Global Surface Quality Evaluation Procedure Overview

26th February, 2008

Global Surface Quality Evaluation Procedure

Purpose
To define the standardized process for performing and documenting surface evaluation of exposed sheet metal parts

Scope
Applies to all GM Stamping and Assembly plants and external suppliers on; exposed metal parts, bodies in white and painted panel reviews

Process Overview/Requirements Standardized Work

Documented standardized work (SOS & JES) should be developed and used as a basis for the surface quality evaluation process Job instruction training program shall be in place for surface auditors in order to confirm the required skill level Surface auditors will be evaluated/calibrated regularly in accordance with auditor calibration process (Min. once per year)

Global Surface Quality Evaluation Procedure

Appearance Zone Definition
Applies GCA appearance zones for exposed surface (A-B-C-D Zone)

Vehicle Appearance Zones

APPEARANCE ZONES All VEHICLES (continued) Exterior
190 cm 170 cm

Vehicle Appearance Zones

Openings / Inners

50 cm
50 cm

Openings / Inners

50 cm

50 cm 50 cm

Global Surface Quality Evaluation Procedure

Surface Objection Names
- Standardized names for surface objections defined on the Global Surface Evaluation Sheet must be used to clarify communication and generate common understanding
Common Objection Names & Symbols

Global Surface Quality Evaluation Procedure

Classification of Objections
Class 1 Objections Obvious, heavy surface objections which are easily noticed - Observable under consistent light before they are exposed to the light room and oil - Non-saleable (vehicle) issues - Parts with class 1 objections in Zone A or B require the immediate stoppage of the production lot size and the process must be optimized Class 2 Objections Visually detectable from multiple opposing angles during panel review in light room with oil (light bulb reflections clearly bending/distorted on part surface) and can be felt through the sensing glove - Can be confirmed by conducting a painted panel review process - Parts with class 2 objections in Zone A or B would negatively impact the vehicles ability to pass surface quality requirements and the process must be optimized

Class 2s Visual Guidelines

Side of Panel

Global Surface Quality Evaluation Procedure

Class 3 Objections Minor / subtle irregularities in surface (not easily detectable) Usually need to be gun-sighted - Parts with class 3 objections in Zone A or B would not negatively impact the vehicles ability to pass surface quality requirements
Visual Guideline

Points for Objections - Points for objections will be assigned depending on the classification and respective zone Zone Zone A: Zone B: Zone C: Zone D: 5pts Class 1s (A1) 100pts (B1) 60pts (C1) 30pts (D1) 15pts Class 2s (A2) 35pts (B2) 25pts (C2) 15pts (D2) 10pts Class 3s (A3) 15pts (B3) 10pts (C3) (D3) 5pts

Class 3s Guidelines
Side of Panel

Approx. 180 - 170 Degrees G un Sight

Global Surface Quality Evaluation Procedure

Surface Evaluation Conditions
Recommended practice for static surface evaluation is that they should be performed using horizontal white lights Parts will be evaluated in a light room or portable booth in vehicle position Surface evaluation shall be performed using approved oil Recommended surface evaluation standardized techniques: Five minute inspection time (references only to checking time) Inspection distance from panel is 3 meters (10 feet) maximum

< GME Russelsheim >

< Next Generation Light Booth >

Global Surface Quality Evaluation Procedure

Surface Evaluation Frequency
Evaluations at primary tryout are required after the first panel is produced at each matching event - A reference panel must be provided to the production source for documentation of the objections which determined the score Evaluations at secondary tryout (home line) are required at the beginning of tryout, and iteratively after any die work has been done to improve surface quality and prior to any build event - A reference panel must be maintained for documentation of the objections which determined the score Evaluations during regular production will be conducted on outer surface panels each production run (once/run) - A reference panel must be used to evaluate the acceptability of the panel Painted panels (without rework) are visually evaluated at the Vehicle Assembly Plants during the Manufacturing Validation Build (MVB) to determine customer surface approval

Global Surface Quality Evaluation Procedure

Surface Evaluation Documentation
Surface evaluations are documented on part specific Global Common Surface Evaluation Sheets
Mfg. Controllable Objections Mfg. Non-Controllable Objections

Part Sketch

Objection Names & Symbols No. of Objections

Mark objections on the sketch - Objection Name/Symbol - App. Zones Letter (A/B/C/D) - Objection Classification Number (1/2/3)

Assign point value and then sum up the assigned point values to calculate total points

Convert the total points to a quality grade by dividing by 100 (Ex: 95 / 100 = 0.95, 250 / 100 = 2.5)

Global Surface Quality Evaluation Procedure

Surface Quality Requirements
Project Phase Primary Evaluation Target Quality Grade Outer Surface 2.5 No Class 1 Issues 2.0 No Class 1 Issues 1.5 No Class 1 or 2 Issues 1.0 No Class 1 or 2 Issues Maintain (or improve) baseline established Target Quality Grade Inner Surface 2.5 No Class 1 Issues 2.0 No Class 1 Issues 1.5 No Class 1 Issues 1.0 No Class 1 or 2 Issues Maintain (or improve) baseline established

MVB Non Saleable

MVB Saleable SORP Steady State

- For die to be delivered to the home line production source, a quality grade of 2.5 or lower must be reached by die suppliers and the surface must be free of class 1 objections

Global Surface Quality Evaluation Procedure

Quality Grade Scoring
Quality grade will be reported as a total quality grade for the panel At SORP the quality grade will subsequently be divided into two categories: Manufacturing Controllable surface objections that are from tool maintenance or items from the manufacturing process

Manufacturing Non-Controllable surface objections that are defined to be due to tool engineering or are styling dependent, (i.e. the surface objection is already visible in the styling math data), design criteria violations or impact lines - A decision must be made if the escalation process is required - Die and process conditions must be optimized

Global Surface Quality Evaluation Procedure

Quality Grade Scoring (Continue)
Surface objections associated with one product feature are regarded as one objection (examples): Lows above and below the fuel filler opening or door handle

Waviness as a result of flanging along the bottom of a door

Continuous objections such as a shock line/skid line (double draw) Single up dings appearing sporadically over the part are combined in their rating and evaluated as one A3 objection

Global Surface Quality Evaluation Procedure

Reporting and Escalation
During new vehicle launches, surface evaluation summary reports and the Surface Buy-off Deviation Form should be provided to the appropriate Vehicle Program Review leadership teams, as required For launches covered by major program PQRR (Program Quality & Readiness Review) events, the same reports are provided by the appropriate body manufacturing die leadership contact to the Program Quality Manager (PQM) starting at the Saleable events Leadership Teams should include VLE/VLD, Manufacturing Manager or Plant Manager, Product Engineering, Manufacturing Engineering and Manufacturing Quality

Global Surface Quality Evaluation Procedure

Surface Quality Evaluation Calibration of Auditors

Purpose

To define the standardized process for performing and documenting calibration of surface auditors to ensure consistent surface quality evaluations

Calibration Process
- Calibration will be performed in 2 rounds with a minimum of 4 parts each - There will be 2 options depending on part availability Option 1: Identical parts per round, but different parts from round 1 to 2 Option 2: All parts different - Auditors will evaluate all parts following the requirements as outlined in the main procedure (time, method, lighting conditions, etc.) and fill out one Global Surface Quality Evaluation Sheet per part and evaluation

Global Surface Quality Evaluation Procedure

Calibration Process (Continue)
- After each round the results will be discussed and correlated to ensure compliance with procedure requirements (Focus on correlation will be on type of objection, method, zone and score; score may be corrected accordingly but no objection will be added to or deleted from the Global Surface Quality Evaluation Sheet after discussion)

Calibration Goal
- All results from round 2 evaluations have to be within a range of 1.0 - If the goal is not met after round 2, appropriate training measures have to be defined; calibration must be repeated

Calibration Frequency
- Global: Regional SMEs will be calibrated once per year minimum - Regional: Plant SMEs will be calibrated once per year minimum - Within Plants: Plant Auditors will be calibrated once per year minimum

Any Questions ?

GMAP Roll out Plan

Phase

Action Plans Communicate global procedure draft to AP Procedure Team

Who YS. Cho YS. Cho Global Team YS. Cho Plant Quality Manager YS. Cho/ NK. Noh Plant SMEs Plant SMEs Plant SMEs

When May 25, 2007 Nov. 14, 2007 Nov. 2007 Dec. 2007

Awareness

Communicate global procedure draft to APQL Finalize global procedure Communicate global procedure changes to AP Procedure Team

Assign plant SMEs from each business unit Training

Train & calibrate plant SMEs - AP regional workshop with plant SMEs Train & calibrate plant auditors Trial run to establish baseline quality grades Fully implementation

Dec. 2007
Feb. 2008 1st Qtr. 2008 2nd Qtr. 2008 3rd Qtr. 2008

Implementation