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Vibrate
Ground Rules
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
Supplier Responsibility
Background
ISO/TS 16949
7.1
Planning of Product Realization
Background
Global APQP
GM-1927
GM
General Motors Corporation
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
November 2000
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
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
Review meetings
system development
Global APQP
Customer Monitored APQP vs
02-Technical Reviews
02-Technical Reviews
03-Supplier Eligibility
04-Gate Reviews
06-QSB
07-Flow Chart
07-Flow Chart
08-DFMEA
08-DFMEA
09-Design Reviews
09-Design Reviews
11-GP-11
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
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
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
TR
Initial-TR
GR-1,2,3,4
GR-1,2,4
SOP
GR-2,3
o
Letter 4
o
o
o
o
Update
Production
o
o
RPN Reduction
DFMEA
o
o
GD&T
o
Prod Concept-TR
Letter 3
GR-1,2,3,4
Prototype
GR-1,2,4
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
Gage Design Approval
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
GR-1,2,3,4
17 Lessons Learned
GR-1,2,3,4
o
o
Capacity Analysis
Capacity Analysis
o
Conduct Run@Rate
o
o
o
o
Key points
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.
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.
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
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
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 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 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)
ALL
-78
Key
Deliverables
Review
Within 30 days of
business nomination
advice / contract
Gate 1
Gate 2
-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
-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
Delivery
Initial PFD/PFMEA/PCP
Lessons learned
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
Packaging
Engineer
1st Shift
Contact
nd
2 Shift
Contact
rd
3 Shift
Contact
SubContractor
GM1927-17
Gate Review # 2
PFMEA checklist
Subcontractor planning
Gate Review # 3
Gate Review # 4
Dimensional Report
GP12 Audit
7. Flow Chart
Provide a Logical Pictorial Representation of the Process Flow that can
Purpose:
be used as the Foundation for PFMEAs. Control Plans, Work Station
Layouts, etc.
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
9. Design Review
Key
points
Purpose: Ensure that the Design has been adequately Defined to Build Tools
and Gauges
N
O
KPC
Value
VE:30607.5mm
1
Length
WM:31187.5mm
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
Example: BOM
certified
so as to produce:
quality parts
at rate
according to GM program 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.
12. PFMEA
TOP 5 RPN Reduction Plan (Correct RPN value) !
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
14. GP-12
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
Prototype
Pre-Launch (GP-12)
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
15. PPAP
Production Part Approval Process
Defines generic requirements for production and
bulk materials
PPAP
Applicability
PPAP
Key points
Supplier Production Trial Run
PPAP pre-production
PPAP SPR
PPAP is not one day job
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
Example: Design Lessons learned and best practice to achieve robust design
Thank You