Phone on

Vibrate
Ground Rules
GM Global APQP for Suppliers
Manuel Yamada
Tel Aviv, Israel
April 12
th
, 2010
This is your class, feel free
to ask questions at any time!
Introductions
APQP Process and Expectations
Project Plan
Customer vs Supplier Monitored APQP
APQP management in GQTS
APQP Requirements
GM Requirements
Q & A
AGENDA
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
The goal of a successful
program launch and mass
production is to provide:
Quality @ Rate On Time
Supplier Responsibility
GM
Global
APQP
AIAG APQP
ISO/TS 16949
7.1
Planning of Product Realization
Linkages of the ISO/TS 16949:2002, AIAG
APQP and Global Supplier Quality Manual
Background
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
GM APQP Global Process
Background
GM-1927
Global Supplier
Quality Manual is
the General Motors
Common Global APQP
Manual
GMs common
direction for the
development and
implementation of an
APQP plan
Download from
GMSupplyPower
Global APQP
Advanced Product Quality Planning
Worldwide Purchasing
November 2000
General Motors Corporation
GM
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
GM 1927 Documents and Forms
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
SQE work closely with supplier
Supplier work closely with GM SQE
Supplier Monitored
SQE paper/electronic review of supplier
Supplier keep GM aware
Customer Monitored APQP
Supplier Monitored APQP
Global APQP
GM Global APQP Monitoring
Customer Monitored SQE Responsibilities
Assure quality @ rate on time
Drive the suppliers 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 suppliers or
GMs 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 suppliers quality
system development
Apply APQP Workbook Audits and upload all Key
Deliverables to GQTS
Supplier Monitored SQE Responsibilities
Monitor the suppliers 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
SQE is the responsible for invite and conduct Gate #1 (Kick-Off Meeting) for all parts on both Customer or
Supplier Monitored APQP
There is an inverse relationship
Customer monitoring means more
responsibility for the SQE
Supplier monitoring means more
responsibility for the Supplier
Customer Monitored APQP vs
Supplier Monitored APQP
Global APQP
Global APQP Tasks changed as following:
01-Commodity Key Stakeholders Mtg
02-Technical Reviews
03-Supplier Eligibility
04-Gate Reviews
05-Timing Charts / Open Issues
06-QSB
07-Flow Chart
08-DFMEA
09-Design Reviews
10-Tooling & Equipment Reviews
11-Gage Development & Approval
12-PFMEA
13-Control Plan
14-GP-12
15-PPAP
16-Run @ Rate
17-Lessons Learned
01-Commodity Sourcing Strategy Mtg
02-Technical Reviews
03-Risk Assessment / Sourcing
04-Supplier Gate Reviews
05-Timing Charts / Open Issues
06-Feasibility / Assessment Letters
07-Flow Chart
08-DFMEA
09-Design Reviews
10-Gage, Tooling and Equipment Reviews
11-GP-11
12-PFMEA
13-Control Plan
14-GP-12
15-PPAP
16-Run @ Rate
17-Lessons Learned
Corporate Planning sets time frames
START OF
PRODUCTION
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
GPSC SUPPLIER QUALITY IMPROVEMENT PROCESS
LIFE
OF PART
TIME LINE
EARLY PRODUCTION
CONTAINMENT (GP-12)
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)
GM Global APQP
Combination of the Best Processes
1. Commodity Sourcing Strategy Meetings
The Commodity Sourcing Strategy Meeting is the responsibility of the Buyer
Internal GM people only
The first time the SQE becomes officially involved in the APQP process
Commodity Sourcing Strategy Meeting is the first task that is tracked by the
APQP Project Plan
APQP Project Plan
GM GVDP
APQP Task
Gate
Reviews
Sourcing
Activities
G
R
-
1
G
R
-
2

G
R
-
3

G
R
-
4

1
Commodity Sourcing
Strategy Mtg GR-1 o------o o
2 Technical Reviews GR-1 o------o o
3
Risk Assessment /
Sourcing GR-1,3 TR o o o
4
Supplier Gate
Reviews
5
Timing Charts /
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
6
Feasibility /
Assessment Letters GR-1,2,3,4 o o o o
7 Flow Chart GR-1,2,4 o o o o o o
8 DFMEA GR-1,2,4 o o o o o o o
9 Design Reviews GR-2,3 o o o o
10
Gage, Tooling and
Equipment Reviews GR-1,2,3,4 o o o o o
11 GP-11 GR-2,3 o o o o
12 PFMEA GR-1,2,3,4 o o o o o o o o
13 Control Plan GR-1,2,3,4 o o o o o o o
14 GP-12 GR-3,4 o o o o
15 PPAP GR-4 o o
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
AIAG
APQP
Pilot / Pre-Launch Prototype Launch /
Feedback, Assessment and Corrective Action
Production
Product Design and Development
Planning
Process Design and Development
Product and Process Validation
Gage Concept Approval Gage Design Approval Gage Approval/R&R, Tool Completion
KCDS Workshop
Production
Plan
Initial-TR
Initial -TR
Initial-TR
Initial-TR
GD&T
GP-12 & Production
Exit (Platform Discretion)
Initial-TR
Initial-TR
Plan
Update Risk
Prod Concept-TR
Conduct Run@Rate
Structure
Vehicle
Integration
Vehicle
Validation
Vehicle
MVBs SOP MVBns
Capacity Analysis
Letter 2 Letter 3 Letter 4
Update DFMEA RPN Reduction
DFMEA
Execute Execute
Prototype / RPN Baseline
Prototype
Production / RPN Reduction
RPN Reduction
Prototype
Execute
Capacity Analysis
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
1. Commodity Key Stakeholders Meeting (CKSM)
Supplier Quality Statement of Requirements
Please sign, date and return page 5 of this document with your bid package as
record of your understanding of these requirements. Powertrain suppliers please
sign, date and return page 6 also.
1. All suppliers are expected to supply parts to General Motors with zero defects. Funding is to
be identified in the initial quote and subsequent quotes to reflect error occurrence detection (poka
yoke, error proofing devices, etc) and defect outflow prevention to customers. Controls
implemented at a later date are the financial responsibility of the supplier.
2. ISO/TS 16949 or QS-9000 - Quality System Requirements
All suppliers to General Motors must be certified to one of these standards and have a current
certificate available demonstrating compliance to GM supplements. These standards require
an extensive, formal, audited evaluation of suppliers quality and manufacturing methods.
The evaluation is conducted by a third party certified registrar.

Suppliers not certified to ISO/TS 16949 or QS-9000, or those suppliers constructing or
purchasing facilities to manufacture the parts being quoted, must include an outline of their
certification attainment plan with their quote for further consideration.

3. General Motors Procedures and Reference Documents

Suppliers are to adhere to the requirements contained in the following documents:
Advanced Product Quality Planning & Control Plan Reference Manual (AIAG)
Potential Failure Mode and Effects Analysis (FMEA) Reference Manual (AIAG)
Fundamental Statistical Process Control (SPC) Reference Manual (AIAG)
Measurement Systems Analysis (MSA) Reference Manual (AIAG)
Production Part Approval Process (PPAP) Manual (AIAG)
Key Characteristics Designation System (KCDS) GM-1805QN
GP-5 Supplier Quality Processes and Measurements Procedure. GM-1746
GP-7 Component Verification and Traceability Procedure. GM-1730
GP-8 Continuous Improvement Procedure. GM-1747
GP-9 Run @ Rate. GM-1960
GP-10 Evaluation and Accreditation of Supplier Test Facilities. GM-1796
GP-11 General Procedure for Pre-Prototype and Prototype Material. GM-1820
GP-12 Early Production Containment. GM-1920
GM-Supplier Technical Information GM-1825
Traceability Identifier Requirement TIR-15-300. GM-1731
Supplier Quality Weld Support Manual
Shipping Parts Identification Label Standard. GM-1724
Fixture Standards Requirement GM-1925
Operating Guide for Suppliers of Prototype Material NAO-0065
Signature of Supplier Representative
Supplier Quality SOR
Supplier Quality has a Global
Statement of Requirements that
applies to all suppliers.
SOR Included in the GM RFQ.
Supplier Quotations to GM
must include a signed copy of
the SOR, indicating compliance to
these requirements.
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
Customer
Monitored APQP
or
Supplier
Monitored APQP
Risk Assessment
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
109 Part J
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)
Key points
Intended as a Readiness Review of the suppliers 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 Reviews
4. Gate Review
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
4. Gate Reviews
Gate
Deadline
(Time from
SORP in
weeks)
GVDP 5.0 timing
reference
Review
Key
Deliverables
Form/
Document
ALL
GM Global APQP Supplier Status Summary
Workbook
GM1927-34

Within 30 days of
business nomination
advice / contract
Gate 1
QSB Audit (Gap Analysis) or Greenfield
Checklist (Action Plan)
GM1927-30
GM1927-31
Timing Plan GM1927-2
Kick-Off Check list GM1927-14
-78
Initiated after CVER
and completed 5
weeks after IVER
Gate 2
PFMEA Check list GM1927-37
RPN Reduction Summary GM1927-21
Subcontractor Status GM1927-25
-52
Completed 10 weeks
prior Matching 1 GA
Gate 3
Supplier ADV Plan (ADVP&R) showing
execution status
GM1829
QSB Audit (Compliance) or Greenfield Checklist
(Complete)
GM1927-30
GM1927-31
Run @ Rate Capacity Workbook GM1927-35
-35
Completed 3 weeks
prior PPV MRD
Gate 4
Dimensional Report GM1927-32
PPAP Worksheet (if not fully approved) GM1411
GP12 Audit GM1927-33
-15
Completed 1 week
prior MVBs MRD
PPAP PPAP Approval
-8
Run @
Rate
Run @ Rate Execution R@R Module
PCPA GM1927-16

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
Delivery
Gate Review # 1 - APQP Kick Off Meeting
Who to
Contact?
GM1927-17
List the Key
Positions
needed to
Manage New
Programs
APQP Contact List.doc GM1927-17
Part name: Part number:
GM Program: Model Year:
Supplier Name: DUNS #:
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
SQE
Project
Manager
Buyer Sales Mgr
Design
Engineer
Design
Engineer
VLE PPM Quality
Manager
Proto PE Laboratory
Supv.
Manuf.
Engineer
GM Plant
Rep
GD&T
Readiness
Coord.
Container-
ization
Packaging
Engineer
Reliab.
Engineer
1st Shift
Contact
Paint
Engineer
2
nd
Shift
Contact
Current
SQE
3
rd
Shift
Contact
Sub-
Contractor
GM AND SUPPLIER PROGRAM CONTACTS
APQP Kick Off Meeting
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 # 2
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 # 3
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 Review # 4
Gate Reviews 2,3,4
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
Meeting Subjects Include:
Global APQP for SQEs
Gate Review Delivery
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
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
APQP Timing Chart
Open Issue List
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
6. QSB (Quality Systems Basics)
APQP QSB Task must be
compliant by Gate Review # 4
7. Flow Chart
SQE Responsibility:
Purpose:
Provide a Logical Pictorial Representation of the Process Flow that can
be used as the Foundation for PFMEAs. 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
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
Purpose: Ensure that the Design has been adequately Defined to Build Tools
and Gauges
Key points
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
N
O
KPC Value KCC Control Method
1 Length
VE:30607.5mm
Extrusion: Cutting
Aging: Temperature; time
Finishing: End cutting
Extrusion: Automatic
cutting
Aging: PLC
Finishing: 100% DIM
check & SPC
WM:31187.5mm
2
Compr
ession
Load
VE/WM:
10.75mm
8~14N
Mixing: Ingredient quantity
Extrusion: Temperature;
Line speed
Aging: Temperature; time
Mixing: Bar code
Extrusion: PLC
Aging: PLC control
SPC
Example: KPC/PQC and corresponding control method
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
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
Purpose:
To design, build and certify gages according to latest GD&T
release and per GM requirements.
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.
11. Gage Development and Approval
12. PFMEA
TOP 5 RPN Reduction Plan (Correct RPN value) !
ITS 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
SQE shall define PCPA schedule and
frequency based on the risk priority of part and
process (Based on risk assessment)
Its a living document to address any
change in product/process and reflect
updated control for quality issue
Supplier and SQE shall verify final inspection to
ensure a robust inspection method
Key points
Control Plan
14. GP-12
Prototype
Pre-Launch (GP-12)
Production: shall be validated by Pre-launch PCP
Establish a Containment Plan during Start-up
and acceleration that will Quickly Identify
Quality Issues at the Suppliers Facility; i.e., a
Pre-Launch Control Plan
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.
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.
Duration of GP-12
Indicates the process can consistently meet the
requirements at production rate
Indicates the suppliers understanding of the
engineering design record and specifications
requirements
Defines generic requirements for production and
bulk materials
Production Part Approval Process
15. PPAP
Applies to all internal and external
supplier sites of production and service
parts unless otherwise specified by the
authorized customer representative
Applicability
PPAP
Supplier Production Trial Run
PPAP pre-production
PPAP SPR
PPAP is not one day job
PPAP
Key points
- 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
Supplier Production Trial 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
Significant Production Run
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
Customer Notification
PPAP Submission levels
Level 5 - Warrant, product samples and data for
review at suppliers location
Level 4 - Warrant and customer requirements
Level 3 - Warrant, product samples and data
(considered the default level)
Level 2 - Warrant with product samples
Level 1 - Warrant only
All required information shall be available or included in the
submission (levels 2-4) regardless of submission level!
Verifies capability
1 Day production at supplier site
= 1 Day usage in GM
Required for all new parts
Must meet: QTC on contract
Five working days per week
16. Run @ Rate GP9
Begin from program Kick-Off (Initial GP-9)
No later than 8 weeks prior to SORP
Need to verify from time to time
- Tooling/M&E review
- FOS
- PPAP SPR
- After Salable PPAP (According to Hours per day)
Key points
Run @ Rate GP9
Run @ Rate Approval Decisions
Fail
Pending PPAP
Pass (FULL PPAP)
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
Global APQP for SQEs
Driving GM to be the BEST!!!
Thank You