Supplier Program Review Meeting #1

Supplier Program Review Meeting #1
Advanced Product Quality Planning APQP Kick-off Meeting (Long Version) GM 1 1

Advanced Product Quality Planning General Motors Corporation
Agenda Background - APQP - Global APQP Development APQP Project Plan Overview APQP Kick-off Meeting - SQ Requirements - Program Timing - Review Checklists - Identify Open Issues Summary Advanced Product Quality Planning Worldwide Purchasing November 2000 General Motors Corporation GM

Agenda Background - APQP - Global APQP Development Requirements from Suppliers APQP Project Plan - Supplier Responsible Tasks Summary Advanced Product Quality Planning Worldwide Purchasing November 2000 General Motors Corporation GM Primary

APQP Background Definition Purpose & Structure
Advanced Product Quality Planning -- APQP Structured method defines and establishes steps necessary to ensure product meets customer requirements Required for all new parts Responsibility of the supplier Purpose & Structure Communicates the requirements necessary to develop a product quality plan Top Management support by the supplier is key to the success of the any APQP process Requires an environment of trust and cooperation between all parties Read Slide Purpose of these first few slides is to provide general basic common definitions of what APQP is and the purpose of APQP

APQP Background Benefits Directs resources
Early identification of required changes Facilitates avoidance of late changes Enables delivery of a quality product that meets program timing at required capacity Read Slide

Background AIAG Linkage to QS-9000
AIAG--Automotive Industry Action Group Standardized reference manuals, procedures, reporting formats and technical nomenclature used by Ford, Chrysler and General Motors AIAG APQP manual one of 7 manuals developed; completed June 1994 Provides general guidelines for development of an advanced product quality plan QS-9000 The Harmonization of Ford, Chrysler and General Motors individual Quality System requirements Ford--Q-101 Quality System Standards Chrysler--Supplier Quality Assurance Manual GM--Targets For Excellence Read Slide Purpose of slide is to show link between all the quality documents so there is an understanding of what the purpose of each is 3

Background QS- 9000 APQP Direction
Establishment of an Advanced Product Quality Plan QS-9000 section requires the establishment of an advanced product quality plan AIAG APQP Manual is referenced as the document that should be used Detail of specific deliverables was not clearly defined Separate “unique” Regional & Divisional requirements developed Read Slide

Drivers of a Global Common APQP Process
Background Drivers of a Global Common APQP Process Divisions and regions “Fine Tuned” the AIAG APQP process Result was different direction for suppliers different reporting formats for program updates different timing charts for program events varying levels of detail required at different times throughout the product development cycle Additional variation occurred when SQE’s further “Fine Tuned the requirements and developed unique forms or timing charts etc. Read Slide This is background

Drivers of a Global Common APQP Process
Background Drivers of a Global Common APQP Process Global Suppliers and Global Vehicles compounds varying levels of direction This resulted in regional variations on the APQP process requirements Read Slide Stress different direction from each of the Regions: GMNA--GM North America GME--GM Europe GMLA--GM Latin America GMAP--GM Asia Pacific APQP APQP APQP APQP

Global APQP Development General Motors Global APQP
GM-1927 is the General Motors Common Global APQP Manual GM’s common direction for the development and implementation of an APQP plan Advanced Product Quality Planning Worldwide Purchasing November 2000 General Motors Corporation GM Read Slide

Global APQP Development Goals of this Common Global Process
Identify the critical items Eliminate unnecessary requirements Support the the SQE and Supplier in performing the day-to-day APQP activities Eliminate the divisional & regional specific direction Read Slide

Global APQP Development
Participation by a Global Team: GM North America --GM Europe GM Asia Pacific --GM Latin America Objective: - Define the minimum product quality planning requirements necessary to develop and implement an Advanced Product Quality Plan for a product or service Read Slide Stress that these requirements are the minimum requirements that GM has identified

Global APQP Development Common Global APQP Process for GM Worldwide
GM-1927 replaces all regional and divisional APQP reference manuals GM-1927 harmonized and standardized the multiple regional and divisional APQP manuals Aligns with the 5 phases within the AIAG APQP manual and provides the detail required to implement an APQP plan Aligns with GM’s 4 phase program timing and deliverables Read Slide

Benefits Common APQP process for GM worldwide All GM divisions and regions will use the same process Common requirements Eliminates the need to keep separate files for programs due to divisional or regional “unique” requirements Common forms and charts Interactive computer system (GQTS APQP module) Facilitates timely communication of requirements and data Eliminates manual data storage Common direction and “One Voice” from all GM Supplier Quality Engineers regardless of region or division Read Slide Stress that now GM will have ONE VOICE with common direction for APQP requirements

GM 1927 Documents and Forms 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 then follow these steps: Log in Select Quality Power Select Library Select Supplier Quality Select APQP Manual & Documents Read Slide This starts to explain how the APQP manual is laid out and what is included in the manual When you finish the page show copy of the screen print of the web page that lists all the GM 1927 documents

Summary Points Global APQP driven by QS 9000 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 will be Shared between Regions - All Information Available on GMSupplyPower website at - GQTS APQP Module will Accelerate Global Communication Primary Global APQP Development

Requirements from Suppliers
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 Identify Issues Early in Program and Drive Correction Document on APQP Open Issues List Maintain Communication with GM on Program Status and Issues -- Manufacturing Assessment Letters Expect these Same Requirements from Sub-Suppliers Primary

Global APQP The APQP Project Plan GM 1927-1, consists of
17 major deliverables/requirements These items if completed properly and on time should result in the development of a manufacturing system that is capable of meeting the GM Quality requirements at stated capacity and ship schedules. Read Slide Explain that the focus is on timely execution of the 17 identified APQP elements

APQP 17 Tasks / Deliverables
Global APQP APQP 17 Tasks / Deliverables - Key Stakeholders Meeting - Gage / Tooling / Equipment - Technical Review Review - Risk Assessment / Sourcing - GP-11 - Supplier Program Reviews - PFMEA Strategy - Timing Charts / Open Issues - Control Plan - Feasibility / Manufacturing Letters - GP-12 - Flow Chart PPAP - DFMEA Rate (GP-9) - Design Review Lessons Learned Read Slide This is a listing of the 17 deliverables that are shown on the far left hand column of the APQP Project Plan GM 1927 The detail of each of the 17 deliverables will be explained

Global APQP Manual Contents Preface Table of Contents RASIC Explanation of PMI’s (Process Model Integration) PMI’s for 17 Tasks / Deliverables Appendices Glossary Advanced Product Quality Planning Worldwide Purchasing November 2000 General Motors Corporation GM Read Slide This starts to explain how the APQP manual is laid out and what is included in the manual When you finish the page show copy of the screen print of the web page that lists all the GM 1927 documents The 17 Tasks are the Key for Success!

WWP SUPPLIER QUALITY IMPROVEMENT PROCESS
Combination of the Best Processes START OF PRODUCTION 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 ADVANCE PLANNING & PREVENTION WWP 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) PROBLEM RESOLUTION GM Global APQP Experience Primary

APQP Project Plan APQP “At a Glance”
Shows the linkage of the 17 deliverables to: GM’s 4 phase timing GM’s Sourcing Process AIAG APQP 5 phases within the APQP planning process The focus of the APQP Project Plan is on timing of each deliverable Levels of completeness for specific deliverables is clearly identified The required completion of items is tied to the specific GM build event Read Slide This slide STARTS to explain the APQP Project Plan GM 1927. The main purpose of the slide is to show the linkage of GM’s APQP deliverables to GM’s 4 phase program timing and the AIAG APQP 5 phases. STRESS that we are not requiring anything different than what was has been required in the past. Our focus is on completion of common elements in line with GM’s program TIMING OPTIONAL--You can either show the APQP Project Plan GM 1927 here or wait to show it after slide 20; After slide 20 is recommended

APQP Project Plan Primary

APQP Project Plan Supplier Activities Start Here Task 4
Supplier Program Reviews Supplier Activities

Task 4) Supplier Program Reviews
Overview Four Major Program Reviews: Purpose: Ensure Supplier’s Quality Plan is Progressing to Meet GM Program Timing Provide a Formal Process to Raise Issues for Resolution Pre-Production Meeting (APQP Kickoff) Beta Prototype Build Gamma Prototype Build Pilot (Final PPAP Submission) Meeting Responsibility: Pre-Production Meeting is Scheduled by SQE Meetings 2, 3, 4 are Scheduled by Supplier TODAY Primary 11 13

Supplier Program Review #1 (PR#1)
Task 4) Supplier Program Reviews Supplier Program Review #1 (PR#1) Conducted after the Sourcing decision: -- GM SQE coordinates and leads this first review -- Supplier responsibilities and deliverables are reviewed Purpose: -- Ensure the GM Global APQP requirements and responsibilities are clearly communicated and understood -- Verify Program timing and deliverables associated with program timing Read Slide and explain that today is the Kick-Off meeting or Pre-Production meeting where all deliverables required for Supplier Program Review #1 will be reviewed The supplier should have received a letter from you prior to the Kick-Off meeting explaining what is required at this Kick-Off meeting STRESS that the main objective of today’s meeting is to make sure that the supplier understands all the requirements in GM’s common APQP process

Task 4) Supplier Program Reviews
Supplier Program Review #1 (PR#1) Purpose: (continued) -- Communicate process that will be used to provide program updates for APQP deliverables Supplier Program Reviews - 4 Timing Chart GM Program Tracking Chart GM Feasibility & Manufacturing Assessment Letters GM -- Confirm APQP program communication channels within and between supplier and GM APQP Project Contact List GM Make sure they understand how the updates to the requirements will be done The 4 Supplier Program Reviews are the minimum formal reviews that will take place Additional program meetings will most likely occur these could be engineering work teams or internal supplier team meetings

List the Key Positions needed to Manage New Programs
4) Supplier Program Reviews Program Review #1 (PR#1) Who to Contact? GM List the Key Positions needed to Manage New Programs

Supplier Program Review #1 (PR#1)
4) Supplier Program Reviews Supplier Program Review #1 (PR#1) Review of Pre-Sourcing Quality Requirements Review items listed in the “Required Quality Information” letter GM contained in the RFQ Review the “Supplier Quality Statement of Requirements” (SOR) GM Review page 5 with the appropriate company representative signature Overview of the 17 APQP deliverables and explanation of each Read Slide As this first Supplier Program Review continues each of the documents listed here will reviewed

4) Supplier Program Reviews
Required Quality Information (GM is Included in all GM RFQs. Supplier submits as part of Quote to GM, includes requested documents. Review Supplier Quality Information provided and discuss exceptions. Update APQP Open Issues List for exceptions. Confirm in the APQP Kick-Off meeting notification letter that the supplier should be prepared to review any of the items listed in the Required Quality letter GM With the letter on the screen explain the following: If there are any items you as the SQE would like reviewed from this letter they should be reviewed at this time If the supplier has not supplied these documents prior to Sourcing they should be prepared to review each of them at this meeting

Supplier Quality SOR 4) Supplier Program Reviews
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. Signature of Supplier Representative Review the Supplier Quality SOR GM and make sure the supplier has copies of each of the documents listed and understands the requirements If meetings are required for additional explanation of any of the requirements it is recommended that dates for the meetings be set at this Kick-Off meeting / Pre-Production Meeting this will ensure the supplier fully understands the requirements Request a signed copy of page 5 from the Supplier Quality SOR This request should have been in a list of items in the suppliers pre-work or Kick-Off meeting notice listing all items required at the Kick-Off meeting / Pre-Production meeting

Program Review #1 (PR#1) Define Program Timing Elements -Major Program Benchmark Dates are provided by the SQE - GM provides the Minimum list of activities that must be tracked by the supplier Suppliers Complete the form and return it to the SQE - Updates showing progress are forwarded to the SQE - Detailed evaluations are conducted as part of future Program Reviews. Explain that this Timing Chart is an expansion of the APQP Project Plan GM Be clear that there is not a ONE FOR ONE correlation between the APQP Timing Chart GM and the APQP Project Plan GM the reason for this is because the Timing Chart GM was developed to meet requirements for the GQTS APQP Tracking system This form as it is developed can be used and updated manually until the GQTS APQP Tracking system is implemented (remember the system is targeted for 3rd or 4th quarter 2000) The first 8 items listed on the APQP Timing Chart GM are significant program timing milestones

Lessons Learned Review Lessons Learned in GM SupplyPower website - Obtain worksheet on major components - Evaluate Lessons for application to new part Discuss other Lessons Learned from similar parts Objective of this activity is --- Avoid Repeat Issues Show the GM forms listed and explain what ever sheets you are most comfortable with

Meeting Subjects Include: APQP Major/Open Issues List APQP Timing Chart Updates Progress of Tooling/Fixtures/Gages Supplier Manufacturing Assessment Letters (3 letters) 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 Task 6 Suppliers need to be prepared for each meeting with supporting documents SQEs will Review Documents at Meetings Primary 11 13

Timing Supplier Program Review #2 (PR#2)
4) Supplier Program Reviews Timing Supplier Program Review #2 (PR#2) Program Review #2 (PR2) conducted 2 weeks prior to the Beta Prototype Build Review Supplier conducts the meeting and reports the status of the deliverables due for this review Purpose--Supplier Program Review #2 Ensure the suppliers manufacturing process is capable of meeting GM’s requirements for the Beta Prototype Build Review (applicable for suppliers providing parts for Beta) Communicate issues that have been identified during the preparation for the Beta Build Review. Verify program timing for remaining APQP deliverables Read Slide Make sure the supplier understands the purpose

4) Supplier Program Review #2
Specific Review Items Items designated on the APQP Project Plan GM with a 2 in Program Review column Timing Chart GM Verify timing is on track Only require detail on items where timing has slipped APQP Open Issues list GM Feasibility Letter #2- Supplier Manufacturing Assessment of Design Flow Chart-should be more detailed than the initial one due at the Technical Review DFMEA - status if design responsible, availability of data if GM design responsible Read Slide Suggest you put a copy of the APQP Project Plan GM on the screen and just show where the “2” is listed in the Program Review column This just reinforces how they determine what item is reviewed during each of the reviews Cover each of the items, ensure the supplier understands the level of detail that is required at Program Review #2 The detail is listed on the slide, it should be clear

Specific Review Items-(continued)
4) Supplier Program Review #2 Specific Review Items-(continued) Control Plan--review and verification of continued development since initial review during the APQP Kick-Off/Pre-Production meeting The same logic that applied to the PFMEA applies here If supplier currently produces a similar part, the Control Plan should be very detailed If this is a new process for the supplier the level of detail will not be as complete This build event and the Prototype events are where the supplier clearly identifies where error proofing techniques and audit type controls are necessary Read Slide Slide explains what level is required

Specific Review Items -(continued)
4) Supplier Program Review #2 Specific Review Items -(continued) PFMEA Strategy--review and verification of continued development since initial review during the APQP Kick-Off/Pre-Production meeting If supplier currently produces a similar part, the PFMEA should be very detailed If this is a new process for the supplier the level of detail will not be as complete Detail of Recommended Actions may not be identified for all listed Potential Failure Modes Recommended Actions may not be completed Read Slide Detail is explained on the slide If the process is new remember the supplier is involved in the “Learning” process and the PFMEA may not be as complete as if the process was proven Do NOT expect to have a “COMPLETED” PFMEA with all Recommended Actions filled in for each Potential Failure Mode

Specific Review Items -(continued)
4) Supplier Program Review #2 Specific Review Items -(continued) Design Review-discussions should be around a KCDS workshop GM design responsible-GM leads workshop Supplier design responsible- Supplier leads the workshop or appropriate activity to identify the Key Product Characteristics Gage, Tooling & Equipment Review Gage Concept approval status Specific tooling timing-ensure timing is meeting the plan for the program timing GP-11--Discussions should take place between the supplier and the GM engineer on the plan to provide parts for the Prototype build plan should include dimensional data requirements and the method of collection necessary i.e. , CMM holding fixture, what is the serialization process required etc. Read Slide Slide explains the level of detail required Reinforce to the supplier that if timing on ANYTHING slips there must me a recovery plan Any item that timing is delayed for is a potential candidate for the Launch Alert process.

Specific Review Items-(continued)
4) Supplier Program Review #2 Specific Review Items-(continued) Lessons Learned -- update of lessons learned identified during the process to date Include design items and manufacturing items Items should be tracked back to the DFMEA if supplier is design responsible Track manufacturing items back to PFMEA Read Slide Explain the Lessons Learned Global Process with the next couple of slides

Insert a copy of GM and GM these show overviews of how the Lessons Learned process was developed and should function Show the GM forms listed and explain what ever sheets you are most comfortable with

Insert copy of GM this is a copy of the ACTUAL Global Lessons Learned criteria check-sheet that was developed for Exterior Mirrors. Review a few of the questions listed on this actual check-sheet so that there is an understanding of the types of questions looked at for a commodity. Please STRESS that the supplier needs to understand that there is NO CONIFDENTIAL INFORMATION put into any of these sheets. Questions are kept at a generic level but at the same time detailed.

Timing Supplier Program Review #3 -- (PR#3)
Program Review #3 (PR3) conducted 2 weeks prior to the Gamma Prototype Build Review Supplier conducts the meeting and reports the status of the deliverables due for this review Purpose--Supplier Program Review #3 Ensure the suppliers manufacturing process is capable of meeting GM’s requirements for the Prototype review (applicable for suppliers providing parts for Prototype) Communicate issues that have been identified during the preparation for the Gamma Prototype Build Review. Verify program timing for remaining APQP deliverables Read Slide This review follows the same logic that program review 2 followed Basically, more detail will be required on any item that was reviewed at PR#2

Specific Review Items (continued)
4) Supplier Program Review #3 Specific Review Items (continued) Items designated on the APQP Project Plan GM with a 3 in Program Review column Timing Chart GM Verify timing is on track Only require detail on items where timing has slipped These items are candidates for a “Launch Alert” APQP Open Issues list GM What is the status of major items since the last review Feasibility Letter #3- Supplier Manufacturing Assessment of Prototype Signature required by manufacturing location plant management Read Slide You may want to have the APQP Project Plan GM handy to put on the screen again and identify items with a 3

Insert a copy of “Supplier Manufacturing Assessment Of Prototype” GM letter 3 Explain that this letter will be required at the time of Supplier Program Review #3. This is notification from the supplier that they either have issues or do not have any issues Stress that this an opportunity to verbalize to GM that they concerns Understand that these issues may be due to engineering and the design We in SQ need to be the suppliers ally and work with the suppler and the GM engineer to try to resolve the issues Remind the supplier that this is a REQUIRED form and will be an interactive form when the GQTS APQP system is active (targeted for 3rd or 4th quarter 2000) Until the system is active this will be completed “manually”

4) Supplier Program Review #3 Specific Review Items (continued) Design Review KPC’s should have been identified through the KCDS Workshop process GD&T discussions should also be completed by the Prototype build event Gage/Tooling Review Gage Design approval status Specific tooling timing Require detail on any item where timing has slipped in relation to GM’s program timing Read Slide Detail is spelled out on the slide

4) Supplier Program Review #3 Specific Review Items (continued) GP-11--confirm the supplier has met the engineering requirements for Pre-Prototype and Prototype builds This should include a review of the dimensional results and any quality issues identified during the Prototype build Ensure the GM engineer is involved to approve any dimensional issues PFMEA Strategy--review and verification of continued development emphasis on items identified during any and Prototype manufacturing processes (see Lessons Learned) Read Slide Understand that GP-11 or Pre-Prototype and Prototype requirements are NOT the responsibility of the SQE, BUT we need to be involved in making sure the engineer is clearly communicating what is required for these builds The requirements include what dimensional checks will be needed to be completed by the supplier, will parts need to be serialized? These requirements are the GM engineers responsibility

4) Supplier Program Review #3 Specific Review Items (continued) Control Plan--review and verification of continued development since Supplier Program Review #2 meeting This should include all necessary controls and error proofing techniques identified during all early build events Lessons Learned -- update of lessons learned that were identified during the Prototype build process Include design items and manufacturing items These items should be tracked back to the DFMEA if design responsible Manufacturing items tracked back to PFMEA Read Slide Level of detail explained on slide

Risk Assessment Risk Assessment is updated for the current status in program Review of the overall risk associated with the program is updated by the SQE after Supplier Program Review #3 This is reported to internal GM Program Management Read Slide Clearly explain supplier that this is a GM INTERNAL document and IS NOT SHARED IN DETAIL WITH THE SUPPLEIR WHEN IT IS COMPLETED NEVER PROVIDE A COPY TO THE SUPPLEIR OF A COMPLETED FORM

Timing Supplier Program Review #4 (PR #4)
4) Supplier Program Reviews Timing Supplier Program Review #4 (PR #4) Program Review #4 (PR4) conducted 2 weeks prior the the Pilot Build Review Supplier conducts the meeting and reports the status of the deliverables due for this review Purpose Supplier Program Review #4 “Dress Rehearsal” for PPAP Ensure the suppliers manufacturing process is capable of meeting GM’s requirements for the Pilot build. Manufacturing process and all support is to be representative of ALL Production systems and processes Communicate issues that have been identified since the Prototype Build Review Verify program timing for remaining APQP deliverables Read Slide Items due for review are all the PPAP required documents

Specific Review Items Items designated on the APQP Project Plan GM with a 4 in Program Review column All Quality documentation at this review is to be ready for PPAP submission Timing Chart GM Verify timing is on track Only require detail on items where timing has slipped These items are candidates for a “Launch Alert” APQP Open Issues list GM Feasibility Letter #4- Supplier Manufacturing Assessment of Manufacturing Process Capability and Production Readiness Flow Chart--Ready for PPAP submission Read Slide

Insert copy of “Supplier manufacturing Assessment of Manufacturing Process Capability and Production Readinesss” GM letter 4 Review the letter and the same information applies that was stated for Feasibility Letters #2 and #3. This is the suppliers opportunity to confirm they are ready for the Pilot event or have issues. Stress that if there are issues going into the Pilot event that they should be communicated as soon as they were identified. Stress that the supplier SHOULD NOT WAIT for this Supplier Program Review #4 to inform you of issues

4) Supplier Program Review #4 Specific Review Items (continued) All Quality documentation (continued) DFMEA--completed if supplier is design responsible Gage/Tooling Review Gage R&R should be reviewed and acceptable Corrective Action plan reviewed if R&R is unacceptable Specific tooling timing at this point should be completed to schedule Any tooling issue is a “Launch Alert” candidate Read Slide Slide explains the requirements

4) Supplier Program Review #4 Specific Review Items (continued) All Quality documentation (continued) PFMEA Strategy--review and verification of evidence that supports RPN reductions throughout the manufacturing process (see Lessons Learned) Control Plan--review and verification of evidence that indicates error proofing techniques are in place and that all process operation are controlled GP-12--review of the specific controls put in place to prevent defective parts from reaching the GM manufacturing site This is the supplier’s Pre-Launch Control Plan, reference GM 1920 Read Slide The PFMEA Strategy is nothing more than the suppliers plan for how they will work to reduce the RPNs (Risk Priority Numbers) on the PFMEA. An example might be that they will work on the top 10 RPNs and as each is reduced move to the next highest. Their plan might be that they will work the highest “severity” numbers.

4) Supplier Program Review #4 Specific Review Items (continued) Rate--final details for the Rate should be confirmed, this includes those parts designated as Customer or Supplier Monitored Confirm with the supplier the quantities required i.e. LCR and Contracted Tool Capacity Lessons Learned -- ensure all lessons learned during the entire APQP process have been documented in the appropriate quality documents DFMEA PFMEA Control Plans This documentation is critical for future programs success Read Slide The supplier should have a plan for how they intend to conduct their Rate by the time of Supplier Program Review #3. There is a good chance that the Rate has already been completed by the time Supplier Program #4 is conducted.

5) Timing Charts / Open Issues
SQE Responsibility: Purpose: Ensure Program Deliverables are Executed on Schedule Review the APQP Timing Chart and APQP Issues List Identify and Communicate Key Timing and Program Issues with GM Management Supplier Responsibility: Create and maintain an APQP Timing Chart and Open Issues List Maintain Detail behind Each High Level APQP Chart Review Timing Chart and Issues List at All Program Reviews Identify and Communicate Any Changes to SQE Identify and Communicate Key Timing and Program Issues with SQE Primary 11 13

6) Manufacturing Assessment Letters
Purpose: Supplier Evaluates Manufacturability of the Part Manufacturing Assessments: Design -- can the Design be Manufactured to Conform to all GM Performance Requirements? Prototype -- using the Intended Production Process, will all Parts Conform to GM Requirements? Process Capability -- will the Production Process Provide Parts that Conform to GM Requirements? Supplier Responsibility: Evaluate Feasibility during 3 stages of program development Submit Letters Signed by the Manufacturing Plant Manager 11 13

6) Manufacturing Assessment Letters
Design Is Manufacturable to GM Required Quality Levels… Manufacturing is making a commitment to achieve zero defects.. Minor concerns about the design .. Confident that design will be modified..manufacturable to Required Quality Levels… commitment to achieve zero defects.. Major concerns about design, not confident part can be produced at GM Required Quality Levels…

7) Flow Chart Purpose: SQE Responsibility: Supplier Responsibility:
Provide a Logical Pictorial Representation of the Process Flow that can be used as the Foundation for PFMEA’s. 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 Primary 11 13

8) Design Failure Mode and Effects Analysis
Purpose: Support the Design Process in Reducing the Risk of Failure SQE Responsibility: Confirm that a DFMEA has been Completed Ensure that Supplier has a DFMEA for input to PFMEA Lessons Learned Checklist to Design Owner Supplier Responsibility: GM Design Responsible Suppliers must participate in DFMEA Reviews with Product Engineer Share Knowledge and Experience on Similar Designs Recommend Action Plans for Severity, Occurrence, Detection Targets Supplier Design Responsible Lead Cross-functional Team to Develop and Improve FMEA Schedule Review Meetings with GM Product Engineer Develop Action Plans for Severity, Occurrence, Detection Targets Maintain DFMEA for PPAP Submission Primary

9) Design Reviews Purpose: SQE Responsibility:
Ensure that the Design has been adequately Defined to Build Tools and Gauges SQE Responsibility: Participate in KCDS Workshop and GD& T Reviews Participate in Design Reviews addressing changes in Manufacturing Process/ Quality/Timing/ Risk Supplier Responsibility: Participate in KCDS Workshop and GD& T & Design Reviews Participate in Defining Measurable KPC’s Participate in Defining Appearance Specifications Satisfy all Performance and Material Testing Requirements Ensure that the Manufacturing Process can achieve Tolerances on a Continuing Basis Quality of the Design Directly Impacts Process Design and Process Quality Primary

10) Gage, Tooling & Equipment Reviews
Purpose: Ensure that the Manufacturing process is being designed, built and certified to produce parts with quality at rate according to GM program requirements SQE Responsibility: Confirm that Gage, Tooling and Equipment Timing is on Schedule to Support Program Requirements Confirm that the Gauge Agrees with the Functional Part Usage, Complies with GD&T, Includes Measurement of KPCs and is at the Correct Change Level Ensure Gage is Used as Indicated in Process Flow Chart and Control Plan Supplier Responsibility: Design, Build and Obtain Certification of Gages Participate in Reviews with General Motors Relative to Design, Build and Certification of the Gage

11) GP 11 Prototype Purpose: Supplier Responsibility:
Ensure Part Problems are Identified and Corrected in order to Minimize the Impact of Part Variation upon Design Evaluation, Manufacturing, and Assembly. Supplier Responsibility: Adhere to Requirements Specified in GP-11. Ship Parts and Documentation as Specified in GP-11 and the Prototype Purchase Order. Respond to and Resolve Issues Identified in Prototype Build. Revise the Flow Chart, PFMEA, and Control Plan as Problems are Identified throughout GP-11 and the Prototype Build. Update the APQP Open Issues List and APQP Timing Chart as Problems and Changes Occur. Prototype will act as a Mirror for Problems that will Appear at Pilot = Address Issues Early in Program! Primary

12) PFMEA Strategy Purpose: SQE Responsibility:
Assure Potential Failure Modes of the Process have been Considered and Addressed SQE Responsibility: Attend initial PFMEA Development Team Meeting Monitor Progress and Review PFMEA with Supplier Supplier Responsibility: Initiate PFMEA prior to Sourcing as part of the Quotation to GM Drive Error Prevention and Detection throughout the Process Prepare PFMEA - Multi-disciplinary team Insure that PFMEA results have been incorporated into Control Plan Revise PFMEA if Process / Material / Manufacturing Location Changes Develop and Implement RPN Reduction Plans Primary

13) Control Plans Purpose: SQE Responsibility:
Define the Method being used to Control all KPCs and KCCs for Parts being Manufactured for Vehicle Builds. SQE Responsibility: Verify use of PFMEA & Statistical Data to determine Necessary Controls Verify Update of Control Plan with Solutions from PFMEA Verify Pre-Launch Issues have been Incorporated into Production Plan Supplier Responsibility: Develop Pre-sourcing Control Plan Ensure Control Plan Flows from PFMEA & Process Flow Chart Use Pre-Launch Control Plan to Validate Production Control Plan Update Control Plan Process Control Plan Audits will be Conducted at Rate Primary

14) GP 12 Early Production Containment
Purpose: Establish a Containment Plan during Start-up and Acceleration that will Quickly Identify Quality Issues at the Supplier’s Facility; i.e., a Pre-Launch Control Plan. SQE Responsibility: Provide GP-12 Timing to the Supplier Review the Supplier’s Process and Pre-Launch Control Plan Verify that any PR&R, Prototype or Pilot Issues are in Control Verify that the Supplier used PFMEA & Statistical Data to Set Controls Supplier Responsibility: Develop the Pre-Launch Control Plan Based on Experience from Prior Issues Implement the Pre-Launch Control Plan Monitor GP 12 Data and Modify Internal Process to Eliminate Issues Monitor Customer Issues and PR&Rs, Update Control Plans Primary

15) Production Part Approval Process
Purpose: Determine if All Customer Engineering Design Records & Specifications Requirements are properly understood by the Supplier and that the Process has the Potential to Produce Product Meeting these Requirements during Production at the Quoted Rate. SQE Responsibility: Review PPAP Documentation Prior to Submission - Verify Completion of all 19 Required Items - Many Documents Can be Reviewed in Advance of PPAP Submission Follow-up on PPAP Rejections Supplier Responsibility: Produce Parts in the Production Environment Complete all Documents and Test Requirements in Advance of PPAP Date Target for Full PPAP on First Submission Primary

16) Run at Rate Purpose: Verify that the Supplier’s Actual Manufacturing Process is Capable of Producing Parts that Meet: - GM’s On-going Quality Requirements - Quoted Tool Capacity - GM’s Daily Volume Requirements SQE Responsibility: Evaluate the Supplier’s Run at Rate Plan Determine if the Run at Rate should be Customer or Supplier Monitored Participate in Customer Monitored, or Review the Results of Supplier Monitored Confirm Actual Capacity Exceeds Quoted Capacity and GM Daily Requirements Status Run at Rate According to Results Supplier Responsibility: Develop Run at Rate Plan and Review with SQE Confirm Quoted Tool Capacity and Duration of Run at Rate Conduct Run at Rate, Complete Worksheets and Forward to SQE

17) Lessons Learned Purpose:
Review Experience from Previous Programs and Consider Opportunities to Improve Performance on New Programs. SQE Responsibility: Acquire Information about Previous Experiences with Similar Commodities - Other SQEs, Local or in Other Regions - Product Engineers Share Personal Knowledge and Experience Verify that the Supplier Applies Lessons Learned in New Process Supplier Responsibility: Share Lessons Learned from Similar Commodities Evaluate Lessons Learned from External Sources Incorporate All Applicable Items into Production Process and Tool Designs Primary

Summary Let’s Get Going!!
Proactive Conformance to AIAG APQP Requirements and GM APQP Tasks Supplier Drives Tasks 4 through 17 to Completion Identify Issues Early in Program and Drive Correction Maintain Communication with GM on Program Status and Issues -- Manufacturing Assessment Letters -- Schedule Program Review 2,3,4 with the SQE Expect these Same Requirements from Sub-Suppliers Let’s Get Going!! Primary

Supplier Program Review Meeting #1

Similar presentations

Presentation on theme: "Supplier Program Review Meeting #1"— Presentation transcript:

Similar presentations

About project

Feedback

Log in

Auth with social network:

Supplier Program Review Meeting #1

Similar presentations

Presentation on theme: "Supplier Program Review Meeting #1"— Presentation transcript:

Similar presentations

About project

Feedback