpackage 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.
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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
Supplier Quality SOR
Supplier Quality Statement of Requirements
• Supplier Quality has a Global
Statement of Requirements that
applies to all suppliers.
• SOR Included in the GM RFQ.
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 (poka
yoke, error proofing devices, etc) and defect outflow prevention to customers. Controls
implemented 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 current
certificate available demonstrating compliance to GM supplements. These standards require
an 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 further consideration.
3. General Motors Procedures and Reference Documents
• Supplier Quotations to GM
must include a signed copy of
the SOR, indicating compliance to
these requirements.

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
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
Risk
Assessment
Customer
Monitored APQP
or
Supplier
Monitored APQP
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
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)
109 Part J
4. Gate Reviews
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 Review
4. Gate Reviews
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
Gate
Deadline
(Time from
SORP in
weeks)
GVDP 5.0 timing
reference
ALL
-78
Key
Deliverables
Review
Within 30 days of
business nomination
advice / contract
Gate 1
Initiated after CVER
and completed 5
weeks after IVER
Gate 2
GM Global APQP Supplier Status Summary
Workbook
QSB Audit (Gap Analysis) or Greenfield
Checklist (Action Plan)
Timing Plan
Kick-Off Check list
PFMEA Check list
RPN Reduction Summary
Subcontractor Status
Supplier ADV Plan (ADVP&R) showing
execution status
QSB Audit (Compliance) or Greenfield Checklist
(Complete)
Run @ Rate Capacity Workbook
Dimensional Report
PPAP Worksheet (if not fully approved)
GP12 Audit
-52
Completed 10 weeks
prior Matching 1 GA
Gate 3
-35
Completed 3 weeks
prior PPV MRD
Gate 4
-15
Completed 1 week
prior MVBs MRD
PPAP
PPAP Approval
Run @
Rate
Run @ Rate Execution
PCPA
-8
Form/
Document
GM1927-34
GM1927-30
GM1927-31
GM1927-2
GM1927-14
GM1927-37
GM1927-21
GM1927-25
GM1829
GM1927-30
GM1927-31
GM1927-35
GM1927-32
GM1411
GM1927-33
R@R Module
GM1927-16
Gate Review # 1 - APQP Kick Off Meeting
Delivery

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
APQP Kick Off Meeting
GM AND SUPPLIER PROGRAM CONTACTS
Who to
Contact?
GM1927-17
List the Key
Positions
needed to
Manage New
Programs
Part name:
GM Program:
Supplier Name:
Manufacturing Location Address:
Supplier Mfg. Plant Manager:
Position
Advance
SQE
Buyer
Name
Design
Engineer
VLE PPM
Proto PE
Part number:
Model Year:
DUNS #:
Phone:
GM
Phone (fax,mobile)
E-mail
Position
Project
Manager
Sales Mgr
Name
SUPPLIER
Phone (fax,mobile)
E-mail
Design
Engineer
Quality
Manager
Laboratory
Supv.
Manuf.
Engineer
GM Plant
Rep
GD&T
Readiness
Coord.
Containerization
Reliab.
Engineer
Paint
Engineer
Current
SQE
APQP Contact List.doc
Packaging
Engineer
1st Shift
Contact
nd
2 Shift
Contact
rd
3 Shift
Contact
SubContractor
GM1927-17
Gate Review # 2

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 # 3

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 # 4

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 Reviews 2,3,4
Meeting Subjects Include:
•
•
•
•
•
•
•
•
•
•
•
•
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
Gate Review Delivery
Global APQP for SQEs
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
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
Open Issue List
6. QSB (Quality Systems Basics)
• 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
APQP QSB Task must be
compliant by Gate Review # 4
7. Flow Chart
• Provide a Logical Pictorial Representation of the Process Flow that can
Purpose:
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
SQE
Responsibility:
• 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
Key
points
Purpose: Ensure that the Design has been adequately Defined to Build Tools
and Gauges

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
Example: KPC/PQC and corresponding control method
N
O
KPC
Value
VE:3060±7.5mm
1
Length
WM:3118±7.5mm
2
Compr
ession
Load
VE/WM:
10.75mm
8~14N
KCC
Control Method
Extrusion: Cutting
Aging: Temperature; time
Finishing: End cutting
Extrusion: Automatic
cutting
Aging: PLC
Finishing: 100% DIM
check & SPC
Mixing: Ingredient quantity
Extrusion: Temperature;
Line speed
Aging: Temperature; time
Mixing: Bar code
Extrusion: PLC
Aging: PLC control
SPC
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
11. Gage Development and Approval
Purpose:
To design, build and certify gages according to latest GD&T
release and per GM 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
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.
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
Control Plan
Key points
 SQE shall define PCPA schedule and
frequency based on the risk priority of part and
process (Based on risk assessment)
 Supplier and SQE shall verify final inspection to
ensure a robust inspection method
 It’s a living document to address any
change in product/process and reflect
updated control for quality issue
14. GP-12
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
 Prototype
 Pre-Launch (GP-12)
 Production: shall be validated by Pre-launch PCP
GP-12
 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.
Duration of 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.
15. PPAP
Production Part Approval Process
 Defines generic requirements for production and
bulk materials
 Indicates the supplier’s understanding of the
engineering design record and specifications
requirements
 Indicates the process can consistently meet the
requirements at production rate
PPAP
Applicability
 Applies to all internal and external
supplier sites of production and service
parts unless otherwise specified by the
authorized customer representative
PPAP
Key points
 Supplier Production Trial Run
 PPAP pre-production
 PPAP SPR
 PPAP is not one day job
Supplier Production Trial Run
- 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
Significant Production 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
Customer Notification
 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
PPAP Submission levels
Level 1 - Warrant only
Level 2 - Warrant with product samples
Level 3 - Warrant, product samples and data
(considered the default level)
Level 4 - Warrant and customer requirements
Level 5 - Warrant, product samples and data for
review at supplier’s location
All required information shall be available or included in the
submission (levels 2-4) regardless of submission level!
16. Run @ Rate GP–9
 Verifies capability
 Must meet: QTC on contract
Five working days per week
 Required for all new parts
 1 Day production at supplier site
= 1 Day usage in GM
Run @ Rate GP–9
Key points
 Begin from program Kick-Off (Initial GP-9)
 Need to verify from time to time
- Tooling/M&E review
- FOS
- PPAP SPR
- After Salable PPAP (According to “Hours per day”)
 No later than 8 weeks prior to SORP
Run @ Rate Approval Decisions
 Pass (FULL PPAP)
 Pending PPAP
 Fail
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
Driving GM to be the BEST!!!
Thank You
Global APQP for SQEs