Transcript Before RFQ-package is sent out - RFQ Kick

Supplier Program Review Meeting #1
Advanced Product Quality Planning
APQP Kick-off Meeting (Long Version)
GM1927-15
1
Agenda
• Background
GM
- APQP
- Global APQP Development
General Motors Corporation
• APQP Project Plan Overview
• APQP Kick-off Meeting
- SQ Requirements
- Program Timing
- Review Checklists
- Identify Open Issues
Advanced Product Quality Planning
• Summary
Worldwide Purchasing
November 2000
2
Agenda
• Background
GM
- APQP
- Global APQP Development
General Motors Corporation
• Requirements from
Suppliers
• APQP Project Plan
- Supplier Responsible
Tasks 4 -- 17
Advanced Product Quality Planning
• Summary
Worldwide Purchasing
November 2000
3
Primary
Background
APQP
Definition
Advanced Product Quality Planning -- APQP
• Structured method defines and establishes steps
necessary to ensure product meets customer requirements
• Required for all new parts
• Responsibility of the supplier
Purpose & Structure
• Communicates the requirements necessary to develop a
product quality plan
• Top Management support by the supplier is key to the success
of the any APQP process
• Requires an environment of trust and cooperation between all
parties
4
Background
APQP
Benefits
•
•
•
•
Directs resources
Early identification of required changes
Facilitates avoidance of late changes
Enables delivery of a quality product that meets
program timing at required capacity
5
Background
AIAG Linkage to QS-9000
AIAG--Automotive Industry Action Group
•
Standardized reference manuals, procedures, reporting formats and
technical nomenclature used by Ford, Chrysler and General Motors
•
AIAG APQP manual one of 7 manuals developed; completed June 1994
– Provides general guidelines for development of an advanced
product quality plan
QS-9000
• The Harmonization of Ford, Chrysler and General Motors
individual Quality System requirements
– Ford--Q-101 Quality System Standards
– Chrysler--Supplier Quality Assurance Manual
– GM--Targets For Excellence
6
Background
QS- 9000 APQP Direction
Establishment of an Advanced Product Quality Plan
• QS-9000 section 4.2.3.1 requires the establishment of an
advanced product quality plan
• AIAG APQP Manual is referenced as the document that should
be used
– Detail of specific deliverables was not clearly defined
– Separate “unique” Regional & Divisional requirements developed
7
Background
Drivers of a Global Common APQP Process
• Divisions and regions “Fine Tuned” the AIAG APQP process
• Result was different direction for suppliers
– different reporting formats for program updates
– different timing charts for program events
– varying levels of detail required at different times throughout
the product development cycle
• Additional variation occurred when SQE’s further “Fine Tuned
the requirements and developed unique forms or timing charts
etc.
8
Background
Drivers of a Global Common APQP Process
• Global Suppliers and Global Vehicles compounds varying levels
of direction
– This resulted in regional variations on the APQP
process requirements
APQP
APQP
APQP
APQP
9
Global APQP Development
General Motors Global APQP
• GM-1927 is the General Motors
GM
General Motors Corporation
Common Global APQP Manual
• GM’s common direction
for the development and
implementation of an
APQP plan
Advanced Product Quality Planning
Worldwide Purchasing
November 2000
10
Global APQP Development
Goals of this Common Global Process
• Identify the critical items
• Eliminate unnecessary requirements
• Support the the SQE and Supplier in performing
the day-to-day APQP activities
• Eliminate the divisional & regional specific
direction
11
Global APQP Development
• Participation by a Global Team:
– GM North America
--GM Europe
– GM Asia Pacific
--GM Latin America
• Objective:
- Define the minimum product quality planning requirements
necessary to develop and implement an Advanced Product
Quality Plan for a product or service
12
Global APQP Development
Common Global APQP Process for GM Worldwide
• GM-1927 replaces all regional and divisional APQP reference manuals
• GM-1927 harmonized and standardized the multiple regional and
divisional APQP manuals
– Aligns with the 5 phases within the AIAG APQP manual and
provides the detail required to implement an APQP plan
– Aligns with GM’s 4 phase program timing and deliverables
13
Global APQP Development
Benefits
• Common APQP process for GM worldwide
– All GM divisions and regions will use the same process
– Common requirements
– Eliminates the need to keep separate files for programs due
to divisional or regional “unique” requirements
• Common forms and charts
• Interactive computer system (GQTS APQP module)
– Facilitates timely communication of requirements and data
– Eliminates manual data storage
• Common direction and “One Voice” from all GM Supplier
Quality Engineers regardless of region or division
14
Global APQP Development
GM 1927 Documents and Forms
• Ordering:
Ordering information for all documents and manuals listed or referenced
throughout this manual (GM 1927) is contained on page II
Electronic Copies:
This manual and all documents that are part of this manual (this includes any
document with a GM 1927 number) can be found through the internet at the
GMSupplyPower website
The address is www.gmsupplypower.com, then follow these steps:
•
•
•
•
•
Log in
Select Quality Power
Select Library
Select Supplier Quality
Select APQP Manual & Documents
15
Global APQP Development
Summary Points
• Global APQP driven by QS 9000 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 will be Shared between Regions
- All Information Available on GMSupplyPower website at
www.gmsupplypower.com
- GQTS APQP Module will Accelerate Global Communication
16
Primary
Requirements from Suppliers
• Proactive Conformance to AIAG APQP Requirements
and GM Global APQP Tasks
• Develop Detail Plans for Each Part / System
- Robust Part Designs
- Robust Processes with Error-proofing
ZERO DEFECTS
• Maintain Program Timing
- Design Completion
- Prototype Part Delivery
- Accurate Sample Submissions and Part Delivery
• Identify Issues Early in Program and Drive Correction
• Document on APQP Open Issues List
• Maintain Communication with GM on Program Status
and Issues -- Manufacturing Assessment Letters
• Expect these Same Requirements from Sub-Suppliers
17
Primary
Global APQP
• The APQP Project Plan GM 1927-1, consists of
17 major deliverables/requirements
• These items if completed properly and on time
should result in the development of a
manufacturing system that is capable of meeting
the GM Quality requirements at stated capacity and
ship schedules.
18
Global APQP
APQP 17 Tasks / Deliverables
- Key Stakeholders Meeting
- Gage / Tooling / Equipment
- Technical Review
Review
- Risk Assessment / Sourcing
- GP-11
- Supplier Program Reviews
- PFMEA Strategy
- Timing Charts / Open Issues
- Control Plan
- Feasibility / Manufacturing Letters
- GP-12
- Flow Chart
- PPAP
- DFMEA
- Run @ Rate (GP-9)
- Design Review
- Lessons Learned
19
Global APQP
Manual Contents
GM
• Preface
General Motors Corporation
• Table of Contents
• RASIC
• Explanation of PMI’s
(Process Model Integration)
• PMI’s for 17 Tasks / Deliverables
• Appendices
• Glossary
Advanced Product Quality Planning
Worldwide Purchasing
November 2000
The 17 Tasks are the Key for Success!
20
Combination of the Best Processes
WWP 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)
LIFE
OF PART
RUN @ RATE (GP-9)
GM Global APQP
PRODUCTION PART
APPROVAL (PPAP)
PROTOTYPE SAMPLE
APPROVAL (GP-11)
PRE-PRODUCTION MEETING
Experience
ADVANCED PRODUCT
QUALITY PLANNING (APQP)
SOURCING DECISION
POTENTIAL SUPPLIER
ASSESSMENT
START OF
PRODUCTION
21
Primary
APQP Project Plan
APQP “At a Glance”
•
Shows the linkage of the 17 deliverables to:
– GM’s 4 phase timing
– GM’s Sourcing Process
– AIAG APQP 5 phases within the APQP planning process
•
The focus of the APQP Project Plan is on timing of each
deliverable
– Levels of completeness for specific deliverables is clearly
identified
– The required completion of items is tied to the specific GM
build event
22
APQP Project Plan
APQP Project Plan
Prototype
Pilot / Pre-Launch
Launch /
Production
Planning
AIAG
APQP
Product Design and Development
Process Design and Development
Product and Process Validation
Feedback, Assessment and Corrective Action
Structure
Vehicle
Integration
Vehicle
Validation
Vehicle
Alpha
Beta
Gam m a /
Proto
2 Technical Reviews
Risk Assessment /
3 Sourcing
Supplier Gate
4 Reviews
Timing Charts /
5 Open Issues
Feasibility /
6 Assessment Letters
GR-1
GR-1
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
GR-2,3
o
o
o
o
GR-3,4
15 PPAP
GR-4
GR-1,2,3,4
17 Lessons Learned
GR-1,2,3,4
o
o
o
o
o
o
o
o
o
o
o
o
RPN Reduction
Production / RPN Reduction
o
o
o
Execute
o
o
Gage Approval/R&R, Tool Completion
o
o
o
o
o
GP-12 & Production
o
o
o
o
Execute
o
Capacity Analysis
o
Capacity Analysis
o
o
o
o
23
Exit (Platform Discretion)
o
o
o
o
o
Gage Design Approval
o
o
o
o
Plan
o
o
Letter 4
o
Prototype
Plan
16 Run @ Rate (GP-9)
o
o
o
Initial-TR
14 GP-12
o
RPN Reduction
Prototype / RPN Baseline
o
o
GD&T
o
GR-1,2,3,4
o
o
o
o
GR-2,3
o
o
Gage Concept Approval
Initial-TR
13 Control Plan
SSF
Production
o
o
o
o
Update
o
GR-1,2,3,4
o
Letter 3
o
Prod Concept-TR
Initial-TR
12 PFMEA
Pilot /
Pilot 2
o
o
o
GR-1,2,3,4
o
Prototype
o
GR-1,2,4
o
Letter 2
Execute
11 GP-11
Pre-Pilot
/ Pilot 1
Initial-TR
GR-1,2,3,4
KCDS Workshop
9 Design Reviews
Gage, Tooling and
10 Equipment Reviews
SOP
Update Risk
GR-1,3
DFMEA
8 DFMEA
MVBs
o
Initial -TR
7 Flow Chart
FE1 FE2 FE3
GR-3
Gate
Sourcing
Reviews Activities
GR-2
APQP Task
Commodity Sourcing
1 Strategy Mtg
GR-1
Generic
MVBns
GR-4
GM GVDP
o
Conduct Run@Rate
o
o
o
o
Primary
APQP Project Plan
APQP Project Plan
4 Phase
GM
Phase 0
Pre-sourcing
Plan and Define
Phase 1
Phase 3
Product Design and Development
Process Design and Development
Product and Process Validation
Feedback, Assessment and Corrective Action
AIAG
1 Key Stakeholder's Mtg
PR-1
o------------o
2 Technical Reviews
PR-1
o--------o
3 Risk Assessment
PR-1, 2, 3
TR
-4
0
SSF
4
8
12
16
20
PR-4
PR-3
APQP Task
Progra
m Revie
ws
PR-2
Presourcin
VDP
g
-96 -92 -88 -84 -80 -76 -72 -68 -64 -60 -56 -52 -48 -44 -40 -36 -32 -28 -24 -20 -16 -12 -8
Generic
Alpha
Beta
Proto
FE1 FE2 FE3
PPAP
Pilot
PR-1
Start
Here
Task 4
Phase 2
Supplier Program Reviews
Update Risk
o-----------------------o
Kick-off
4 Supplier Program Reviews
o
o
o
o
o
o
initial-
5 Timing Charts/Open Issues
PR-1,2,3,4
o
o
o
o
o
o
o
o
initial-
6 Feasibility Letters
PR-1,2,3,4
o
7 Flow Chart
PR-1,2,4
o
8 DFMEA
PR-1,2,4
o
PR-2,3
o---------------------o
o
o
GD&T
o
o
concept
10 Gage Review
11 GP-11
PR-2,3,4
13 Control Plan
Pla
complete/sta
o----- ----------------o
PR-2,3
PR-1,2,3,4 TR
PR-4
15 PPAP
PR-4
prototype
o
PR-1,2,3,4 initial-
14 GP-12
gage approval,
design
o--------------------------------------------------------------------------------------------------------------o
initial -
12 PFMEA Strategy
o
f inal
o----------------o
KCDS
9 Design Review
o
prototype
initial -
o----------------o
f inal
o
o---------------------o
o
o
f inal
prototype
o---------------o
o---------------------o
o
Complete (Platf orm
plan
o-----------------------------------------------------------------------------------------------------------------o
o------------------o
Pla
16 Run @ Rate (GP-9)
17 Lessons Learned
PR-1,4
PR-1,2,3,4
o
o
o
o
o
o------------------------------------o
o
o
24
o
24
Task 4) Supplier Program Reviews
Overview
Purpose:
• Ensure Supplier’s Quality Plan is Progressing to Meet
GM Program Timing
• Provide a Formal Process to Raise Issues for Resolution
Four Major Program Reviews:
TODAY
• Pre-Production Meeting (APQP Kickoff)
• Beta Prototype Build
• Gamma Prototype Build
• Pilot (Final PPAP Submission)
Meeting Responsibility:
• Pre-Production Meeting is Scheduled by SQE
• Meetings 2, 3, 4 are Scheduled by Supplier
25
Primary
Task 4) Supplier Program Reviews
Supplier Program Review #1 (PR#1)
• Conducted after the Sourcing decision:
-- GM SQE coordinates and leads this first review
-- Supplier responsibilities and deliverables are reviewed
• Purpose:
-- Ensure the GM Global APQP requirements and
responsibilities are clearly communicated and understood
-- Verify Program timing and deliverables associated with
program timing
26
Task 4) Supplier Program Reviews
Supplier Program Review #1 (PR#1)
• Purpose: (continued)
-- Communicate process that will be used to provide
program updates for APQP deliverables
• Supplier Program Reviews - 4
• Timing Chart GM 1927-1
• Program Tracking Chart GM 1927-2
• Feasibility & Manufacturing Assessment Letters - 4
GM 1927-19
-- Confirm APQP program communication channels within
and between supplier and GM
• APQP Project Contact List GM 1927-17
27
4) Supplier Program Reviews
Program Review #1 (PR#1)
Who to
Contact?
GM1927-17
List the Key
Positions
needed to
Manage New
Programs
GM AND SUPPLIER PROGRAM CONTACTS
Part name:
GM Program:
Supplier Name:
Manufacturing Location Address:
Supplier Mfg. Plant Manager:
Position
Advance
SQE
Buyer
Name
Part number:
Model Year:
DUNS #:
Phone:
GM
Phone (fax,mobile)
Design
Engineer
VLE PPM
E-mail
Position
Project
Manager
Sales Mgr
Design
Engineer
Quality
Manager
Laboratory
Supv.
Proto PE
Manuf.
Engineer
GM Plant
Rep
GD&T
Readiness
Coord.
Containerization
Reliab.
Engineer
Paint
Engineer
Current
SQE
Packaging
Engineer
1st Shift
Contact
nd
2 Shift
Contact
rd
3 Shift
Contact
SubContractor
28
Name
SUPPLIER
Phone (fax,mobile)
E-mail
4) Supplier Program Reviews
Supplier Program Review #1 (PR#1)
• Review of Pre-Sourcing Quality Requirements
– Review items listed in the “Required Quality Information” letter
GM 1927-4 contained in the RFQ
– Review the “Supplier Quality Statement of Requirements” (SOR)
GM 1927-3
• Review page 5 with the appropriate company representative
signature
– Overview of the 17 APQP deliverables and explanation of each
29
4) Supplier Program Reviews
Required Quality Information
• (GM1927-4 is Included in
all GM RFQs.
• Supplier submits as part of
Quote to GM, includes
requested documents.
• Review Supplier Quality
Information provided and
discuss exceptions.
Required Quality Information
Please gather the following information in a binder or envelope marked “Quality” and submit it with
your bid package.
If you have any questions relative to the required information, please contact your GM Supplier
Quality Engineer for clarification. All information must relate to the manufacturing site that the
product will be manufactured and must reference the RFQ number and part numbers. All
listed information is required in your Quote Package.
Be prepared to answer questions during the Technical Review Meeting.
Referenc
Submitted
Required information
Explanation
e
documen
t
1. Preliminary timing charts.

2. Review of the manufacturing
facility.




3. Preliminary process flow
diagrams.
4. Location of Engineering and
Technical Support
5. Warranty Risk and Reward
Plan.

6. Preliminary Control plans
7. Organizational chart


8.
Tier 2 plan

9.
Capability studies

10. Plan to reduce major disruptions
11. Checking fixtures
12. Outsourcing of prototype
manufacturing (if applicable)
13. Continuous Compliance testing
14. Preliminary PFMEA












• Update APQP Open Issues
List for exceptions.
30
15. ISO/TS 16949 or QS9000
Certification


16. Environmental Management
System

17. Operator-training program
18. Team Feasibility Commitment




Highlight any concerns relative to tooling / testing that may impact
providing a quality process/part on time.
Where is it located?
How long has it been in operation?
What modifications to the facility would be required to support the
RFQ volumes?
Has any SQE from General Motors reviewed the facilities? If so,
when?
Include any special assembly techniques, test methods, and
containment procedures utilized.
Where will the engineering and technical support be located?
How do they communicate to the manufacturing location?
(If indicated by the GM buyer as a risk & reward commodity).
What plans do you have in place to meet your IPTV targets?
Capability studies on similar parts, along with plans for error proofing,
data analysis, and record keeping must be included in plan
Complete with error proofing, and any part traceability techniques
Emphasis on people that will be involved from quality and program
management.
Proposed component suppliers and the plan to manage these
suppliers (Your in-house resources/expertise, APQP, PPAP, R@R
etc.)
On similar parts that you manufacture for the Automotive Industry,
and the tolerances assigned to those parts.
PR/R’s and PPM to the Vehicle Assembly Centers.
What is included in the tooling price? Describe in detail.
How do you plan to track and maintain responsibility for all prototype
tools, part fabrication, and GP-11?
Included in the quote response?
Does the manufacturing facility have the test capability on site?
Including potential failures, potential causes, and error occurrence
prevention /defect outflow detection.
PFMEA strategy must strive for zero defects and include any lessons
learned from previous programs.
Proof ofCertification to GM specific requirements
If the manufacturing facility does not have certification, submit your
Certification timetable/implementation plan. (Suppliers with new
facilities)
Proof of compliance in accordance with ISO14001 and GM
requirements – or -Plan for achieving compliance by Jan. 2003 (GM required date).
Describe your operator-training program.
Are critical operations identified?
Required by QS-9000
GM-1927-2
GM-1927-8
GM-1927-9
QS-9000 3rd
Edition 3/98,
Section 4.2.3.3
4) Supplier Program Reviews
Supplier Quality SOR
• Supplier Quality has a Global
Statement of Requirements that
applies to all suppliers.
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 (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.
• SOR Included in the GM RFQ.
• Supplier Quotations to GM
must include a signed copy of
the SOR, indicating compliance
to these requirements.
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

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
31
4) Supplier Program Reviews
APQP Timing Chart
Program Review #1 (PR#1)
Tas k
P ro gra m Da te s : Alpha __________ B e ta _________ Ga m m a /P ro to _________
S u p p lie r
GM
R e q u ire d
R e s p o n s ib le
R e s p o n s ib le
A c t u a lS
La s t
C o m p le t io n
C o nt a c t
C o nt a c t
t a rt
Up d a t e
D a te
Date Revised:___________
P ilo t_________
S c h e d u le d
C o m p le t e
S S F ___________
S u p p lie r
C o m p le t e
GM
R e v ie we d
QTR
1 '0 0
QTR
2
'0 0
QTR
3
'0 0
QTR
4
'0 0
A lp h a M R D
B e ta M R D
P ro t o t yp e / G A M M A M R D
• Define Program Timing Elements
-Major Program Benchmark Dates
are provided by the SQE
D e s ig n F re e z e D a t e
F in a l P P A P S u b m is s io n
R u n @ R a t e C o m p le t e D a t e
P ilo t M R D
S t a rt o f S ys t e m F ill
AP QP Kic ko ff Mtg
Tim ing C ha rts S ubm itte d
DF MEA
F e a s ibility/As s e s s m e nt Le tte rs
- De s ign
- P ro to type
- C a pa bility & R e a dine s s
KC DS / GD&T
- GM 1927-2 provides the Minimum
list of activities that must be tracked
by the supplier
- KC DS wo rks ho p
- GD&T C o m ple te /Ma th Dra wing
De s ign R e vie w
To o l P .O. is s ue d by GM
Ga ge R e vie w
- De s ign
- B uild
Me a s ure m e nt S ys te m R &R
- C e rtific a tio n
F a c ility & La yo ut P la n
To o ling/Ma c hine ry P la n
P ro c e s s F lo w C ha rt
• Suppliers Complete the form and
return it to the SQE
- Updates showing progress are
forwarded to the SQE
- Detailed evaluations are conducted
as part of future Program Reviews.
- P re lim ina ry
- P ro to type
- P ro duc tio n
P F MEA S tra te gy
- P re lim ina ry
- P ro to type
- P ro duc tio n
R P N R e duc tio n P la ns
P a c ka ging P la n
Tie r 2 Tim ing P la n
GP -11
P ro c e s s C a pa bility S tudie s
C o ntro l P la n
- P re lim ina ry
-P ro to type
- P ro d u c tio n
P P A P s u b m itte d
R u n @ R a te (G P -9 ) P la n
G P -12 (P re -La u n c h C o n tro l P la n )
Le s s o n s Le a rn e d R e v ie ws
S u p p lie r D e s ig n a te d A d d 'l In fo
Target
P la n t M a n a g e r S ig n a tu re :
32
S u p p lie r P ro g ra m R e v ie w # 1
D a te :
S u p p lie r P ro g ra m R e v ie w # 2
D a te :
S u p p lie r P ro g ra m R e v ie w # 3
D a te :
S u p p lie r P ro g ra m R e v ie w # 4
D a te :
A ctual
4) Supplier Program Reviews
Lessons Learned
• Review Lessons Learned in GM SupplyPower website
- Obtain worksheet on major components
- Evaluate Lessons for application to new part
CO M M O DITY CRITERIA CH ECK LIST FO R: Axles
N o.
C riteria D escription
1.0
DESIG N
1.1
Are m agnets secure on cover pan? Is there a
m ethod to insure/prevent m agnets from
falling off due to interaction between
adhesive/oil or flat m agnet to round surface?
Is the shaft stiff enough to prevent the shaft
from bending relative to the disc brake system
and load conditions?
Has the drain/fill plug integrity been properly
defined to assure no loss of fluid?
Has the Front Differential Seal been validated
at low tem peratures to avoid cracking?
Is the swage at the proper diam eter to prevent
puddle weld leaks at the axle tubes?
Has a design/m ethod been validated to
elim inate noisy axles? (Num ber 1 W arranty
Item )
1.2
1.3
1.4
1.5
1.6
2.0
M ANUFACTURING
2.1
Is there a m ethod to insure that all
threads/holes are present in the yoke?
Is there a m ethod to ensure that brake pads are
not shy, possibly using a weigh station or
vision system to m onitor this condition?
Is there a m ethod to verify fluid fill level, i.e.,
m onitor or weigh stations?
Has the process or design been error proofed
to prevent R/H and L/H caliper from being
reversed and in the proper position?
2.2
2.3
2.4
Description of Issue
Issue
C ode
• Discuss other Lessons Learned from similar parts
• Objective of this activity is --- Avoid Repeat Issues
33
Supplier:
Date:
Resolution Status
4) Supplier Program Reviews
Supplier Program Reviews 2,3,4
Meeting Subjects Include:
•
•
•
•
•
•
•
•
•
•
•
•
APQP Major/Open Issues List
APQP Timing Chart Updates
Progress of Tooling/Fixtures/Gages
Task 6
Supplier Manufacturing Assessment Letters (3 letters)
Lessons Learned
Design Issues
Suppliers need to be
RPN Reduction Plans
prepared for each
AIAG New Equipment Checklist (A-3)
AIAG Process Flow Checklist (A-6)
meeting with
AIAG PFMEA Checklist (A-7)
supporting documents
AIAG Control Plan Checklist (A-8)
GP-12 Plan
SQEs will Review Documents at Meetings
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Primary
4) Supplier Program Reviews
Timing Supplier Program Review #2 (PR#2)
• Program Review #2 (PR2) conducted 2 weeks prior to
the Beta Prototype Build Review
– Supplier conducts the meeting and reports the status of the
deliverables due for this review
• Purpose--Supplier Program Review #2
– Ensure the suppliers manufacturing process is capable of
meeting GM’s requirements for the Beta Prototype Build Review
(applicable for suppliers providing parts for Beta)
– Communicate issues that have been identified during the
preparation for the Beta Build Review.
– Verify program timing for remaining APQP deliverables
35
4) Supplier Program Review #2
Specific Review Items
• Items designated on the APQP Project Plan GM 1927-1
with a 2 in Program Review column
– Timing Chart GM 1927-2
• Verify timing is on track
• Only require detail on items where timing has slipped
– APQP Open Issues list GM 1927-5
– Feasibility Letter #2- Supplier Manufacturing Assessment of Design
– Flow Chart-should be more detailed than the initial one due at the
Technical Review
– DFMEA - status if design responsible, availability of data if GM
design responsible
36
4) Supplier Program Review #2
Specific Review Items-(continued)
– Control Plan--review and verification of continued development since initial
review during the APQP Kick-Off/Pre-Production meeting
– The same logic that applied to the PFMEA applies here
• If supplier currently produces a similar part, the Control Plan
should be very detailed
• If this is a new process for the supplier the level of detail will not
be as complete
– This build event and the Prototype events are where the
supplier clearly identifies where error proofing techniques
and audit type controls are necessary
37
4) Supplier Program Review #2
Specific Review Items -(continued)
– PFMEA Strategy--review and verification of continued development since
initial review during the APQP Kick-Off/Pre-Production meeting
– If supplier currently produces a similar part, the PFMEA should be
very detailed
• If this is a new process for the supplier the level of detail will not
be as complete
– Detail of Recommended Actions may not be
identified for all listed Potential Failure Modes
– Recommended Actions may not be completed
38
4) Supplier Program Review #2
Specific Review Items -(continued)
– Design Review-discussions should be around a KCDS workshop
• GM design responsible-GM leads workshop
• Supplier design responsible- Supplier leads the workshop or appropriate
activity to identify the Key Product Characteristics
– Gage, Tooling & Equipment Review
• Gage Concept approval status
• Specific tooling timing-ensure timing is meeting the plan for the
program timing
– GP-11--Discussions should take place between the supplier and the GM
engineer on the plan to provide parts for the Prototype build
– plan should include dimensional data requirements and the method
of collection necessary i.e. , CMM holding fixture, what is the
serialization process required etc.
39
4) Supplier Program Review #2
Specific Review Items-(continued)
– Lessons Learned -- update of lessons learned identified during the process
to date
• Include design items and manufacturing items
• Items should be tracked back to the DFMEA if supplier is design
responsible
• Track manufacturing items back to PFMEA
40
4) Supplier Program Review #2
• Insert a copy of GM 1927-10 and GM 1927--11
– these show overviews of how the Lessons
Learned process was developed and should
function
41
4) Supplier Program Review #2
• Insert copy of GM 1927-12--this is a copy of
the ACTUAL Global Lessons Learned criteria
check-sheet that was developed for Exterior
Mirrors.
42
4) Supplier Program Review #3
Timing Supplier Program Review #3 -- (PR#3)
• Program Review #3 (PR3) conducted 2 weeks prior to the
Gamma Prototype Build Review
– Supplier conducts the meeting and reports the status of the
deliverables due for this review
• Purpose--Supplier Program Review #3
– Ensure the suppliers manufacturing process is capable of meeting
GM’s requirements for the Prototype review (applicable for suppliers
providing parts for Prototype)
– Communicate issues that have been identified during the preparation
for the Gamma Prototype Build Review.
– Verify program timing for remaining APQP deliverables
43
4) Supplier Program Review #3
Specific Review Items (continued)
• Items designated on the APQP Project Plan GM 1927-1 with
a 3 in Program Review column
– Timing Chart GM 1927-2
• Verify timing is on track
• Only require detail on items where timing has slipped
• These items are candidates for a “Launch Alert”
– APQP Open Issues list GM 1927-5
• What is the status of major items since the last review
– Feasibility Letter #3- Supplier Manufacturing Assessment of
Prototype
• Signature required by manufacturing location plant management
44
4) Supplier Program Reviews
• Insert a copy of “Supplier Manufacturing Assessment
Of Prototype” GM 1927-19 letter 3
45
4) Supplier Program Review #3
Specific Review Items (continued)
– Design Review
• KPC’s should have been identified through the KCDS Workshop
process
• GD&T discussions should also be completed by the Prototype
build event
– Gage/Tooling Review
• Gage Design approval status
• Specific tooling timing
– Require detail on any item where timing has slipped in
relation to GM’s program timing
46
4) Supplier Program Review #3
Specific Review Items (continued)
– GP-11--confirm the supplier has met the engineering requirements for
Pre-Prototype and Prototype builds
• This should include a review of the dimensional results and any
quality issues identified during the Prototype build
• Ensure the GM engineer is involved to approve any
dimensional issues
– PFMEA Strategy--review and verification of continued development
• emphasis on items identified during any and Prototype
manufacturing processes (see Lessons Learned)
47
4) Supplier Program Review #3
Specific Review Items (continued)
– Control Plan--review and verification of continued development since
Supplier Program Review #2 meeting
• This should include all necessary controls and error proofing
techniques identified during all early build events
– Lessons Learned -- update of lessons learned that were identified during
the Prototype build process
• Include design items and manufacturing items
• These items should be tracked back to the DFMEA if design
responsible
• Manufacturing items tracked back to PFMEA
48
Risk Assessment
• Risk Assessment is updated for the current status in
program
– Review of the overall risk associated with the program is
updated by the SQE after Supplier Program Review #3
– This is reported to internal GM Program Management
49
4) Supplier Program Reviews
Timing Supplier Program Review #4 (PR #4)
• Program Review #4 (PR4) conducted 2 weeks prior the
the Pilot Build Review
– Supplier conducts the meeting and reports the status of the
deliverables due for this review
• Purpose Supplier Program Review #4
• “Dress Rehearsal” for PPAP
– Ensure the suppliers manufacturing process is capable of
meeting GM’s requirements for the Pilot build.
• Manufacturing process and all support is to be representative
of ALL Production systems and processes
– Communicate issues that have been identified since the
Prototype Build Review
– Verify program timing for remaining APQP deliverables
50
4) Supplier Program Review #4
Specific Review Items
• Items designated on the APQP Project Plan GM 1927-1 with a 4 in
Program Review column
• All Quality documentation at this review is to be ready for PPAP
submission
– Timing Chart GM 1927-2
• Verify timing is on track
• Only require detail on items where timing has slipped
• These items are candidates for a “Launch Alert”
– APQP Open Issues list GM 1927-5
– Feasibility Letter #4- Supplier Manufacturing Assessment of
Manufacturing Process Capability and Production Readiness
– Flow Chart--Ready for PPAP submission
51
4) Supplier Program Review #4
• Insert copy of “Supplier manufacturing Assessment of
Manufacturing Process Capability and Production
Readinesss”
GM 1927-19 letter 4
52
4) Supplier Program Review #4
Specific Review Items (continued)
•
All Quality documentation (continued)
– DFMEA--completed if supplier is design responsible
– Gage/Tooling Review
• Gage R&R should be reviewed and acceptable
• Corrective Action plan reviewed if R&R is unacceptable
• Specific tooling timing at this point should be completed to
schedule
– Any tooling issue is a “Launch Alert” candidate
53
4) Supplier Program Review #4
Specific Review Items (continued)
• All Quality documentation (continued)
– PFMEA Strategy--review and verification of evidence that supports RPN
reductions throughout the manufacturing process (see Lessons Learned)
– Control Plan--review and verification of evidence that indicates error
proofing techniques are in place and that all process operation are
controlled
– GP-12--review of the specific controls put in place to prevent defective
parts from reaching the GM manufacturing site
• This is the supplier’s Pre-Launch Control Plan, reference GM
1920
54
4) Supplier Program Review #4
Specific Review Items (continued)
– Run @ Rate--final details for the Run @ Rate should be confirmed,
this includes those parts designated as Customer or Supplier
Monitored
– Confirm with the supplier the quantities required i.e. LCR and
Contracted Tool Capacity
– Lessons Learned -- ensure all lessons learned during the entire APQP
process have been documented in the appropriate quality documents
– DFMEA
• PFMEA
• Control Plans
This documentation is critical for future programs success
55
5) Timing Charts / Open Issues
Purpose:
• Ensure Program Deliverables are Executed on Schedule
SQE Responsibility:
• Review the APQP Timing Chart and APQP Issues List
• Identify and Communicate Key Timing and Program Issues with GM
Management
Supplier Responsibility:
• Create and maintain an APQP Timing Chart and Open Issues List
• Maintain Detail behind Each High Level APQP Chart
• Review Timing Chart and Issues List at All Program Reviews
• Identify and Communicate Any Changes to SQE
• Identify and Communicate Key Timing and Program Issues with SQE
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Primary
6) Manufacturing Assessment Letters
Purpose:
Supplier Evaluates Manufacturability of the Part
Manufacturing Assessments:
Design -- can the Design be Manufactured to Conform to
all GM Performance Requirements?
Prototype -- using the Intended Production Process,
will all Parts Conform to GM Requirements?
Process Capability -- will the Production Process Provide
Parts that Conform to GM Requirements?
Supplier Responsibility:
• Evaluate Feasibility during 3 stages of program development
• Submit Letters Signed by the Manufacturing Plant Manager
57
6) Manufacturing Assessment Letters
Design Is Manufacturable to
GM Required Quality Levels…
Manufacturing is making a
commitment to achieve zero
defects..
ABC Company
123 Part Lane
Anywhere, Michigan 48000
(313)777-7777
July 12, 1997
GM Supplier Quality Engineer
GM Release Engineer
General Motors Corporation
SUPPLIER MANUFACTURING ASSESSMENT OF DESIGN
As required by General Motors, ABC Company held a manufacturing review of the Model
Year design on date. The review has led us to the following position:
(Select one)
 Manufacturing is confident the design is manufacturable to GM required
quality levels, within PPAP design specifications, and within PPAP
capability requirements. Manufacturing is making a commitment to
achieve zero defects as specified in the GM Supplier Quality Statement of
Requirements. There are no concerns to report.
 Manufacturing has minor concerns about the design which have been
reported to the design community and are described below. We are
confident that the design will be modified to accommodate our issues and
be manufacturable to GM required quality levels, within PPAP design
specifications, and within PPAP capability requirements. Manufacturing
is making a commitment to achieve zero defects as specified in the GM Supplier
Quality Statement of Requirements.
 Manufacturing has major concerns about the design and we are not confident that we can
produce this part at required quality levels. These concerns are described below.
58
Minor concerns about the
design .. Confident that design
will be modified..manufacturable
to Required Quality Levels…
commitment to achieve zero
defects..
Major concerns about design,
not confident part can be
produced at GM Required
Quality Levels…
7) Flow Chart
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.
SQE Responsibility:
• 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
59
Primary
8) Design Failure Mode and Effects Analysis
Purpose:
Support the Design Process in Reducing the Risk of Failure
SQE Responsibility:
• Confirm that a DFMEA has been Completed
• Ensure that Supplier has a DFMEA for input to PFMEA
• Lessons Learned Checklist to Design Owner
Supplier Responsibility:
• GM Design Responsible
• Suppliers must participate in DFMEA Reviews with Product Engineer
• Share Knowledge and Experience on Similar Designs
• Recommend Action Plans for Severity, Occurrence, Detection Targets
• Supplier Design Responsible
• Lead Cross-functional Team to Develop and Improve FMEA
• Schedule Review Meetings with GM Product Engineer
• Develop Action Plans for Severity, Occurrence, Detection Targets
• Maintain DFMEA for PPAP Submission
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Primary
9) Design Reviews
Purpose:
Ensure that the Design has been adequately Defined to Build Tools and Gauges
SQE Responsibility:
• Participate in KCDS Workshop and GD& T Reviews
• Participate in Design Reviews addressing changes in Manufacturing Process/
Quality/Timing/ Risk
Supplier Responsibility:
• Participate in KCDS Workshop and GD& T & Design Reviews
• Participate in Defining Measurable KPC’s
• Participate in Defining Appearance Specifications
• Satisfy all Performance and Material Testing Requirements
• Ensure that the Manufacturing Process can achieve Tolerances on a
Continuing Basis
Quality of the Design Directly Impacts Process Design and Process Quality
61
Primary
10) Gage, Tooling & Equipment Reviews
Purpose:
• Ensure that the Manufacturing process is being designed, built and certified to
produce parts with quality at rate according to GM program requirements
SQE Responsibility:
• Confirm that Gage, Tooling and Equipment Timing is on Schedule to Support
Program Requirements
• Confirm that the Gauge Agrees with the Functional Part Usage, Complies with
GD&T, Includes Measurement of KPCs and is at the Correct Change Level
• Ensure Gage is Used as Indicated in Process Flow Chart and Control Plan
Supplier Responsibility:
• Design, Build and Obtain Certification of Gages
• Participate in Reviews with General Motors Relative to Design, Build and
Certification of the Gage
62
11) GP 11 Prototype
Purpose:
• Ensure Part Problems are Identified and Corrected in order to
Minimize the Impact of Part Variation upon Design Evaluation,
Manufacturing, and Assembly.
Supplier Responsibility:
• Adhere to Requirements Specified in GP-11.
• Ship Parts and Documentation as Specified in GP-11 and the
Prototype Purchase Order.
• Respond to and Resolve Issues Identified in Prototype Build.
• Revise the Flow Chart, PFMEA, and Control Plan as Problems
are Identified throughout GP-11 and the Prototype Build.
• Update the APQP Open Issues List and APQP Timing Chart as
Problems and Changes Occur.
Prototype will act as a Mirror for Problems that will
Appear at Pilot = Address Issues Early in Program!
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Primary
12) PFMEA Strategy
Purpose:
Assure Potential Failure Modes of the Process have been Considered and
Addressed
SQE Responsibility:
• Attend initial PFMEA Development Team Meeting
• Monitor Progress and Review PFMEA with Supplier
Supplier Responsibility:
• Initiate PFMEA prior to Sourcing as part of the Quotation to GM
• Drive Error Prevention and Detection throughout the Process
• Prepare PFMEA - Multi-disciplinary team
• Insure that PFMEA results have been incorporated into Control Plan
• Revise PFMEA if Process / Material / Manufacturing Location Changes
• Develop and Implement RPN Reduction Plans
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Primary
13) Control Plans
Purpose:
Define the Method being used to Control all KPCs and
KCCs for Parts being Manufactured for Vehicle Builds.
SQE Responsibility:
• Verify use of PFMEA & Statistical Data to determine Necessary Controls
• Verify Update of Control Plan with Solutions from PFMEA
• Verify Pre-Launch Issues have been Incorporated into Production Plan
Supplier Responsibility:
• Develop Pre-sourcing Control Plan
• Ensure Control Plan Flows from PFMEA & Process Flow Chart
• Use Pre-Launch Control Plan to Validate Production Control Plan
• Update Control Plan
Process Control Plan Audits will be Conducted at Run@ Rate
65
Primary
14) GP 12 Early Production Containment
Purpose:
• Establish a Containment Plan during Start-up and Acceleration that will
Quickly Identify Quality Issues at the Supplier’s Facility; i.e., a Pre-Launch
Control Plan.
SQE Responsibility:
• Provide GP-12 Timing to the Supplier
• Review the Supplier’s Process and Pre-Launch Control Plan
• Verify that any PR&R, Prototype or Pilot Issues are in Control
• Verify that the Supplier used PFMEA & Statistical Data to Set Controls
Supplier Responsibility:
• Develop the Pre-Launch Control Plan Based on Experience from Prior Issues
• Implement the Pre-Launch Control Plan
• Monitor GP 12 Data and Modify Internal Process to Eliminate Issues
• Monitor Customer Issues and PR&Rs, Update Control Plans
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Primary
15) Production Part Approval Process
Purpose:
• Determine if All Customer Engineering Design Records & Specifications
Requirements are properly understood by the Supplier and that the Process has
the Potential to Produce Product Meeting these Requirements during Production
at the Quoted Rate.
SQE Responsibility:
• Review PPAP Documentation Prior to Submission
- Verify Completion of all 19 Required Items
- Many Documents Can be Reviewed in Advance of PPAP Submission
• Follow-up on PPAP Rejections
Supplier Responsibility:
• Produce Parts in the Production Environment
• Complete all Documents and Test Requirements in Advance of PPAP Date
• Target for Full PPAP on First Submission
Primary
67
16) Run at Rate
Purpose:
• Verify that the Supplier’s Actual Manufacturing Process is Capable
of Producing Parts that Meet:
- GM’s On-going Quality Requirements
- Quoted Tool Capacity
- GM’s Daily Volume Requirements
SQE Responsibility:
• Evaluate the Supplier’s Run at Rate Plan
• Determine if the Run at Rate should be Customer or Supplier Monitored
• Participate in Customer Monitored, or Review the Results of Supplier Monitored
• Confirm Actual Capacity Exceeds Quoted Capacity and GM Daily Requirements
• Status Run at Rate According to Results
Supplier Responsibility:
• Develop Run at Rate Plan and Review with SQE
• Confirm Quoted Tool Capacity and Duration of Run at Rate
• Conduct Run at Rate, Complete Worksheets and Forward to SQE
68
17) Lessons Learned
Purpose:
• Review Experience from Previous Programs and Consider Opportunities to
Improve Performance on New Programs.
SQE Responsibility:
• Acquire Information about Previous Experiences with Similar Commodities
- Other SQEs, Local or in Other Regions
- Product Engineers
• Share Personal Knowledge and Experience
• Verify that the Supplier Applies Lessons Learned in New Process
Supplier Responsibility:
• Share Lessons Learned from Similar Commodities
• Evaluate Lessons Learned from External Sources
• Incorporate All Applicable Items into Production Process and Tool Designs
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Primary
Summary
• Proactive Conformance to AIAG APQP Requirements
and GM APQP Tasks
• Supplier Drives Tasks 4 through 17 to Completion
• Identify Issues Early in Program and Drive Correction
• Maintain Communication with GM on Program Status
and Issues
-- Manufacturing Assessment Letters
-- Schedule Program Review 2,3,4 with the SQE
• Expect these Same Requirements from Sub-Suppliers
Let’s Get Going!!
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Primary