Apqp-gm
This document was uploaded by user and they confirmed that they have the permission to share it. If you are author or own the copyright of this book, please report to us by using this DMCA report form. Report DMCA
Overview
Download & View Apqp-gm as PDF for free.
More details
- Words: 4,378
- Pages: 73
Loading documents preview...
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 • • • • • • • •
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: • • • • •
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.
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
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 • • • • • • • •
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: • • • • •
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.
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)
Position Project Manager Sales Mgr
Name
SUPPLIER Phone (fax,mobile)
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
More Documents from "pbvr"
