GP - 12 Audit

Supplier Name: Supplier Phone:

Mfg. DUNS: Plant Location & Country:

Auditor: (SQE) Auditor Phone:

Auditor: E-Mail: GM Division:

Technical Information Availability

0 1. Actual Drawing 0 2. Approved Drawing
0 Total Potential 8 0%

Quality System Documentation

3. Has the PFMEA been reviewed to 4. Was Quality data reviewed to develop 5. Is there a GP-12 Process Control
0 0 0
develop the GP-12 list? the GP-12 list? Plan?

6. Is the check frequency 100% or a GM

0 0 7. Have operators been properly trained?
approved lot sampling process?
0 Total Potential 20 0%

Quality System Implementation Plan

9. Is the flow of material and material
0 8. Is GP-12 area set up correctly? 0 0 10. Are all gauges calibrated?
status clearly identified?
11. Do all gauges have proper operator 12. Are proper operator instructions
0 0 0 13. Is there Standardized Work?
instructions? available for GP-12 area?

14. Have operators been trained 15. Are boundary samples available and 16. Are Master Parts or samples
0 0 0
effectively to follow Standardized Work? used? available to confirm inspection?

17. Are Error Proofed operations
0 checked in GP-12 to verify error proofing
effectiveness?
18. Is there a reaction plan established
0 0
and documented for each defect found?
19. Does packaging and material
handling protect parts from
damage?

20. Does the GP-12 plan verify all parts
0 and components are packaged and
labeled properly?
23. Is GP-12 enforced at Tier 2 suppliers
0 by Tier 1 (or is it conducted at Tier 1 as
incoming inspection)?
0 Total Potential
22. Are conforming parts labelled as
21. Is there inspection data for all
0 0 per GP-12 requirements prior to
components in GP-12 area?
exiting?
24. Is there a robust process to prevent
0 shipment of material that has not gone
through GP-12?
68 0%

Quality System Implementation by Management

25. Process exisits for documenting and
0 0
tracking GP-12 Problem Reports?
0 28. Are results properly documented?
0 Total Potential
27. If more than one shift, does part
26. Does leadership ensure
0 problem information pass across
discrepancies are managed?
shifts?
30. Does Management understand
29. Is there evidence of a plan for
0 0 the implication of not conforming to
Layered Audits by plant leadership?
GP-12?
24 0%

0% 0 Technical Information Availability RED

0% 0 Quality System Documentation RED
0% 0 Quality System Implementation Plan RED
0% 0 Quality System Implementation by Management RED
0% 0 Overall RED

Pts Element Scoring Summary Scoring:

0 Element is not in place and no evidence of plans to implement Green 80%
1 Element is not in place but a plan to implement is documented Yellow 60-79%
2 Element is in place but it is not being followed Red <59%
3 Element in place but not followed at each job or all the time
4 Element is in place and it is being followed

Follow-Up Date:

Supplier Representative Signature GM Representative Signature

September 24, 2008 1 of 8 GM1927-33

 A. Technical Information Availability AUDIT WORKSHEET

QUESTION: In regard to EVIDENCE /

QUESTIONS TO ASK AND WHAT G/Y
Technical Information DOCUMENTATION Score OBSERVATIONS
TO LOOK FOR /R
Availability, REQUIRED
Are actual drawings available at GP-12 Blue Print Do you have drawings?
1 R
area with the latest change level? Material Spec Sheets Do you have math data?
Does the supplier have the final customer Blue Print Have you checked EWO and revision
2 R
approved drawing? Math Data date?
B. Quality System Documentation AUDIT WORKSHEET
EVIDENCE /
QUESTION: In regard to Quality QUESTIONS TO ASK AND WHAT G/Y
DOCUMENTATION Score OBSERVATIONS
System Documentation, TO LOOK FOR /R
REQUIRED
Significant
Verify that ALL high RPN, Error Proofed or
Has the PFMEA been reviewed to develop Characteristics (SC)
3 Critical line items are included in the GP- R
the GP-12 list? List / Pre launch control
12 list.
plan.
Have Lessons learned, previous PRR's Significant Verify that previous PRR's lessons learned
and internal quality data been reviewed to Characteristics (SC) and internal failures, PRTS and any
4 R
develop the GP-12 checklist. (including List / Pre launch control validation build learnings are incorporated
tiered supply items)? plan. in GP-12 plan.
Current Pre launch Verify current dates, etc. of Pre-Launch
Is there a GP-12 Process Control Plan Process Control Plan PCP document, GP-12 PCP, as separate
6 R
(PCP) available? (AIAG Control Plan documents over and above regular
format) production PCP.
Are redundant 100% checks in place to
Is the GP-12 check frequency 100% or is
verify the standard control plan
6 there a documented, GM approved, lot Pre Launch Control Plan R
effectiveness? Are Tier 2 pass-thru
sampling process?
features 100% checked in GP12?

Training matrix covers all GP-12 inspectors

Training matrix available and parts to be inspected, operators have
7 Have operators been properly trained? R
in the GP-12 area been trained by qualified staff? Inspectors
are independent from normal production.

C. Quality System Implementation Plan AUDIT WORKSHEET

EVIDENCE /
QUESTION: In regard to Quality QUESTIONS TO ASK AND WHAT G/Y
DOCUMENTATION Score OBSERVATIONS
System Implementation Plan, TO LOOK FOR /R
REQUIRED
Separated from main production line.
Identification of GP-12
Large label indicating GP-12 area and foot
8 Is GP-12 area set up correctly? station and located away R
printed, scrap containers clearly identified.
from normal production
Part flow clearly identified.
Logical flow of material into and out of GP-
Documented process
Is the flow of material through GP-12, and 12 being followed.
9 flow. R
material status, clearly identified? Segregation and identification of good,
Part labels / containers
scrap and rework parts.

September 24, 2008 2 of 8 GM1927-33

 Check to make sure gauges are calibrated.
Gage and Tool
10 Are all gauges calibrated? Verify tools and gages are to the latest R
Certification Records
engineering change level.

Do all gauges have proper operator Ensure that Gauge Instructions are
11 Gauge Instructions R
instructions? available at the gauge station.

Verify operator instructions are firmly

attached and visible to operator.
Are proper operator instructions available
12 Operator Instructions Verify instructions are to the latest R
for GP-12 area?
engineering change level. Verify reaction
plan is included for discrepant parts found.

Standardized Verify that there are Standardized

13 Is there Standardized Work in GP-12? R
Worksheets Worksheets available in-station.
Ask operator to demonstrate station and
Have operators been trained effectively to explain implication of conforming and non-
14 Operator Instructions R
follow Standardized Work? conforming parts. Verify against
Standardized Worksheets.

Verify operations are being performed as

Are boundary samples (BS) available to
15
operators and are they being used?
indicated in work instructions (job time,
Operator Instructions handling of non-conforming material etc). R
Verify that supplier has actual boundary
samples for review.

Are Master Parts or samples available to Master Parts

16 Verify Master Parts R
confirm inspection? Samples
Are Error Proofed operations checked in
GP-12 Control Plan Check all regular process error proofing is
17 GP-12 to verify error proofing R
Error Proofing plan verified again through GP-12 inspection.
effectiveness?
Is there a reaction plan established and
Verify escalation process is immediate and
18 documented for every single defect found Reaction Plan R
operators recognize urgency.
in GP-12 stations?

Does WIP protection at supplier have

adequate protection to protect parts from
Is the effectiveness of packaging and damage until packed and on carrier?
Dock and Incoming Audit
19 material handling to protect parts from For Material handling for the entire R
Sheets
damage verified in GP-12? process, are parts protected from
damage? Are necessary checks in place in
GP-12?

Shipping Label Does the Shipping Label match the Part

Does the GP-12 plan verify all parts and
Part Print Print?
20 components are packaged and labeled R
Process Control Plan Verify Control Plan and In-Process
properly?
Inspection Sheets Inspection sheets.
Inspection sheets should contain: quantity
Is there inspection data for all components Inspection sheets
21 checked, total OK, total not OK and R
in GP-12 area? available
description of fault.

September 24, 2008 3 of 8 GM1927-33

 All parts exiting GP-12 have the
Are conforming parts labelled as per GP- Green dot signed by staff identification and controls in place to
22 R
12 requirements prior to exiting GP-12? member accountable ensure only approved material leaves GP-
12 area
Is GP-12 enforced at Tier 2 suppliers by Tiered supplier GP-12
Use of GP-12 audit, identification of
23 Tier 1 (or is it conducted at Tier 1 as plan R
incoming material as conforming to GP-12.
incoming inspection)? GP-12 plan audit
Is there a robust process in place to Material plan or pre- Who approves shipment of material to GM
24 prevent shipment of material that has not shipment verification and how can they be confident parts have R
gone through GP-12? plan passed GP-12?

D. Quality System Implementation by Management AUDIT WORKSHEET

QUESTION: In regard to Quality EVIDENCE /

QUESTIONS TO ASK AND WHAT G/Y
System Implementation by DOCUMENTATION Score OBSERVATIONS
TO LOOK FOR /R
Management, REQUIRED

Look for daily updated I charts, Corrective

Action Reports exist for each issue
Plant Informational
Is there a process for documenting and identified in GP-12.
25 Board R
tracking GP-12 Problem Reports? Look for process to verify all steps from
Current I Charts
immediate containment through to
irreversible corrective action.
Does leadership ensure that
discrepancies from GP-12 area are GP-12 issues are reviewed at the daily
26 Daily meetings R
managed as priority areas for process management meeting.
improvement?

Look for shift log/notes.

Look for evidence of a closed loop on shift
problems.
If more than one shift, does part problem
27 Shift Log Check for up to date information board R
information pass across shifts?
with training records, I-chart, layered audit
plan/results, quality emerging issues / high
focus areas

PFMEA Is there evidence that all GP-12 concerns

28 Are results properly documented? R
Process Control Plan are tracked back to the PCP and PFMEA?

Is there evidence of a plan for Layered

Audit frequency, schedule by auditor,
29 Audits by plant leadership to verify GP-12 Layered Audit plan R
report form or checklist.
execution?
Verify understanding that failure to execute
Does Management understand the GP-12, or shipment of a single defect
30 GM GP-12 (GM 1920) R
implication of not conforming to GP-12? during GP-12 period, will result in
immediate CS2

September 24, 2008 4 of 8 GM1927-33

 Summary Scoring Definitions

Green – GP-12 plan considered adequate to protect GM assembly

plant from defects over launch, track remaining issues to closure on
mainstream Open Issues list

Yellow – GP-12 plan implementation currently inadequate to

protect GM plant during launch, GP-12 specific gap closure plan required
and re-audit required within 2 weeks to confirm gap closure

X Red – GP-12 plan inadequate, no parts to be shipped to GM until

GP-12 re-audit confirms Yellow status minimum, or additional
containment put in place (CS-2)

September 24, 2008 5 of 8 GM1927-33

 Special Characteristic Sheet

Supplier: Part Name:

Drawing #/Rev: Part Number:

Qty in stock:

Measurement
# Description of SC Specification
Device
1

September 24, 2008 6 of 8 GM1927-33

 Process Performance SUPPLIER ACTION PLAN REPORT Rev. 7 1/7/02

Supplier Start Date: SQE

Location Rev. Date: SQE Phone & Fax #:
Duns Grad Date: Manager:
Commodity Program: Group:
Prepared by: Creativity Team:

"Color Codes"
G Green - Task Completed on Time
Y Yellow - Task May Be Late
R Red - Task is Late
W White - Task Re-Timed, No Status
B Blue - Task Status is Incorrect / Not Updated
On Track (Bold Box/No Color)
TOTAL TOTAL STATUS
0 0
STATUS HISTORY
TARGET ACTUAL
ACTION DATE LAST
ITEM ACTION ITEM CLOSE CLOSE Most COUNTER MEASURES
LEADER OPENED UPDATE
DATE DATE Oldest Recent

# 1 2 3 4 5 6
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29

7 of 8
 Process Performance SUPPLIER ACTION PLAN REPORT Rev. 7 1/7/02

B5: Person at supplier that prepared the form for the GM SQE. (If applicable)

C16: ACTION ITEM: The item that requires action to improve the process or quality of the product being produced.

D3: Graduation Date:

This Date Will Be Determined By GM SQ Directors

D4: For PDC SQE Only:

Identify which program your supplier is in "IQ' or "SQA".

D16: ACTION LEADER: The person that leads the team to make the improvements. This should be the suppliers person but may be a GM Management person.

E15: Formula: DO NOT TYPE IN THIS CELL, UNLESS YOUR ARE MODIFYING THE FORMULA

E16: START DATE: The date the action item was identified and listed in the action item column

F16: TARGET CLOSE DATE: The date the supplier will complete the action item.

This date may change. If the date changes, you are required to entry the correct color code in the pass status and present status columns.
A comment on why the change to be entered in the comment field

G15: Formula: DO NOT TYPE IN THIS CELL, UNLESS YOUR ARE MODIFYING THE FORMULA

G16: ACTUAL CLOSE DATE: The date the action item was closed TO INCLUDE VALIDATION.

The SQE should validate the action item as being closed and RESOLVED.

H16: LAST UPDATE: The date the SQE reviewed the action item.

I16: PAST STATUS: The cell is filled in when the status changes. Oldest status to the left
If status is WHITE put a "W" in the cell. Do not leave blank.
Copy the cell for the correct color.

COLOR CODE:
GREEN: Task Completed on Time
YELLOW: Action item is in trouble and may affect target date.
RED: Action item has missed target date.
WHITE: Task Re-Timed, No Status
BLUE: Task Status is incorrect / Not Updated

O16: COUNTER MEASURES:

8 of 8