Quality Control Operation

System (QCOS)

GME Quality

GMU Europe / page 1

JFJ Aug 06
 Built-In Quality – Right First Time!
Goal of Manufacturing
A key objective of the Manufacturing process is to
build ‘Right First Time’ through Built-In Quality
Satisfy your customer
Accept
Do not Build a defect!
Ship
Solve problems through teamwork!

A key Element from GM-GMS Built-In Quality is

“In Process Control & Verification”

GMU Europe / page 2

JFJ Aug 06
 In-Process Control & Verification
The BIQ principle of “Do Not Accept, Build, Ship a Defect” is
supported by the following objectives:
1. Prevention – avoid making a problem
2. Detection – find the problem if one should occur
3. Containment – stop the problem from flowing to the next
process or customer

Inputs 1. Prevention Outputs

2. Detection
OK

Next
NOK Process
or
Feedback 3. Containment Customer

GMU Europe / page 3

JFJ Aug 06
 Principles of Process Control
Objective
Process control planning aims to identify actions in a
Manufacturing process aimed at controlling risk, as follows:
• Provides “thought starters” for different elements of process
control (e.g. tooling, error-proofing, control checks, etc.)
• Documents a plan for different elements / resources that
require action or monitoring
• Communicates necessary actions or controls to the people
responsible for performing them
• Provides a method of confirming that the control plan elements
are being followed
• Provides a basis for standardisation & continuous improvement

GMU Europe / page 4

JFJ Aug 06
 Principles of Process Control
Developing a Process Control Plan
Process control plans are developed following the
principles of Plan-Do-Check-Act; firstly risk assessment
must identify priority processes.
The control plan is then developed, applied, confirmed and
then improved if required.

Identify and Improve

Outline & Apply Confirm
quantify controls, as
plan controls controls controls
risk required

Plan Do Check Act

GMU Europe / page 5

JFJ Aug 06
 Quality Control Operation System
Process Control Planning in GME
In GM Europe, the method for developing process control plans
is ‘Quality Control Operation System’ (QCOS).
QCOS uses the principles of ‘Failure Mode Effects Analysis’
(FMEA) to assess risk and develop control plan elements.
Uses FMEA principle to develop control plan:
• Severity: considers impact of failure on customer
• Occurrence: control plan objective is ‘zero occurrence’
through robust controls - Prevention
• Detection: if failure occurs, the control plan aims to find and
prevent flow-out - Detection

GMU Europe / page 6

JFJ Aug 06
 Quality Control Operation System
QCOS – Assessing Risk (Severity)
QCOS assesses the risk of a vehicle feature failing by
establishing a QCOS Rank.
The QCOS rank considers the impact of ‘failure’ on customer
safety or satisfaction; the priority ranking is to avoid the
following:
• Safety, legal and campaigns issues
• Walk Home Failures
• Major customer complaints
• Minor customer dissatisfiers

GMU Europe / page 7

JFJ Aug 06
 Quality Control Operation System
QCOS Rank Definition
QCOS GCA
KPC* Description Rank Rank

Directly relates to human safety – leads to

12
an accident with impact on passenger safety

Safety/
Indirectly relates to human safety – has impact
Compl. on passenger safety in the event of an accident 50
Legal requirements
9
Functional breakdown of vehicle: ‘walk home failure’
Functional breakdown of component (non-WHF) or 10 /
Fit/ many customer complaints – not safety-related
6 5.0
Function
Non-functional breakdown but some
customer complaints – not safety-related
3 1.0

*Key Product Characteristic

GMU Europe / page 8

JFJ Aug 06
 Quality Control Operation System
Product Risk Assessment to basic Control Plan
• Product features are risk-assessed by Product Engineering for
customer safety or satisfaction, or for legal compliance – key
product characteristics (KPCs) are established.
• KPCs are communicated to Manufacturing Engineering to
begin developing the QCOS control plan.
• The basic for the control plan is deployed to plant level for
detailed development Key Key
Product risk assessment: Product Control
Key Product
Characteristic Description
QCOS
Rank
Characteristic Characteristic
Directly relates to human safety – leads to an
12
accident with impact on passenger safety
Safety/
Compliance Indirectly relates to human safety – has impact
on passenger safety in the event of an accident
9
Legal requirements

Fit/
Function
Functional breakdown of vehicle: ‘walk home failure’
Functional breakdown of component (non WHF)
or many customer complaints – not safety-related
6 KCDS APS
Non-functional breakdown but some
customer complaints – not safety-related 3

GMU Europe / page 9

JFJ Aug 06
 Quality Control Operation System
Control Plan deployment to Plant level
• The QCOS control plan is communicated via APS* to Plant level and
will form part of the shop floor standardised work
Product risk assessment:
Key Product QCOS
Description
Characteristic

Directly relates to human safety – leads to an

Rank

12 KPC KCC
accident with impact on passenger safety
Safety/
Compliance Indirectly relates to human safety – has impact
on passenger safety in the event of an accident
9
Legal requirements
Functional breakdown of vehicle: ‘walk home failure’ KCDS APS
Functional breakdown of component (non WHF)
Fit/ 6
Function or many customer complaints – not safety-related
Non-functional breakdown but some
customer complaints – not safety-related 3

Shop floor standardised work

QCOS Manual
Standard QCOS Equipment
1
Operation QCOS Weld Control 1
Sheet
QCOS Torque Control
1
Job
Element
Sheet

QCOS Sheets (for each operation type)

GMU Europe / page 10
JFJ Aug 06
 Quality Control Operation System
Developing the QCOS control plan
For each Key Product Characteristic, ‘controls’ are planned into
the process which support the principles of ‘Built-In Quality’
Process controls are based on the following 5 resources which
support either Prevention, Detection or Containment
Prevention Detection/Containment

1 2 3 4 5
Process
Tooling or Error- 100% Process
control
Method* Proofing checks
Inspection Audit

*Depending on
type of operation

GMU Europe / page 11

JFJ Aug 06
 Quality Control Operation System
Building the QCOS control plan
The QCOS control plan is established by determining the level of resources to
be applied; control points are assigned considering level of resource:
Control Error Process Process
points
Tooling Inspection
proofing control audit
100%
Tool with Process stop inspection of
advanced based on
X bar R chart automatically Min. 1/shift
3 control element machine applied
(DC tool) measurement verification
check
Audible or
Tool with basic sensory signal 100% SIP
based on machine Min. 2/week for
2 control element
(pulse tool) measurement
Trend chart touch/visual
check
each shift
check

Visual signal 100% check of

manually applied
Tool without based on
verification Min. 2/month
1 specific control machine OK/NOK sheet
or for each shift
element measurement 100% neighbour
check check

GMU Europe / page 12

JFJ Aug 06
 Quality Control Operation System
Building the QCOS control plan
As the process controls are determined, control points are added from each
column to provide a total (sum) for the operation:
Example:
Control Error Process Process
points
Tooling Inspection
proofing control audit
100%
Tool with Process stop inspection of
advanced based on
X bar R chart automatically Min. 1/shift
3 control element machine applied
(DC tool) measurement verification
check
Audible or
Tool with basic sensory signal 100% SIP
based on machine Min. 2/week for
2 control element
measurement
Trend chart touch/visual
each shift
(pulse tool) check
check

Visual signal 100% check of

manually applied
Tool without based on
verification Min. 2/month
1 specific control machine OK/NOK sheet
or for each shift
element measurement 100% neighbour
check check
Total
3 + 3 + 2 + 2 + 2 = 12 points

GMU Europe / page 13

JFJ Aug 06
 Quality Control Operation System
Confirming the QCOS control levels
When the draft control plan is completed, a calculation is made to confirm that
sufficient Prevention or Detection has been incorporated.
The control calculation must be > 1,0 to confirm sufficient controls; the
calculation is made as follows:
Control points
= Control value
QCOS rank

1 2 3 4 5
Tooling or Error- Process 100% Process
Method* Proofing control Inspection Audit

12
Example: 3 + 3 + 2 + 2 + 2 = 1,0 (OK)
12

GMU Europe / page 14

JFJ Aug 06
 Quality Control Operation System
Confirming the QCOS control levels
Additional examples of the Control Value calculation are as follows:
1 2 3 4 5
Tooling or Error- Process 100% Process
Method* Proofing control Inspection Audit

12
Example 1: 3 + 3 + 2 + 2 + 2 = 1,0 (OK)
12

10
Example 2: 2 + 2 + 2 + 2 + 2 = 0,8 (NOK)
12

10
Example 3: 2 + 2 + 2 + 2 + 2 = 1,1 (OK)
9

GMU Europe / page 15

JFJ Aug 06
 Quality Control Operation System
QCOS – flexibility of control planning
By planning different resource levels the control strategy can be determined:
Control Tooling or
Points Error-Proofing Process control 100% Inspection Process Audit
Levels Method

HIGH 3
‘High Tech’
strategy

MEDIUM 2
‘Low Tech’ strategy

LOW 1

¾‘High Tech’/’Low People’ strategy needs high equipment investment

¾‘Low Tech’/’High People’ strategy needs strong control & disciplined culture

GMU Europe / page 16

JFJ Aug 06
 Quality Control Operation System
QCOS – deployment to shop floor
The control plan is described on a QCOS sheet which is posted on the shop
floor:
Process controls determined for
each resource

Error
proofing Inspection
Tooling or Process Process
method controls audit

Process controls are planned and

recorded in the QCOS planning sheet

Calculation is made confirming the

control value vs. risk assessment

Example calculations:
Control Points 8 11
= Control Value = 0,88 (NOK) = 1,22 (OK)
QCOS Rank 9 9

GMU Europe / page 17

JFJ Aug 06
 Quality Control Operation System
QCOS – process control plan summary
• Structured risk assessment with control requirements
communicated from Design through to Manufacturing
• QCOS Control Value calculation confirms application of
sufficient control levels
• Defines clear cross-functional roles & responsibilities,
actions, frequencies, etc. for ‘Planning’ and ‘Doing’
• Supports manufacturing process validation and process
capability
• Ensures that the control plan elements are clearly
communicated to the work station – incorporated in
standardised work

GMU Europe / page 18

JFJ Aug 06