1. Supplier Program Review Meeting #1
Advanced Product Quality Planning
APQP Kick-off Meeting GM 1 1

2. Supplier Program Review Meeting #1
Purpose:
Communicate the process that will be used to provide program updates for APQP Deliverables.
Confirm APQP communication Channels between Supplier and GM.
Ensure that GM requirements are understood.
Understand current program status to ensure conformance to GM Timing.
Provide a formal process to raise open issues for resolution.
Form joint focus on future steps.

3. 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

4. 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

5. 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

6. Global APQP Development
GM 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

7. 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

8. Global APQP Development
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

9. 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 SQ
Global APQP
Experience

10. Advanced Product Quality Planning General Motors Corporation
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!

11. APQP Project Plan APQP “At a Glance”SQ
Global APQP
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

12. APQP Project Plan

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

14. 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 Review
Gamma Prototype Build Review
Pilot (Final PPAP Submission) Review
Meeting Responsibility:
Pre-Production Meeting is Scheduled by SQE
Meetings 2, 3, 4 are Scheduled by Supplier
TODAY 11 13

15. 4) Supplier Program Reviews
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 11 13

16. 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 11 13

17. 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

18. 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…

19. 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 11 13

20. 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

21. 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

22. 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

23. 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!

24. 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

25. 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

26. 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

27. 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

28. 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

29. 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

30. Advanced Product Quality Planning General Motors Corporation
APQP Kick-off Meeting
Agenda
Advanced Product Quality Planning
Worldwide Purchasing
November 2000
General Motors Corporation GM
SQ Requirements
Program Timing
Review Checklist
Open Issues
Summary

31. 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.
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

32. Required Quality Information Letter
(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

33. 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

34. Program Timing Information
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

35. List the Key Positions needed to Manage New Programs
Program Contacts
Who to
Contact? GM
List the Key Positions needed to Manage New Programs

36. APQP Kick-Off Meeting Checklist
Review Checklist
Identify Open Issues
- GM responsibility
- Supplier Responsibility
Add Items to APQP Open Issue List (GM1927-5)
Drive all Issues to Closure!
APQP Open Issues

37. 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

38. 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!!