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

GM-1927 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 Advanced Product Quality Planning

Download from Worldwide Purchasing

GMSupplyPower 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
• Drive the supplier’s progress in the development
of all quality related documents listed on APQP
Project Plan
• Raise issues that might jeopardize a quality part
within the program timing – either to supplier’s or
GM’s upper management, as appropriate
• Participate in the remaining Supplier Gate
Review meetings
• Adhere to supplier manufacturing site protocol
when in the manufacturing facility
• Attend PDT and associated program meetings
• Drive/Enforce the process of supplier’s quality
system development
• Apply APQP Workbook Audits and upload all Key
Deliverables to GQTS
• Supplier Monitored – SQE Responsibilities
• Monitor the supplier’s adherence to program
timing and track open issues addressing
• Customer Monitored – Supplier Responsibilities
• Execute the content and provide updates per the
APQP Project Plan
• Implement an advanced product quality
planning process with all sub-tier suppliers
• Invite and conduct all remaining Gate Reviews
• Work closely with GM SQE
• Supplier Monitored – Supplier Responsibilities
• Execute the content of the APQP Project Plan
• Implement an advanced product quality
planning process with all sub-tier suppliers
• Responsible for meeting quality, timing and
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

TIME LINE CONTINUOUS IMPROVEMENT (GP-8)

EARLY PRODUCTION
CONTAINMENT (GP-12)
LIFE
RUN @ RATE (GP-9)
OF PART
PRODUCTION PART
APPROVAL (PPAP) GM Global APQP
PROTOTYPE SAMPLE
APPROVAL (GP-11)
PRE-PRODUCTION MEETING

ADVANCED PRODUCT
QUALITY PLANNING (APQP)
SOURCING DECISION

POTENTIAL SUPPLIER
ASSESSMENT
START OF
PRODUCTION
 1. Commodity Sourcing Strategy Meetings
APQP Project Plan
Prototype Pilot / Pre-Launch Launch /
Planning Production
AIAG Product Design and Development
APQP Process Design and Development
Product and Process Validation
Feedback, Assessment and Corrective Action
Structure Integration Validation MVBns MVBs SOP
GM GVDP Vehicle Vehicle Vehicle

GR-1

GR-2

GR-3

GR-4
Gate Sourcing
APQP Task Reviews Activities
Commodity Sourcing
1 Strategy Mtg GR-1 o------o o

2 Technical Reviews GR-1 o------o o

Risk Assessment / Update Risk
3 Sourcing GR-1,3 TR o o o
Supplier Gate
4 Reviews
Timing Charts / Initial-TR
5 Open Issues GR-1,2,3,4 o o o o o o o o o o o o o o o o o o o o o o o o o o o o
Feasibility / Initial-TR Letter 2 Letter 3 Letter 4
6 Assessment Letters GR-1,2,3,4 o o o o
Initial -TR Prototype Production
7 Flow Chart GR-1,2,4 o o o o o o
DFMEA Update RPN Reduction
8 DFMEA GR-1,2,4 o o o o DFMEA
o o o
KCDS Workshop GD&T
9 Design Reviews GR-2,3 o o o o
Gage, Tooling and Prod Concept-TR Gage Concept Approval Gage Design Approval Gage Approval/R&R, Tool Completion
10 Equipment Reviews GR-1,2,3,4 o o o o o
The Commodity Sourcing Strategy Execute Meeting is the responsibility of the Buyer –
Execute
11 GP-11 GR-2,3 o o o o
 InternalInitial-TR
GM people only
Prototype / RPN Baseline Production / RPN Reduction RPN Reduction
12 PFMEA GR-1,2,3,4 o o o o o o o o
 The first time the SQEPrototype
Initial-TR becomes “officially” involved GP-12 & Production in the APQP process
13 Control Plan GR-1,2,3,4 o o o o o o o
 Commodity Initial-TR Sourcing Strategy Meeting is thePlanfirst task that Execute is trackedExitby the
(Platform Discretion)
14 GP-12 GR-3,4 o o o o
APQP Project Plan
15 PPAP GR-4 o o
Plan Capacity Analysis Capacity Analysis Conduct Run@Rate
16 Run @ Rate (GP-9) GR-1,2,3,4 o o o o o o o

17 Lessons Learned GR-1,2,3,4 o 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 RFQ-
package 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

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.

Statement of Requirements that 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.

applies to all suppliers. 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.

• SOR Included in the GM RFQ.  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:

• Supplier Quotations to GM
 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)

must include a signed copy of  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

the SOR, indicating compliance to  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

these requirements.  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
GVDP 5.0 timing Key Form/
(Time from Review
reference Deliverables Document
SORP in
weeks)
GM Global APQP Supplier Status Summary
ALL GM1927-34
Workbook
QSB Audit (Gap Analysis) or Greenfield GM1927-30
Within 30 days of Checklist (Action Plan) GM1927-31
business nomination Gate 1
Timing Plan GM1927-2
advice / contract
Kick-Off Check list GM1927-14
Initiated after CVER PFMEA Check list GM1927-37
-78 and completed 5 Gate 2 RPN Reduction Summary GM1927-21
weeks after IVER Subcontractor Status GM1927-25
Supplier ADV Plan (ADVP&R) showing
GM1829
execution status
Completed 10 weeks
-52 Gate 3 QSB Audit (Compliance) or Greenfield Checklist GM1927-30
prior Matching 1 GA
(Complete) GM1927-31
Run @ Rate Capacity Workbook GM1927-35
Dimensional Report GM1927-32
Completed 3 weeks
-35 Gate 4 PPAP Worksheet (if not fully approved) GM1411
prior PPV MRD
GP12 Audit GM1927-33
Completed 1 week
-15 PPAP PPAP Approval
prior MVBs MRD
Run @ Run @ Rate Execution R@R Module
-8
Rate PCPA 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

Part name: Part number:

Who to GM Program:
Supplier Name:
Model Year:
DUNS #:

Contact? Manufacturing Location Address:

Supplier Mfg. Plant Manager: Phone:

GM SUPPLIER
Position Name Phone (fax,mobile) E-mail Position Name Phone (fax,mobile) E-mail
Advance Project
GM1927-17 SQE
Buyer
Manager
Sales Mgr
List the Key Design Design
Engineer Engineer
Positions VLE PPM Quality
Manager
needed to Proto PE Laboratory
Supv.
Manuf.
Manage New Engineer
GM Plant
Programs Rep
GD&T

Readiness
Coord.
Container- Packaging
ization Engineer
Reliab. 1st Shift
Engineer Contact
nd
Paint 2 Shift
Engineer Contact
rd
Current 3 Shift
SQE Contact
Sub-
Contractor

APQP Contact List.doc 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
SQE that the Production Version is linked to the PFMEA and Control Plan
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
KPC Value KCC Control Method
O

Extrusion: Automatic
VE:3060±7.5mm Extrusion: Cutting cutting
1 Length Aging: Temperature; time Aging: PLC
WM:3118±7.5mm Finishing: End cutting Finishing: 100% DIM
check & SPC

Mixing: Ingredient quantity Mixing: Bar code

Compr VE/WM:
Extrusion: Temperature; Extrusion: PLC
2 ession 10.75mm
Load Line speed Aging: PLC control
8~14N
Aging: Temperature; time 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