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General Motors Corporation Worldwide Purchasing Global Purchasing and Supply Chain September 21, 2009 I GM1927 Global Global Supplier Supplier Quality Quality Manual Manual
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Page 1: GM_APQP

General Motors Corporation

Worldwide Purchasing

Global Purchasing and Supply Chain

Preface

September 21, 2009 I GM1927

GlobalGlobalSupplier QualitySupplier Quality

ManualManual

Page 2: GM_APQP

This Reference Manual represents the collaborative efforts of multiple GM worldwide teams engaged to develop a GM Common process manual that includes APQP, Launch, and Current Quality. Prior to this, multiple documents existed to define a Supplier Quality process from APQP through Current Quality.

APQPThe APQP portion of this manual defines GM’s common global product quality planning requirements that are necessary to develop and implement an APQP process for a product or service. It is intended as a standard to provide the Supplier Quality Engineer, and the supplier, a common format from which to proceed with all steps of APQP.

LaunchThe Launch portion of this manual defines standardized processes that support specific supplier launch readiness activities and APQP deliverables. These globally approved activities are designed to assist in the assessment of launch readiness of all suppliers and ensure execution of flawless launches.

CurrentThe Current portion of this manual defines the standardized work around common processes used globally to protect our manufacturing/assembly plants and to drive systemic improvement to the supply base.

Approved by:

Global Supplier Quality Directors

September 21, 2009 II GM1927

Page 3: GM_APQP

Table of Contents

Preface...............................................................................................................................IITable of Contents.............................................................................................................IIIManual Content Explanation............................................................................................V

Section 1 – Global APQP

Customer Monitored/Supplier Monitored Matrix..............................................................2Global APQP RASIC.........................................................................................................3Document Usage Guidelines.............................................................................................5

APQP Task DefinitionsTask 1: Commodity Key Stakeholders Meeting...............................................................6Task 2: Technical Reviews...............................................................................................7Task 3: Sourcing Eligibility .............................................................................................8Task 4: Supplier Gate Reviews.......................................................................................10Task 5: Timing Charts/Open Issues................................................................................12Task 6: Quality Systems Basics......................................................................................13Task 7: Flow Chart.........................................................................................................14Task 8: DFMEA..............................................................................................................15Task 9: Design Reviews.................................................................................................17Task 10: Tool & Equipment Reviews.............................................................................18Task 11: Gage Development & Approval......................................................................19Task 12: PFMEA............................................................................................................20Task 13: Control Plan.....................................................................................................22Task 14: GP-12 Early Production Containment.............................................................24Task 15: PPAP................................................................................................................25Task 16: Run @ Rate......................................................................................................27Task 17: Lessons Learned...............................................................................................29

September 21, 2009 III GM1927

Page 4: GM_APQP

Section 2 – Global Launch

Document Usage Guidelines...........................................................................................31Supplier Quality Launch Project Plan.............................................................................31

Launch Task DefinitionsTask 1: Launch Management Team................................................................................32Task 2: Global Launch Reporting...................................................................................34Task 3: Supplier Launch Risk Analysis..........................................................................35Task 4: Launch Issue Escalation.....................................................................................36Task 5: Supplier Communication Conferences..............................................................37Task 6: Supplier Layered Audits....................................................................................38Task 7: APQP Team Reviews........................................................................................39Task 8: Key Supplier Reviews........................................................................................40Task 9: Supplier Launch Audit (SLA) Process..............................................................42Task 10: Build Issue Tracking........................................................................................43Task 11: Plant Daily Build Summary Report.................................................................44Task 12: 3rd Party Containment (ESEP) - optional.........................................................45Task 13: Boundary Samples - optional...........................................................................46

Section 3 – Global Current

Document Usage Guidelines by Global Region..............................................................48Supplier Training.............................................................................................................49Approved 3rd Party Providers...........................................................................................49

Current Task DefinitionsTask 1: Continuous Improvement...................................................................................50Task 2: Quality Systems Basics......................................................................................52Task 3: Shutdown/Start Up Activity...............................................................................56Task 4: Process Control Plan Audit................................................................................58Task 5: Creativity Team Support....................................................................................60Task 6: Global Emerging Issue/Alert Process................................................................63Task 7: Major Disruption Prevention Activity...............................................................65Task 8: Controlled Shipping 1........................................................................................68Task 9: Controlled Shipping 2........................................................................................71Task 10: Supplier Performance Review Meetings.........................................................75Task 11: 3rd Party Provider Process................................................................................77Task 12: Top Focus Process...........................................................................................84Task 13: New Business Hold/Exit..................................................................................86

Revision History.............................................................................................................88

Glossary of Terms..........................................................................................................93

September 21, 2009 IV GM1927

Page 5: GM_APQP

Manual Content Explanation

This manual contains three (3) sections. Each section has tasks that are referenced by a task number and includes the following:

Task name Task Owner(s) Task Timing (approximate) Task Description Key Deliverables upon completion of the specific task Customer(s) for the deliverables Necessary Inputs to complete the specific task including source for each input Listing of Resources—this includes people of organizations involved in completing the task Methodology—brief description of actions in table format arranged by action owner References and additional information

Document Procurement

FormsGM forms and documents referenced in this manual GM 1927 can be obtained through GM SupplyPower at www.gmsupplypower.com and be copied for use.

GM General Procedures (GPs)General Procedures (GPs) referenced can be obtained through GM SupplyPower at www.gmsupplypower.com and be copied for use.

Labels & TagsLabels and tags referenced in the APQP process can be obtained as follows:

GMAP and GME – contact the SQEGMLAAM – Labels and tags can be obtained from any supplier as long as it meets standards

identified in the General Procedures GMNA – Contact CMS Print Solutions 1-734-953-3266, extension 211, Fax 1-734-953-3265

AIAG DocumentsAll AIAG specific documents referenced can be obtained by contacting AIAG at 01-248-358-3003. Documents can also be ordered by accessing the web at www.AIAG.org. In Europe contact Carwin Ltd at 44-1708-861333.

Note to Suppliers:This manual is intended to be comprehensive and “all-encompassing”; however, certain circumstances will prompt questions. If you have any questions regarding any part of this manual you are encouraged to contact your respective Supplier Quality Engineer

September 21, 2009 V GM1927

VV

Page 6: GM_APQP

Global APQP Process

Section 1

Global APQP

September 21, 2009 1 GM1927

Page 7: GM_APQP

Global APQP Process

Customer vs. Supplier Monitored APQP

The following matrix describes the responsibility differences between “Customer-Monitored” and “Supplier-Monitored” APQP. Suppliers are responsible for carrying out all the “R” activities shown in the supplier column of the matrix, whether or not their parts are designated as customer or supplier-monitored APQP. If a part is designated as customer-monitored APQP, a GM representative will monitor and approve the APQP activities.

APQP ActivityCustomer Monitored

APQP Supplier GM

Supplier MonitoredAPQP

Supplier GM1 Commodity Key Stakeholders Meeting. N/A R N/A R

2 Technical Reviews S R S R

3 Sourcing Eligibility N/A R N/A R

4 Gate Review #1 (Kick-Off Meeting)Remaining Gate Reviews

SR

RA

SR

RI

5 Timing Charts/Open Issues R A R I

6 QSB R A R A

7 Flow Chart R I R I

8 DFMEA (1 – Supplier Design Responsible, 2 – GM Design Responsible)

R (1)S (2)

A RS

I

9 Design Review (1 – Supplier Design Responsible, 2 – GM Design Responsible)

R (1)S (2)

S (1)R (2)

R (1)S (2)

I

10 Tool and Equipment Review R A R I

11 Gage Review & Approval R A R A

12 PFMEA R I R I

13 Control Plan R I R I

14 GP-12 R I R I

15 PPAP R A R A

16 Run @ Rate (GP-9) R A R I

17 Lessons Learned R I R I

R Responsible - Task Owner (GM or Supplier) A Approve - Approve deliverables (GM) S Support – Support Completion of deliverables (GM or Supplier) I Inform - Review deliverables at discretion of SQE (GM)

N/A Not Applicable

September 21, 2009 2 GM1927

Page 8: GM_APQP

Global APQP Process

Global APQP RASICGlobal CT SQE

(multiple region

sourcing)

Regional CT SQE

(1 region sourcing)

Dev. SQE Mfg SQE

Pre-Sourcing (APQP Tasks 1, 2, 3)On-time completion of Sourcing Eligibility (APQP Task 3)

R R S S

SQ Participation in CKSM (APQP Task 1) R R A S

SQ support at Technical Review (APQP Task 2)

R R A I

Completion of QBC QUAD Report (as required)

A A S R

SQ Signature on Recommendation Sheet

R R C C

Handover from Dev SQE to Mfg SQE S S R APost-Sourcing (APQP Tasks 4-17)

APQP Kick-off / Gate Review #1 S S S R APQP Gate Review #2 (-78wks) - - S R APQP Gate Review #3 (-52wks) - - S R APQP Gate Review #4 (-35wks) - - S R PPAP (-15wks) - - S R R@R (-8wks) - - S R Business Processes (GQTS, RLA, etc) - - S RKeyMultiple Region Sourcing

1 Region Sourcing

Global CT (Creativity Team) SQE

Regional CT (Creativity Team) SQE

Dev SQE - Development SQE

Mfg SQE - Manufacturing SQE

R - Responsible

A - Approving

S - SupportingI - InformedC - Consulted

Those who are to be kept informed about proceedings

Development SQE is co-located with GM Product Engineer (i.e. located in the GM Engineering Homeroom for the product being sourced) - may also fill Mfg SQE role when supplier Mfg location is near the GM Engineering homeroom

Manufacturing SQE is located in the sourced Supplier's Manufacturing country

Those solely and directly accountable for ensuring task completion

The party (or parties) that reviews and assures the work product's quality

Individuals or groups who help to create the work product

Those who help design the product or put in place quality review criteria

APQP

Sourcing involving GM Manufacturing plants in >1 region

Sourcing for 1 plant or multiple plants within 1 GM region

Globally responsible for CT in SQ, may also fill Dev SQE role when co-located with Product Engineer

Regionally responsible for CT in SQ, may also fill Dev SQE role when co-located with Product Engineer

September 21, 2009 3 GM1927

Page 9: GM_APQP

Global APQP Process

Global APQP RASIC (Cont.)Global CT SQE

(multiple region sourcing)Regional CT SQE

(1 region sourcing)Development SQE Manufacturing SQE

Pre-Sourcing (APQP Tasks 1, 2, 3)On-time completion of Sourcing Eligibility (APQP Task 3)

R = Responsible to track all cross region sourcings within the CT and ensure

appropriate SQ approvals from all regions are provided on time to guarantee

recommendation date

R = Responsible to track single region sourcings within the CT and ensure appropriate SQ approvals from all regions are provided on time to

guarantee recommendation date

S = Support by attending CSSMs and TRs, distributing information back to Global CT SQE and providing general follow-up as required to ensure Sourcing date is met in accordance with

SQ requirements

S = Support by attending TRs as required and completing timely audits and QUAD reports

SQ Participation in CKSM (APQP Task 1)

R = Responsible to drive for 100% sourcings to be CKSM compliant within

CT and ensure appropriate Dev SQE assignment and attendance

R = Responsible to drive for 100% sourcings to be CKSM compliant within

CT and ensure appropriate Dev SQE assignment and attendance

A = Attendee at CKSM, approve Engineering and Purchasing inputs as acceptable to proceed to RFQ and ensure completeness of SQ inputs (i.e. inclusion of Product / Process specific SQ

SOR)

S = Support CKSMs where required and practical if requested by the Dev SQE

SQ support at Technical Review (APQP Task 2)

R = Responsible to ensure Dev SQE and/or Mfg SQE is identified to attend the

Technical Review and receives timely communication from the Buyer

R = Responsible to ensure Dev SQE and/or Mfg SQE is identified to attend

the Technical Review and receives timely communication from the Buyer

A = Default attendee at Technical Review (unless delegated, with agreement, to Mfg

SQE); Review supplier inputs versus SQ SOR for approval OR follow-up to ensure corrected,

completed documentation

I = Optional attendee at TRs by conference call, Required attendee where TRs occur in Mfg

Region, same Approver duties as Dev SQE in this case

Completion of QBC QUAD Report (as required)

A = Approver to confirm the Regional Mfg SQE completes the QUAD approvals as

required in line with APQP Task 3 expectations

A = Approver to confirm the Regional Mfg SQE completes the QUAD approvals

as required in line with APQP Task 3 expectations

S = Support to define audit requirements (as per APQP Task 3) and ensure supplier

understands and provides necessary input data

R = Responsible to complete audits (PCPA, PSA), Greenfield assessments and provide QUAD Approvals / Rejections from the Mfg

Region in line with APQP Task 3

SQ Signature on Recommendation Sheet

R = Responsible to sign recommendations on behalf of all regions confirming APQP

Task 3 requirements were met and regional buy-in was given to support sourcing (even in the case of Green

supplier on bidlist)

R = Responsible to sign recommendations on behalf of all regions confirming APQP Task 3

requirements were met and regional buy-in was given to support sourcing (even in the case of Green supplier on

bidlist)

C = to be consulted by the Global CT SQE prior to sign-off of the recommendation sheet

C = to be consulted for confirmation via Approved QUAD or, for DUNs locations Green

to the bidlist, by email acceptance, that a supplier DUNs location is acceptable for

recommendation

Handover from Dev SQE to Mfg SQE S =Provide information and documentation from Pre-Sourcing

S =Provide information and documentation from Pre-Sourcing

R =Provide information and documentation from the CKSM and Technical Reviews to the

Mfg SQE

A =Receive all Pre-Sourcing documentation from the other functions to utilize in Post-

Sourcing work

Post-Sourcing (APQP Tasks 4-17)APQP Kick-off / Gate Review #1 S = Support Kick-Off by communicating

the award to the responsible APQP Manager and ensuring the link between

the Lead Buyer and Mfg SQE is established

S = Support Kick-Off by communicating the award to the responsible APQP

Manager and ensuring the link between the Lead Buyer and Mfg SQE is

established

S = Support Mfg SQE execution of APQP by providing the direct information link to the

Engineering and Program Homeroom, including but not limited to: attending Gate Reviews as requested, direct follow-up of

Engineering Open Issue actions, communication of Design Release level EWO

changes, confirmation and sharing of B1 Appendix volume revisions from DRE and

communication of program homeroom timing revisions

R = Responsible to ensure supplier compliance to GM1927-34 ahead of the program deadline date including approval of mandatory GQTS upload documents; responsible to engage support of Dev SQE as required and track

information follow-up; responsible to confirm part number and DUNs accuracy within GQTS

APQP Gate Review #2 (-78wks) - - S = as above R = as above

APQP Gate Review #3 (-52wks) - - S = as above R = as above

APQP Gate Review #4 (-35wks) - - S = as above R = as above

PPAP (-15wks) - - S = as above, specifically including M1 GM1411 sign-off support and GM 3660 sign-off follow-

up

R = as above

R@R (-8wks) - - S = as above R = as above

Business Processes (GQTS, RLA, etc) - - S = Support Mfg SQE with part number information and root cause investigation of part numbers missing in GQTS (release vs

contract)

R = Responsible to ensure accurate documentation within GQTS, including Key

Documents by APQP Gate, PPAP, R@R and Red Launch Alerts. Responsible to escalate missing

Part Number / DUNs combination to Buyer and Program Homeroom

APQP

September 21, 2009 4 GM1927

Page 10: GM_APQP

Global APQP Process

Document Usage GuidelinesF = Reference Only (information only, nothing to fill out)MD = Mandatory Document (specific format required)MI = Mandatory Information (format may vary, content mandatory)RD = Recommended Document (not mandated, at a minimum content should be reviewed)

Document NumberMandatory (Upload to

GQTS)Mandatory Recommended

APQP Project Plan GM1927-01 FAPQP Timing Chart GM1927-02 MISupplier Quality Statement of Requirements (SOR)

GM1927-03 MD

APQP Open Issues GM1927-05 MICommodity Key Stakeholders Meeting Checklist

GM1927-06 RD

APQP Supplier Assessment GM1927-07 MDTechnical Review Checklist GM1927-13 RDAPQP Kick-Off Meeting Checklist GM1927-14 MD

Process Control Plan Audit Worksheet GM1927-16 MDGM and Supplier Program Contacts GM1927-17 MIProcess Capability Over Time GM1927-20 RDRPN Reduction Summary Chart GM1927-21 MDDirected Buy/Directed Source Checklist

GM1927-23 MD

Subcontractor Program Status Matrix GM1927-25 MD

Subcontractor Detailed Status Matrix GM1927-26 MI

Global Gage Request GM1927-29 MDQSB Audit GM1927-30 MDGreenfield & Brownfield Development Assessment Process

GM1927-31 MD

Dimensional Results GM1927-32 MDGP12 Audit GM1927-33 MDAPQP Supplier Status Workbook GM1927-34 MDRun @ Rate Capacity Workbook GM1927-35 MDQSB Workshop Presentation GM1927-36 FGlobal PFMEA Checklist GM1927-37 MD

Obsolete Documents: GM1927-4, GM 1927-8, GM 1927-9, GM 1927-10, GM 1927-11, GM 1927-12, GM 1927-15, GM1927-18, GM1927-19, GM1927-22M, GM 1927-24M,

GM1927-27, GM1927-28, GM1927-38, GM 1927-39, GM 1927-46, GM 1927-47, GM 1927-48, GM 1927-49, and GM1927-50.

September 21, 2009 5 GM1927

Page 11: GM_APQP

Global APQP ProcessTask Number: 1

Task Name: Commodity Key Stakeholders Meeting (CKSM)

Task Owner: Buyer

Task Timing: Pre-Sourcing

Task Description: 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.

Key Deliverables: SQ approval of the RFQ package content, timing and preliminary Bid List

Customer for Deliverables: Purchasing, Engineering, Supplier Quality and Marketing, PC&L as required

Necessary Inputs: Source of Input: Technical documents (BOM, SOR & Appendices e.g. SSTS/CTS) Engineer Creativity Team Bidders List (enhanced quality metrics) Buyer Proposed Sourcing Strategy Buyer Part-Specific Quality & Process SOR SQE Lessons Learned (including warranty items) on previous programs Buyer/SQE/Engineer Program related information Key Stakeholders

Resources: Purchasing, Supplier Quality, Engineering

Responsible Methodology :Buyer Invite appropriate Key Stakeholders identified for specific component/commodity/system and conduct

the meeting as stated on typical Engineering & Advance Purchasing Sourcing process (E&APSP) agenda (this meeting is to be conducted on all parts listed in the sourcing plan at the time stated in the sourcing plan).

Buyer Clarify the timing of each step in the AP Sourcing process, what is expected from each Stakeholder and get agreement on the process, content, timing and strategy for the sourcing package.

Buyer Propose roles and responsibilities through the initiation of GM1927-23 (to be added to the RFQ if applicable) for any directed buy part that will not follow the default rules established by GM1927-3.

Buyer Establish timing and lead question development for Supplier Workshops (Technology, Cost Reduction or Problem Resolution). Define a core group (sub-group of Stakeholders) to attend Supplier Workshops, summarize results and refine functional requirements based on workshop findings (if applicable).

Buyer Apply E&APSP CKSM & SOR checklists as appropriate.Buyer Start Open Issues list with any items that need to be addressed.DRE Present SOR content & allowable cost status and clarify what is being sourced (technological,

dimensional, functional and test requirements).DRE Present Warranty Data – i.e. Incidents per Thousand Vehicles (IPTV), Cost per Vehicle (CPV) and

engineering benchmark data (consult warranty champion if necessary).SQE 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 as established by GM Global APQP task #3 and start planning any required audits.

SQE 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.

SQE Provide an overview of commodity specific Lessons Learned from previous programs.SQE Inquire about any sequencing plans.SQE Apply the Commodity Key Stakeholders Meeting Checklist GM1927-6 as appropriate.

Reference Documents: Supplier Quality Statement of Requirements GM1927-3 / Part-Specific Quality & Process SOR Open Issues list GM1927-5 Commodity Key Stakeholders Meeting Checklist GM1927-6 E&APSP : Commodity Key Stakeholders Invitees / Key Stakeholders Checklist / SOR Checklist

September 21, 2009 6 GM1927

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Page 12: GM_APQP

Global APQP ProcessTask Number: 2

Task Name: Technical Review

Task Owner: Buyer

Task Timing: Pre-Sourcing

Task Description: Review the supplier technical proposal to ensure that all requirements in the RFQ-package have been understood and supplier has a plan to produce parts meeting GM expectations.

Key Deliverables: Identification of suppliers that are capable Completed APQP Supplier Assessment GM1927-7

Customer for Deliverables: Buyer, SQE, Engineer, Manufacturing Engineer

Necessary Inputs: Source of Input: Technical documents Engineer Supplier’s Quality History SQE List of Directed Buys Buyer Carryover part contact list Buyer Required Quality Information as per GM1927-3 item #12 Supplier

Resources: Purchasing, Engineering, Supplier Quality, Manufacturing Engineer, Supplier

Responsible Methodology :Buyer Invite potential suppliers to Technical Review Meetings.Buyer Update the Open Issues List with concerns related to the supplier’s ability to meet the requirements.DRE Identify specific agenda items for Suppliers to cover in Technical Review. DRE Assess Supplier technical capability for continuation in the sourcing process. SQE At the conclusion of the Technical Review, the Buyer, SQE and Engineer complete the APQP Supplier

Assessment GM1927-7 (this is required prior to signing the Sourcing Recommendation form).SQE Prior to the meeting, review specific documents provided in the supplier’s quote package as per SQ SOR

GM1927-3 and prepare questions related to quality and manufacturability in order to assess supplier capability and to support SQ recommendation about supplier continuation in the sourcing process.

SQE Ensure Supplier understands the SQ SOR GM1927-3, and Part-Specific Quality & Process SOR (if applicable) and returns them properly signed.

SQE Provide a brief overview of the Lessons Learned process.SQE Complete the Technical Review Checklist GM1927-13 (recommended). Supplier Review information as requested by “Required Quality Information” item in the SQ SOR GM1927-3:

Preliminary timing charts: Highlight concerns relative to tooling, gages or testing that may impact PPAP Revisions to manufacturing facility, including Greenfield or Brownfield plans Manpower resource commitment to ensure successful completion of program; proper skills

and training to perform the necessary tasks.Preliminary process flow diagrams, PFMEA and Control Plan:

Highlight any special assembly techniques, test methods or containment procedures used.Capability studies on similar parts :

Confirm error proofing, data analysis, and record keeping is included and review plan to meet any GM warranty targets (review existing open PRR and warranty sufficiency/action plans, data on similar products and plans for future reductions).

Tiered supplier management: Present process and resource plan for evaluation and management of tiered suppliers.

Supplier Provide evidence of prior product experience or technical expertise relevant to new product.Reference Documents: Supplier Quality Statement of Requirements GM1927-3 / Part-Specific Quality & Process SOR / APQP Open

Issues List GM1927-5 / APQP Supplier Assessment GM1927-7 / Tech Review Checklist GM1927-13 E&APSP : Tech Review Example Agenda / Tech Review Checklist

September 21, 2009 7 GM1927

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Page 13: GM_APQP

Global APQP ProcessTask Number: 3

Task Name: Sourcing Eligibility

Task Owner: SQE

Task Timing: Pre-sourcing

Task Description: 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.

Key Deliverables: SQ Signed GPS recommendation sheet or equivalent and appropriate back-up documentation – either a copy of

the latest CTBL report OR an approved QBC QUAD report with supporting audit approval

Customer for Deliverables: Purchasing

Necessary Inputs: Source of Input: Bidding DUNs number / Supplier manufacturing location list Buyer Minimum information by location:

Supplier name, address and DUNs number (if available) Buyer Greenfield/Brownfield Y/N, Buyer/SQE Existing TS-16949 certification Y/N, Buyer/SQE Location currently ships specific commodity to GM Y/N Buyer/SQE

Assessment required completion date Buyer Supplier contact details by location Buyer Current CTBL report Quality status (R/G/NR) Buyer/SQE

Resources: Purchasing, Supplier Quality and Supplier.

Responsible Methodology :Buyer Provide final supplier location inputs, required to determine audit requirements, a minimum of 2 weeks

prior to nomination date (information should be provided pre-Technical Review where feasible).SQE Based on the input information provided, using the table below, determine any audit required prior to

sourcing for each supplier location in order to assess sourcing eligibility: Where supplier location has TS-16949 certification the audit requirement is PCPA, otherwise PSA

audit should be applied. SQE Work jointly with the Sourcing Team to identify any DUNs numbers not Green for Quality on the CTBL

at time of nomination and plan audits / QBC QUAD report follow-up accordingly.SQE Work with the Regional SQE (if different) to ensure audit scheduling and completion ahead of

nomination date as required.SQE Work with the Regional SQE (if different) to ensure signed QBC QUAD report is provided ahead of the

nomination date as required.SQE Communicate regularly with Buyer to comprehend any supplier location changes and, in particular,

communicate any rejections / non-sourceable supplier locations as early as possible for escalation to CT.SQE Ensure completion of required audits in time for nomination and provide signed QBC QUAD report to

Buyer where necessary ahead of sourcing table.SQE For a new supplier location sourcing:

In QBC QUAD report, capture all open action items and plans for correction/mitigation and obtain SQ approval (from region where the supplier is located) to support the sourcing recommendation.

SQE Sign sourcing recommendation for selected supplier.Supplier Provide necessary information as required and support audit requests at short notice.

September 21, 2009 8 GM1927

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Page 14: GM_APQP

Global APQP Process

Task Number: 3 continued

Task Name: Sourcing Eligibility

Sourcing Approval Matrix:

Supplier Location Type

CTBL Quality Rating

TS16949 Quality

Standard Certified?

Required Audit Comments

Greenfield (New Construction) ORBrownfield (Existing Building)

N/A No, butSister Facility Yes.

PCPA on Sister Facility Building

Like Product.

Company Performance Data from Other Customers or Internal Data. QBC from Regional SQ Required. Buyer Must Request Duns be Loaded into CSIDS when Available.

Greenfield (New Construction) ORBrownfield (Existing Building)

N/A No, and Sister Facility No.

PSA on Sister Facility Building

Like Product.

Company Performance Data from Other Customers or Internal Data. QBC from Regional SQ Required. Buyer Must Request Duns be Loaded into CSIDS when Available.

Current Supplier to GM Green Yes None SQ signature / approval required on GPS Recommendation Sheet or Equivalent.

Current Supplier to GM Red Yes None Location cannot be sourced. Refer to SQ Regional Director.

Current Supplier To GM New CT Different Product

Green Yes PCPA Acceptable PCPA, QBC (Quad Report) from Regional SQ Required. SQ signature / approval required on GPS Recommendation Sheet or Equivalent.

Current Supplier to GM New CT Different Product

Red Yes None Location cannot be sourced. Refer to SQ Regional Director.

Current Supplier to GM New CT Different Product

NR Yes PCPA Acceptable PCPA. Need Company Performance Data from Other Customers or Internal Data. QBC from Regional SQ Required. SQ signature / approval required on GPS Recommendation Sheet or Equivalent.

New to GM, no business with any GM locations

NR Yes PCPA Need Company Performance Data from other Customers or Supplier Internal Data. QBC from Regional SQ Required.

New to GM, no business with any GM locations

NR No PSA Need Company Performance Data from other Customers or Supplier Internal Data. QBC from Regional SQ Required.

New DUNS #, other Duns currently ship to GM

NR Yes PCPA Review data from other Duns locations. QBC from Regional SQ Required.

New DUNS #, other Duns currently ship to GM

NR No PSA Review data from other Duns locations. QBC from Regional SQ Required.

Not on CT Bidlist. Currently Shipping to location that is not using GQTS.

N/A Yes None Current Local Bidlist Showing Green on Quality Metrics or Local SQ Approval. – Only Valid for Additional Business to Current GM Customer Location.

Not on CT Bidlist. Currently Shipping to location that is not using GQTS.

N/A Yes PCPA Current Local Bidlist Showing Green on Quality Metrics. QBC from Regional SQ Required. – Only Valid for Additional Business to New GM Location.

Not on CT Bidlist. Currently Shipping to location that is not using GQTS.

N/A No PSA Current Local Bidlist Showing Green on Quality Metrics. QBC from Regional SQ Required. – Only Valid for Additional Business to New GM Location.

No Duns Number N/A Yes PCPA Apply to Dun and Bradstreet for Duns Number. Follow Quality, Audit and Bidlist Requirements Previously Stated Depending on Supplier Situation. Buyer Must Request Duns be Loaded into CSIDS when Available. QBC from Regional SQ Required.

No Duns Number N/A No PSA Apply to Dun and Bradstreet for Duns Number. Follow Quality, Audit and Bidlist Requirements Previously Stated Depending on Supplier Situation. Buyer Must Request Duns be Loaded into CSIDS when Available. QBC from Regional SQ Required.

Reference Documents: QUAD report form GM1927-71 PSA audit PCPA GM1927-16

September 21, 2009 9 GM1927

Page 15: GM_APQP

Global APQP ProcessTask Number: 4

Task Name: Gate Reviews

Task Owner: SQE for Kick-off Meeting, Supplier for remaining meetings

Task Timing: As shown on APQP Project Plan

Task Description: 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.

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.

Gate Deadline

(Time from SORP in weeks)

GVDP 5.0 timingreference

ReviewKey

DeliverablesForm/

Document

ALLGM Global APQP Supplier Status Summary Workbook

GM1927-34

Within 30 days of business nomination

advice / contractGate 1

QSB Audit (Gap Analysis) or Greenfield Checklist (Action Plan)

GM1927-30GM1927-31

Timing Plan GM1927-2Kick-Off Check list GM1927-14

-78Initiated after CVER

and completed 5 weeks after IVER

Gate 2PFMEA Check list GM1927-37RPN Reduction Summary GM1927-21Subcontractor Status GM1927-25

-52Completed 10 weeks prior Matching 1 GA

Gate 3

Supplier ADV Plan (ADVP&R) showing execution status

GM1829

QSB Audit (Compliance) or Greenfield Checklist (Complete)

GM1927-30GM1927-31

Run @ Rate Capacity Workbook GM1927-35

-35Completed 3 weeks

prior PPV MRDGate 4

Dimensional Report GM1927-32PPAP Worksheet (if not fully approved) GM1411GP12 Audit GM1927-33

-15Completed 1 week prior MVBs MRD

PPAP PPAP Approval

-8Run @ Rate

Run @ Rate Execution R@R ModulePCPA GM1927-16

Customer for Deliverables: SQE, Buyer, Engineer, Readiness Coordinator, Manufacturing as appropriate.

Necessary Inputs: Source of Input: Program timing for key events Engineer/Buyer Detailed program timing Supplier APQP Open Issues List GM1927-5 Supplier/SQE APQP Timing Chart GM1927-2 Supplier/SQE

Resources: Buyer, DRE, SVE, SQE, Readiness Coordinator, Manufacturing Engineer

Task Number: 4 continuedSeptember 21, 2009 10 GM1927

44

Page 16: GM_APQP

Global APQP Process

Task Name: Gate Reviews

Responsible Methodology:SQE Two Kick-Off meetings could potentially occur. One for Purchasing scheduled by the Buyer (It is

optional in the AP process) and one for Supplier Quality scheduled by the SQE. It is desirable that the two meetings be combined into one. If the Buyer conducts a Kick-Off meeting, the SQE must ensure that the content of Global APQP Gate Review #1 is included or a separate APQP Gate #1 must be conducted.

SQE Audit tasks & deliverables identified in the GM Global APQP Supplier Status Summary Workbook Gate 1 (Kick-Off Meeting) / Gate 2 / 3 / 4 / PPAP and Run & Rate for all customer monitored APQP parts.

SQE At the APQP Kick-off Meeting, review Lessons Learned, SQ SOR GM1927-3 and the Part-Specific Quality & Process SOR (if applicable) to re-emphasize discussion from the Technical Review.

SQE Throughout the program, ensure Lessons Learned are documented by the supplier in the appropriate FMEA (design, process, system) or DRBFM.

SQE Confirm that the supplier’s process capability and RPN reduction plans will satisfy design requirements and zero PPM requirements.

SQE Ensure that the supplier’s plan for installing capacity, using the GM1927-35 Run at Rate Workbook, is sufficient to meet contractual requirements and pass the Run at Rate.

SQE Lead Greenfield/Brownfield development assessment process GM1927-31 (if applicable). It is encouraged that the Buyer and the Product Engineer take part in the audits.

SQE Engage the Directed Buy sub-component assigned GM SQE in the System/Assembly Gate Reviews, in case GM1927-23 (approved by SQ Director) has stated that Directed Buy sub-components PPAP or Run@Rate must be approved by GM and once the component SQE is other than System/Assembly SQE.

SQE Identify and communicate key timing and program issues to GM management.Supplier For customer monitored APQP parts, coordinate the gate reviews after the Gate #1 Kick-Off meeting.

For supplier monitored APQP parts, the supplier is expected to conduct and manage all gate reviews after the Gate #1 Kick-Off meeting internally and report the result to GM.

Supplier For customer monitored APQP, prepare and present to GM APQP Team the current status for tasks & deliverables identified in the GM Global APQP Supplier Status Summary Workbook Gate 1 (Kick-Off Meeting) / Gate 2 / 3 / 4 / PPAP and Run @ Rate Review Audits. For supplier monitored APQP, present internally in a management review and submit the results to GM.

Supplier Throughout the program, ensure all Timing Charts are adhered to and any necessary recovery plans are comprehensive and protect program timing and objectives. All open tasks, issues and road blocks are to be tracked to closure in the APQP Open Issues List GM 1927-5.

Supplier Suppliers of systems / assemblies must ensure that subcontractors conduct APQP Gate Reviews and, where necessary, participate in Tier 1 Gate Reviews with GM.

Supplier Guarantee completion of the APQP Supplier Status Workbook GM1927-34 in line with Expectations.

Reference Documents :

APQP Supplier Status Workbook GM1927-34

Task Number: 5

September 21, 2009 11 GM19275

Page 17: GM_APQP

Global APQP Process

Task Name: Timing Chart and APQP Open Issues List

Task Owner: Supplier

Task Timing: Reviewed at Gate Reviews and throughout the program

Task Description: A detailed review of all timing charts and concerns is conducted periodically to ensure that program deliverables are executed on schedule. These reviews are conducted on GM monitored parts tracked using the APQP process. For supplier monitored APQP, the supplier reviews and updates the Timing Chart and Open Issues List throughout the APQP process.

Key Deliverables: Up-to-date APQP Timing Chart GM1927-2 or equivalent format containing all required information (to be uploaded to GQTS at Gate Review #1) APQP Open Issues list GM1927-5

Customer for Deliverables: Supplier Quality Engineer

Necessary Inputs: Source of Input: Open issues SQE/Supplier/Engineer/Buyer Detailed timing for tooling, facilities, gages, etc. Supplier

Resources: Supplier, SQE, Engineer, Manufacturing Engineer, and other members of the program team as appropriate

Responsible Methodology:SQE Review the APQP Timing Chart and APQP Open Issues List, minimum monthly.SQE Drive supplier to develop recovery plans on issues impacting timing, quality or capacity.SQE Identify and communicate key timing and program issues to GM management.Supplier Create an APQP Timing Chart GM1927-2 or equivalent and track tasks to completion in line with chart.

Create an APQP Open Issues List GM1927-5 and present updates to SQE at all Gate Reviews minimum.Supplier Sub-component milestones shall be pulled ahead of Tier 1 assembly milestones by 6 weeks to protect

GM program timing.Supplier Update timing chart as timing changes occur and communicate any changes, concerns and issues to SQE

on an ongoing-basis (maintain additional detail behind each high level APQP Timing Chart item, additional detail must be tied to high level chart to ensure timing is updated automatically).

Supplier Develop recovery plans for issues impacting timing and drive the plan to maintain program timing.Supplier Utilize APQP Open Issues list to capture all issues requiring action.

Reference Documents: APQP Timing Chart GM1927-2 APQP Open Issues list GM1927-5

September 21, 2009 12 GM1927

Page 18: GM_APQP

Global APQP ProcessTask Number: 6

Task Name: QSB – Quality Systems Basics

Task Owner: Supplier

Task Timing: Gate 1 (Gap Analysis) and Gate 3 (Compliance)

Task Description: QSB is a set of the 10 basic strategies in order to assure quality.

1. Fast Response Standardized Work Instructions – SOS Fast Response Process Operator Instructions – JES

Manufacturing Gage Control Problem Solving 5. Standardized Operator Training - JIT Lessons Learned 6. Error Proofing Verification

2. Control of Non-Conforming Product 7. Layered Process Audits 3. Verification Station 8. RPN Risk Reduction (Reverse PFMEA) 4. Standardized Operations 9. Contamination Control

Work Place Organization – The 7 Wastes 10. Supply Chain Management11. Managing Change

Key Deliverables: Action plan for QSB compliance GM1927-30 or Greenfield/Brownfield checklist GM1927-31; (to be uploaded

to GQTS at Gate Review #1) Full compliance with QSB audit GM1927-30 or Greenfield/Brownfield checklist GM1927-31; (to be uploaded to

GQTS at Gate Review #3)

Customer for Deliverables: Supplier Quality

Necessary Inputs: Source of Input QSB Audit Supplier

Resources: SQE

Responsible Methodology:SQE Apply the QSB Audit (Gap Analysis) at Supplier Gate Review #1 using QSB audit form GM1927-30. QSB

is to be assessed against the manufacturing plant Quality Systems independent of product or specific manufacturing process.Rules for the application of the QSB Audits:

Customer Monitored APQP – Mandatory Supplier Monitored APQP – At SQE Discretion (recommended, if not passed within last 3 years Audit must be performed by GM SQE or a Third Party where agreed

SQE / Buyer / DRE

For Greenfield suppliers, apply the Greenfield & Brownfield Development Assessment Process GM1927-31 in place of QSB.

SQE Perform QSB workshop as per QSB Presentation GM1927-36 at supplier, if required.SQE Monitor the Supplier Action Plan on a timely basis.SQE Perform the QSB Compliance Audit and Sign-off the Action Plan final implementation GM1927-30. In face

of lack of full implementation, the open issues will be addressed by Master Dot (attached to the audit form) and the Program Management PRR rules will be applied.

SQE For Greenfield suppliers, Sign-off the Action Plan final implementation of the Greenfield & Brownfield Development Assessment Process GM1927-31.

Supplier At the QSB Gap Analysis audit, or at the Greenfield & Brownfield Development Assessment Process audit, provide action plans with appropriate detail, timing, ownership, etc.

Supplier Implement and verify effectiveness of all the action plan items before Supplier Gate Review #3.Supplier Keep the customer updated regarding implementation status and any issues or concerns with implementation.

Reference Documents: QSB Presentation GM1927-36 QSB Audit Form GM1927-30 Greenfield/Brownfield checklist GM1927-31

September 21, 2009 13 GM1927

6APQP QSB Task must be compliant on or before PPAP Gate 3 (Beginning with Model Year 2010 programs)

Page 19: GM_APQP

Global APQP ProcessTask Number: 7

Task Name: Process Flow Charts

Task Owner: Supplier

Task Timing: Initial chart–prior to sourcing, reviewed at Gate 2 and Gate 3, approved at Gate 4

Task Description: Flow chart provides a logical pictorial representation of the process flow that can be used as the foundation for PFMEA’s, control plans, work station layouts, etc.

Key Deliverables: Process Flow Chart Process Flow Chart depicting sub component production system

Customer for Deliverables: Supplier Quality Engineer

Necessary Inputs: Source of Input: Information on each step of the manufacturing process Supplier Part-Specific Quality & Process SOR (if applicable) SQE

Resources: Supplier, SQE, Manufacturing Engineer

Responsible Methodology:SQE Review the preliminary process flow chart prior to sourcing to ensure completeness.SQE Review the production flow chart for completeness and continue with a comparison to the production

line: Ensure the flow chart is linked to the PFMEA and control plan. Walk the manufacturing line to ensure the chart is representative of the process and includes

receiving, storage, production, inspection, rework, packaging, labeling and shipping. Ensure Part-Specific Quality & Process SOR (if applicable) is applied to support flow chart

development. Ensure completion in line with AIAG A-6

Supplier Create a preliminary process flow chart using a similar process as part of bid package requirement.Supplier Define a production flow chart once product design is released.Supplier Document all items in the flow chart with the respective nomenclature (store, move, inspect, correct,

etc.)Supplier Ensure the process flow chart is linked to the PFMEA and control plan and complete AIAG A-6.Supplier Update flow chart to reflect actual production process.Supplier Communicate any changes on an ongoing-basis to SQE.

Reference Documents: AIAG Advanced Product Quality Planning and Control Plan manual Process Flow Chart checklist A-6

September 21, 2009 14 GM1927

7

Page 20: GM_APQP

Global APQP ProcessTask Number: 8

Task Name: DFMEA

Task Owner: Design Owner (GM Engineer or Supplier)

Task Timing: Initiated before or at design concept

Task Description: The DFMEA is a living document that is initiated before or at design concept and is continually updated as changes occur or additional information is obtained throughout the phases of product development. It supports the design process in reducing the risk of failure by: 1) aiding in the evaluation of design requirements, DFM, and DFA, 2) increasing the probability that potential failure modes have been considered and 3) establishing a priority system for design improvements.

Key Deliverables: DFMEA /DRBFM

Customer for Deliverables: Engineer, Supplier, Supplier Quality Engineer

Necessary Inputs: Source of Input: Requirements as stated in SOR/SSTS/CTS Engineer Design intent Design Responsible Engineer Vehicle requirements Engineer Manufacturing/Assembly requirements Design Responsible Engineer Lessons Learned /Part-Specific Quality & Process SOR SQE/Engineer KCDS Templates (if already identified) Engineer

Resources: Engineer, Design Responsible Engineer

Methodology :

September 21, 2009 15 GM1927

8

Warranty

Prior model EWOs

Current SQE launch & problem reflection

APQP SQE and Supplier input

GM Lessons Learned shared with supplier

Teamwork to:1. Bring Lessons Learned into FMEA format2. Determine RPNs and identify KCDS Designators

Marketing

Build concerns

DFMEAContinue with work to reduce risk (high RPNs, high severity items, KCDS Designators)

Compare with prior model start-ups and revise design guidelines and data bases accordingly

Revise with new Lessons Learned from validation andprototype builds Forward to Task 12

to use in development of PFMEA

Page 21: GM_APQP

Global APQP ProcessTask Number: 8 continued

Task Name: DFMEA

Responsible Methodology:SQE Confirm that the Supplier (if not design responsible) is working with the GM Engineer on development

of the DFMEA, or DRBFM for any design changes made after production release. If not, take appropriate action to initiate this team activity.

SQE Confirm with Design Owner if the DFMEA is updated with the results of the DRBFM analysis.SQE Confirm a DFMEA has been completed by the responsible Design Owner and confirm that the supplier

has access to necessary information from the GM DFMEA as input into the PFMEA.SQE Work with supplier to confirm that a DFMEA and System FMEA have been completed for all sub

components by the responsible engineering function or the sub contractor. Design Owner

Lead the workshops with GM DRE, SQE and Supplier Engineering and complete the DFMEA. In addition, complete the Design FMEA checklist (AIAG A-1). Develop and implement RPN reduction plans and strive to continuously reduce RPN, provide a DRBFM analysis for any design changes made after production release, and update the DFMEA with the results of DRBFM analysis.

Supplier If not design responsible, provide any lessons learned to the GM Engineer and support the development of the DFMEA, and the DRBFM (if applicable). In addition, complete the Design FMEA checklist (AIAG A-1).

Supplier If GM is design responsible and does not provide access to necessary information from the DFMEA or DRBFM (if applicable), document this issue on the APQP Open Issues List.

Supplier If the subcontractor is design responsible ensure that the DFMEA is complete for all sub-components. Monitor and drive the development and implementation of RPN reduction plans on sub components.

Supplier If the subcontractor is not design responsible ensure that any lessons learned are provided to GM engineering for input in developing the DFMEA.

Reference Documents: APQP Open Issues list GM1927-5 AIAG Advanced Product Quality Planning and Control Plan manual Design FMEA checklist A-1 KCDS Manual GMW15049 Generic Supplier Analysis/Development/Validation Tasks & Deliverables for All Programs & Commodities GMN 3600 Design Review Based on Failure Modes GMN 11220

September 21, 2009 16 GM1927

Page 22: GM_APQP

Global APQP ProcessTask Number: 9

Task Name: Design Reviews

Task Owner: Design Owner (GM Engineer or Supplier)

Task Timing: Initial review–prior to CVER, SVER & IVER; subsequent reviews occur on an on-going basis

Task Description: Reviews to ensure the design has been adequately defined to enable construction of tools and gages.

Key Deliverables: Defined and measurable KCDS Designators GD&T Appearance, performance and material testing specifications

Customer for Deliverables: Supplier

Necessary Inputs: Source of Input: SOR / SSTS / CTS Engineer Appearance specifications Engineer Performance and material specifications Engineer Production Assembly Documents if available Engineer Bill of Material (BOM) Engineer

Resources: Engineer, Supplier Quality Engineer, Supplier, Subcontractors

Responsible Methodology:Design Owner

Schedule and conduct KCDS workshop. SQE, GM Engineer and supplier participate in workshop. The purpose of the workshop is to define critical product characteristics, and critical process control characteristics.

Design Owner

Schedule and conduct GD&T review. The SQE, GM Engineer and supplier participate in the review. The purpose of the review is to define design dimensioning and tolerance on the drawing as these items relate to the actual function of the part.

Design Owner

For subcomponents, the same process is used to determine lead responsibility in conducting these reviews. Supplier and SQE participate as necessary in the reviews

DRE GM Engineer is responsible to ensure that all information available in the KCDS template at KCDS website for a specific commodity has been applied, even when supplier is design responsible.

SQE Ensure the GD&T datum scheme guarantees proper gauging and that there are GD&T callouts for all features which are basic dimensions (performed by SQ Gage Engineer, if available in the region).

SQE Confirm the selected KCDS Designators can be measured with variable or attribute gages.SQE/Supplier Confirm the manufacturing process can achieve the specified tolerances on a sustained basis.Supplier Any recommendations / improvements to the design record are documented and submitted to GM for

approval.Supplier Communicate any concerns relative to the KCDS Designators or GD&T scheme and the

manufacturability of the part. Document any open issues on the APQP Open Issues List GM1927-5.Supplier Develop an understanding of the engineering change process with the GM Engineer. Apply AIAG

Checklist (A-2) and address any open action item.

Reference Documents: APQP Open Issues GM1927-5 KCDS Manual GMW15049 AIAG Advanced Product Quality Planning and Control Plan manual AIAG Design Information Checklist A-2 General Motors Global Standard, Restricted and Reportable Substances for Parts GMW3059 Recyclability/Recoverability Design Guide GMW3116

September 21, 2009 17 GM1927

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Page 23: GM_APQP

Global APQP ProcessTask Number: 10

Task Name: Tooling and Equipment Reviews

Task Owner: Supplier

Task Timing: From Tooling Kick Off Meeting (TKO) through PPAP approval.

Task Description: Ensure that the manufacturing process is being designed to the latest drawing change level, built and certified to produce parts with quality at rate according to GM program requirements.

Key Deliverables: Process capable Tooling and Equipment delivered on time.

Customer for Deliverables: Supplier Quality Engineer, Engineer

Necessary Inputs: Source of Input: Approved GD&T, KCDS Designators and Math Data Engineer Part-Specific Quality & Process SOR (if applicable) SQE Process Capability Requirements SQE / Supplier Timing requirements Buyer / SQE / Supplier Capacity requirements Buyer Error proofing Supplier Functional Test Requirements Engineer/Supplier

Resources: Engineer, Supplier, Supplier Quality Engineer, Manufacturing Engineer

Responsible Methodology : SQE Starting at Gate Review #1 review tooling and equipment concept and pass / fail criteria for component

functional test to ensure they meet Part-Specific Quality & Process SOR, they can meet product design intent and achieve process capability requirements and ensure supplier has submitted a detailed timing chart for tooling and equipment development. Conduct equipment reviews throughout build process.

SQE / SQ Tooling Engineer (SQTE), if Available

Review timing to obtain tools and equipment and functional test in line with program targets for, PPAP and Run @ Rate. Verify that the supplier has planned (at minimum) and is working to complete and / or tracking the following activities at appropriate time:

GM Engineering Design Releases Manufacturability Assessment and Tooling Concept Tooling Design GM Tooling Purchasing order Tooling Construction & Try-Out at Tool Shop Tooling Buy-Off with final equipment at final production location previously to PPAP run

Conduct tooling reviews & audits throughout build process.SQE / SQTE

At the tooling buy-off or PPAP approval, verify the existence of GM owned tooling and that it is properly identified as GM property.

Supplier Review all timing and inform GM SQE about any changes from original project timing.Supplier Design, build and obtain certification of and validation of tooling and equipment as per latest math data.Supplier Participate in design reviews with GM and ensure GD&T, KPC, PQC and AQC requirements are included

in the tooling, equipment and functional test design. Also ensure tooling and equipment will produce parts to process capability requirements.

Supplier Inform GM about any design and process changes regarding any new or modified tools, rearrangement of existing tooling or equipment, any product or process changes impacting fit, form, function, performance and durability of saleable product, any test/inspection methods and any new facilities.

Supplier Prior to tools being grained, dimensional verification is required by GM and Approval to Grain form signed (verify with SQE on regional requirements).

Supplier Ensure PFMEA has been comprehended and incorporated into tooling and equipment design.Supplier Complete the AIAG APQP New Equipment Checklist (A-3).

Reference Documents: AIAG Checklist A-3

September 21, 2009 18 GM1927

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Page 24: GM_APQP

Global APQP ProcessTask Number: 11

Task Name: Gage Development & Approval

Task Owner: Supplier

Task Timing: Starting (Concept) at P3 release and complete by PPAP Approval

Task Description: To design, build and certify gages according to latest GD&T release and per GM requirements.

Key Deliverables: GM1927-29 fully approved by SQE or GM Gage Engineer 8 weeks prior to PPAP date.

Customer for Deliverables: GM Gage Engineer, GM Supplier Quality Engineer, Manufacturing Location

Necessary Inputs: Source of Input: Part Math Data (P2) and GD&T (P3=P2 + 4 weeks) Dimensional Engineer and Design Engineer KCDS Designators Design Release Engineer Gage Design and Build Approval GM Gage Engineer Timing requirements Buyer / SQE / Supplier

Resources: Supplier, GM Gage Group, SQE, GM Design Release Engineer, Dimensional Engineering

Responsible Methodology:SQE Starting at Gate Review #1, ensure supplier is aware of GM1927-29 Gage Request and GM 1925

Fixture Standards and ensure supplier has submitted a detailed timing chart for gage development.SQE / SQ Gage Engineer (SQGE), if Available

Review plans and timing to obtain gages in line with program targets for parts, PPAP and Run @ Rate. Ensure supplier is tracking and executing key tasks on time as Purchase orders issue, Gage Concept, Gage Design, Construction, Dimensional Certification and GR&R Validation. Conduct gage build reviews at Gage Shops from material schedule to validation.

SQE / SQGE Review GD&T, part data and gage expectations starting at Gate Review #1 (APQP Kick-Off).SQE / SQGE Review gage concept for the part assembly and sub-components.SQE / SQGE Review completed gage design(s) based on gage concepts approved by GM Gage Engineer.SQE / SQGE Review construction to ensure that gage meets latest GD&T, agrees with functional part usage / datum

strategy and includes measurement of KCDS designators.SQE / SQGE 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.

Supplier Deliver gage request form GM1927-29 at Gate Review #1 and add to PPAP package once gage is finished, form has all tabs filled out and it is approved by GM SQE or GM SQ Gage Engineer, if available in the region.

Supplier Review timing to ensure compliance and inform GM SQ Gage Engineer and SQE about any changes from original project timing, any design and process changes, any new part math data and/or GD&T changes, any test/inspection methods that include gages, any new facilities that would house the gages.

Supplier Participate in design reviews, ensure GD&T scheme is released and variable data collectors required by KPC, PQC and AQC release are incorporated into final gage design.

Supplier 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.

Reference Documents: AIAG Measurement Systems Analysis Manual General Motors Fixture Standards GM1925 Gage Request Certification GM1927-29

September 21, 2009 19 GM1927

11

Page 25: GM_APQP

Global APQP Process

Task Number: 12

Task Name: PFMEA

Task Owner: Supplier

Task Timing: Starting at Kick-Off Meeting and complete by PPAP

Task Description: Ensure that potential failure modes of the process have been considered and addressed to reduce risk of defects through RPN reduction strategy.

Key Deliverables: PFMEA GM1927-37 (to be uploaded to GQTS at Gate Review #2) RPN Reduction Summary GM 1927-21 (initial to be uploaded to GQTS at Gate Review #2)

Customer for Deliverables: Supplier Quality, Supplier

Necessary Inputs: Source of Input: DFMEA Engineer/Supplier Lessons learned and Part-Specific Quality & Process SOR Supplier/SQE Process Flow chart Supplier Warranty data Engineer/SQE PR/R’s on similar parts Supplier/SQE Supplier Performance Report Supplier/SQE Supplier’s manufacturing process capability on similar parts Supplier Error proofing techniques Supplier/SQE DFM / DFA Workshop results Engineer/SQE/Mfg

Resources: Supplier Quality, Engineering, Supplier, Manufacturing Engineer and *Assembly Plant

Methodology:

September 21, 2009 20 GM1927

12

PFMEA Continue with work to reduce risk (high RPNs, high severity items, KCDS Designators)

Clearly identify where in the process flow the prevention of error occurrence and defect outflow will be addressed

Warranty

Prior model EWOs

Current SQE launch & problem reflection

APQP SQE and Supplier input

GM Lessons Learned shared with supplier

Teamwork to:1. Bring Lessons Learned into FMEA format2. Determine RPNs and identify KCDS Designators

Marketing

Build concerns / PRRs

DFMEA (KCDS Designators)

Revise with new Lessons Learned from validation, prototype pre-builds, customer complaints, and internal data for the life of the part

Page 26: GM_APQP

Global APQP ProcessTask Number: 12 continued

Task Name: PFMEA

Responsible Methodology: continuedSQE Attend initial PFMEA development team meeting, provide GM data (Warranty, PR/R’s, Lessons learned,

etc.), and discuss PFMEA methodology.SQE Monitor progression of PFMEA development and confirm participation of multiple cross-functional team

members. SQE Ensure Part-Specific Quality & Process SOR (if applicable) is applied to support PFMEA development.SQE Apply the GM1927-37 Checklist and review RPN Reduction Summary Plans GM 1927-21, and monitor

progress at each Gate review and ensure that action plans have been adequately defined for high RPNs and high severity failure modes as required.

SQE Ensure supplier has completed PFMEA reviews with subcontractors.Supplier Initiate PFMEA prior to sourcing as part of the bid package. This preliminary PFMEA should include

critical error prevention and error detection ideas and consider any lessons learned from previous programs.

Supplier Review PFMEA and updated it as necessary each time a design change is made or a processing change is implemented. Any and all potential areas for failure are included in the PFMEA and appropriate corrective actions implemented (a PFMEA should not consider product design changes to compensate the process deficiencies).

Supplier Prepare PFMEA with input from a multi-disciplinary team (Assembly, Manufacturing Engineering, Materials, Quality, Service, Suppliers, etc.) and identify KCC’s for use in control plan.

Supplier Adhere to PFMEA RPN Reduction Summary GM1927-21, including the categorization of risk, establishment of a top ten list, development of recommended actions, and update on a monthly basis to monitor progress. Present the evidences to meet to Checklist GM1927-37.

Supplier Drive simple and inexpensive mistake / error proof devices into the process to help prevent and detect errors.

Supplier Ensure that all failure modes and related severity numbers from DFMEA are listed in the corresponding PFMEA.

Supplier Ensure that the current process controls and results of recommended actions on the PFMEA are listed on the control plan.

Supplier Ensure that the PFMEA has a link with the manufacturing process flow chart and the control plan.Supplier If the process, material or manufacturing location changes, revise the PFMEA and re-evaluate the impact

on severity, occurrence, and detection ratings.Supplier Ensure that subcontractors’ PFMEAs are developed and RPN reduction activities are implemented.

Reference Documents: AIAG Potential Failure Mode and Effects Analysis Reference Manual AIAG Advanced Product Quality Planning and Control Plan manual Process FMEA Checklist A-7 RPN Reduction Summary Chart GM1927-21 Global PFMEA Checklist GM1927-37

September 21, 2009 21 GM1927

Page 27: GM_APQP

Global APQP ProcessTask Number: 13

Task Name: Control Plans

Task Owner: Supplier

Task Timing: Initial draft prior to Sourcing, updates parallel PFMEA changes and updates prior to PPAP

Task Description: Define the method to be used to control all KPC, PQC, AQC and DR’s (at a minimum) through KCCs for parts being built for vehicle builds, Powertrain, and service applications to ensure customer requirements. Develop in line with the control plan format referenced in the AIAG APQP Manual.

Key Deliverables:

Control Plan Individual Process Control Charts for all KPC, PQC, and DR Process Control Plan Audit Checklist GM1927-16 (to be uploaded to GQTS at Run @ Rate Review)

Customer for Deliverables: Supplier Quality, Manufacturing Engineer, Supplier

Necessary Inputs: Source of Input: Control plans on similar components Supplier Process Flow Chart Supplier PFMEA Supplier Special Characteristics Supplier/Engineer Part-Specific Quality & Process SOR (if applicable) SQE Lessons Learned SQE/Engineer/Supplier

Resources: Supplier and SQE

Responsible: Methodology : SQE Verify that the supplier used the PFMEA and statistical data to determine what controls are necessary.SQE Verify that Process Control Plan (PCP) is linked to the PFMEA and the process flow chart.SQE Verify that the PCP encloses all phase of the process, including re-work, receiving, in-process operations,

packaging, labeling and shipping.SQE Ensure Part-Specific Quality & Process SOR (if applicable) is applied to support PCP development.SQE Verify that the supplier updates the PCP as solutions to open issues are identified.SQE Verify that the supplier has individual process control charts by variable data for all KPC, PQC and DR

and that they have a means to store and recover this information for a period of 3 years.SQE Verify that supplier applies 100% inspection frequency to all AQC and that all Functional Requirements

from SOR and part drawing are included in the PCP.SQE Verify that pre-launch issues have been incorporated into the production PCP.SQE Walk the production floor and verify that the controls listed on the plan are in place and being used.

Complete the Process Control Plan Audit Checklist GM1927-16 as part of the audit of the production process.

Supplier Develop a preliminary PCP using an existing PCP on a similar part. This first version of the control plan is then submitted with the quality portion of the supplier’s bid package.

Supplier Develop a pre-launch PCP for use on the first production parts shipped to assembly plants (GP-12) and production PCP using the preliminary PCP as a foundation. The PFMEA and statistical data are used to determine which steps require additional control. The pre-launch PCP does not need to be separated from the production PCP. Pre-launch controls can be documented on the production PCP as long as they are clearly identified as such. Use the pre-launch PCP to validate the effectiveness of the production PCP. Apply AIAG checklist A-8

Supplier Manufacturing site shall document, maintain, and retain PCP’s and individual Process Control Charts for all characteristics identified as KPC, PQC & DR. Ongoing process control shall be demonstrated (documented) through the continuous use of industry standard statistical methods and techniques and process control charts. Process control charts for KPC, PQC, and DR characteristics shall be retained in a recoverable format for a minimum of 3 years.

September 21, 2009 22 GM1927

13

Page 28: GM_APQP

Global APQP ProcessTask Number: 13 continued

Task Name: Control Plans

Responsible: Methodology continued: Supplier Manufacturing site shall applies 100% inspection frequency to all characteristics identified as AQC and

control all Functional Requirements from SOR and part drawing. They must be clearly stated in the PCP.Supplier Ensure the control plan is linked to the PFMEA and process flow chart.Supplier Identify and communicate any changes to the GM SQE.Supplier Update the control plan as solutions to open issues are implemented.Supplier Review control plans of subcontractors.Supplier Extend control plan to include installation at assembly plant (if supplier is responsible).Supplier Conduct layered audits to verify that the controls listed on the plan are in place and being used.Supplier Validate, on a daily basis, that error proofing devices function properly.

Reference Documents: Process Control Plan Audit Worksheet GM1927-16 AIAG Advanced Product Quality Planning and Control Plan manual AIAG Control Plan Checklist A-8

September 21, 2009 23 GM1927

Page 29: GM_APQP

Global APQP ProcessTask Number: 14

Task Name: Early Production Containment (GP-12)

Task Owner: Supplier

Task Timing: GP-12 start at PPAP non-saleable to meet PPV; containment until achieve agreed exit criteria

Task Description: Establish a containment plan during start-up and acceleration, so that any quality issues are quickly identified at the supplier’s facility and not at the GM customer’s facility. This procedure applies to all new and changed parts that require PPAP for start-up or acceleration.

Key Deliverables: Early Production Containment Plan GP12 Audit GM1927-33 (to be uploaded to GQTS at Gate Review #4) Customer for Deliverables: GM Manufacturing or Assembly Facility, Supplier Quality, Purchasing

Necessary Inputs: Source of Input: Production Control Plan Supplier GP-12 timetable GM Customer

Resources: Supplier, SQE, Assembly Plant

Responsible: Methodology : SQE Ensure GP12 plan is available (agree on timing and exit criteria) at Gate Review #3. Reinforce that failure

to execute GP-12, or shipment of a single defect during GP-12 period, will result in immediate CS2.SQE Verify that high RPNs, KCDS Designators are addressed by the pre-launch control plan. SQE Verify that the supplier used the PFMEA and statistical data to determine what additional controls are

necessary (short term capability data on actual process or long term capability data on similar processes).SQE Verify any PR/R or pilot issues are addressed by the containment process.SQE Review the supplier’s containment process and pre-launch control plan using GP12 audit GM1927-33 at

supplier plant as soon as GP12 is implemented. Verification should include: Actual drawings at GP-12 area with the latest change level. Check frequency (100% or a documented lot sampling with GM approval). Gage operation instructions at GP-12. Master parts or boundary samples to confirm inspection. Inspection data for all components in GP-12 area. Process in place to prevent shipment of material that has not gone through GP-12. Record of results.

SQE Review supplier’s initial GP-12 data to assess compliance to process intent.Supplier Develop an early production containment plan as specified in GP-12, including, but not limited to:

A separate inspection area whenever possible (may require checks within the process for components that are not available for check after assembly).

Process to ensure that all non-conformances are contained within the facility and prompt containment and irreversible corrective actions are applied if non-conformances are discovered.

Identification of the person responsible for the containment process. 100% check of specific features for pre-pilot and pilot material, as required. Use of green dots (signed by a designated senior management representative) on shipping labels to

designate compliance. Use of the Early Production Containment Plan until the agreed exit criteria is met.

Supplier Root Cause any non-conformances found by GM manufacturing locations and implement additional checking provisions to the pre-launch checklist. Identify and communicate any changes to SQE.

Supplier Require compliance to GP-12 from all subcontractors, as well as monitor and maintain their records. This will require that subcontractors pull ahead their GP-12 to allow the Tier 1 GP12 timing compliance.

Reference Documents: AIAG Advanced Product Quality Planning and Control Plan manual & Production Part Approval Process Manual GP 12 & GP-12 Audit GM1927-33Task Number: 15

September 21, 2009 24 GM1927

1415

Page 30: GM_APQP

Global APQP Process

Task Name: Production Part Approval (PPAP)

Task Owner: Supplier

Task Timing: Prior to PPAP Submit Date

Task Description: Determine if all customer engineering design record and specification requirements are properly understood by the supplier and that the process has the potential to produce product meeting these requirements during an actual production run at the quoted production rate.

Key Deliverables: Minimum 100% Dimensional OK PPAP Non-Saleable before PPV with Dimensional Report GM1927-32

and GM Worksheet GM-1411, if required (both documents to be uploaded to GQTS at Gate Review #4) Full PPAP Approved before MVB Saleable (at PPAP Review)

Customer for Deliverables: Purchasing, Engineering, Supplier Quality, VLE Teams, Assembly Plants Manufacturing Plants, Production Control & Logistics

Necessary Inputs: Source of Input: Design Records of Saleable Product Supplier Engineering Change Document Engineer/Supplier General Motors Commodity Validation Sign-Off GM3660, if required Supplier Design FMEA Engineer/Supplier Process Flow Diagrams Supplier Process FMEA Supplier Control Plan (Pre-Launch Control Plan GP-12, plus Production Control Plan) Supplier Measurement Systems Analysis Studies Supplier Dimensional Results Supplier Material, Performance Test Results Supplier Initial Process Study Supplier Qualified Laboratory Documentation Supplier Appearance Approval Report (AAR), if applicable Supplier Sample Product Supplier Master Sample Supplier Checking Aids Supplier Records of Compliance to customer specifics Supplier Part Submission Warrant Supplier Bulk Material Requirements Checklist (for bulk material only) Supplier

Resources: Purchasing, Supplier Quality, Product Engineering, Material Engineering, Validation Engineering, Dimensional Management, Part Approval Laboratory, Appearance Laboratory, Paint Engineering

Responsible: Methodology : Buyer Contract part, establish initial PPAP submission date and enter date into GPS.SQE Determine submission level and quantity of samples.SQE Confirm PPAP submission date with the supplier and ensure supplier updates GQTS as required.SQE Review the submission and determine the PPAP status in accordance with the AIAG PPAP manual. Input

the PPAP approval status into the GQTS system.Attach to the PPAP record in GQTS the following documents :

PSW Dimensional Report Material and Performance Test Report AAR (if applicable) GM1411 (if applicable) GM3660 (if applicable)

SQE Notify supplier of part PPAP status.

September 21, 2009 25 GM1927

Page 31: GM_APQP

Global APQP ProcessTask Number: 15 continued

Task Name: Production Part Approval (PPAP)

Responsible: Methodology continued: SQE Apply the APQP Supplier Status Workbook - PPAP Approval Gate Decision GM1927- 34.SQE Drive adherence to PPAP submission date, as scheduled on GM 1927-2 APQP Timing Chart.SQE Review PPAP submissions as appropriate and confirm the PPAP status as per the AIAG PPAP manual

and GM specifics.SQE Ensure adequate recovery plans GM1411 are provided for PPAP without full approval.SQE Follow up action items on the recovery plan until full PPAP approval is achieved.Supplier Submit PPAP package according to AIAG PPAP requirements for the appropriate submission level on the

date agreed on APQP timing chart GM1927-2Supplier Verify compliance to the part-specific SOR. Provide documentation of compliance with the PPAP

submission (PPAP full approval requires compliance to SOR).Supplier Provide GM1411 for SQE signature for any part submitted that requires action plan to achieve full

approval. Provide any other appropriate signature dependent on issue as required on the GM1411.Supplier Provide the samples applied to Matching verification with dimensional inspection results as per Global

Part Submission Procedure for Matching GM10067 and Dimensional Report GM1927-32.Supplier The supplier shall document containment plans until the SQE is satisfied process capability has been

achieved.Supplier Shipment of parts for Saleable products is only allowed if the PPAP Status (GQTS PPAP Shipping

Status) is Approved or Saleable with a valid expiration date. GM may choose to allow parts with a Non-Saleable Status to ship for a Saleable build but these parts need to be retrofitted before the product is delivered to the customer.

Supplier Notify SQE before the PPAP re-submission if any process change occurs relative to the previous PPAP review.

Supplier Guarantee the accomplishment of the APQP Supplier Status Workbook – PPAP Approval Gate Decision.

Reference Documents: AIAG Production Part Approval Process manual AIAG Statistical Process Control manual AIAG Measurement Systems Analysis (MSA) manual AIAG Advanced Product Quality Planning and Control Plan manual AIAG Potential Failure Mode and Effects manual AIAG Quality System Requirements (ISO/TS16949) GM Worksheet GM-1411 General Motors Commodity sign-off GM3660 Generic Supplier ADV Process Tasks & Deliverables (GMW3600) Global Part Submission Procedure for Matching GM10067 GM Customer Specifics – ISO/TS16949 Part-Specific Quality & Process SOR (if applicable)

September 21, 2009 26 GM1927

Page 32: GM_APQP

Global APQP ProcessTask Number: 16

Task Name: Run @ Rate (R@R)

Task Owner: Supplier

Task Timing: Gate 1, Gate 3, and at Run at Rate

Task Description: Verify that the supplier’s actual manufacturing process, while operating under normal operating conditions and under total customer requirement, is capable of producing components that simultaneously meet Quality and Daily Contracted Capacity

Key Deliverables: Completed R@R Capacity Workbook and R@R for each part Verification Supplier can meet Daily Contract Capacity in one day

Customer for Deliverables: Supplier Quality and Purchasing

Necessary Inputs: Source of Input: PPAP documentation Supplier GM’s daily requirement (LCR) Buyer Supplier’s Contracted Tool Capacity Supplier & Buyer (contract) Planned & unplanned downtime record Supplier Written confirmation of quality, capacity and delivery Supplier

for all sub-components

Resources: SQE, Buyer, Engineer, and Supplier

Responsible: Methodology: (refer to R@R diagram at end of the task)SQE Ensure the supplier is planning to install the proper capacity to meet the Daily Contracted Capacity

through the use of the Capacity Workbook GM1927-35 at Gate 1 and Gate 3.SQE Review and status the actual Run at Rate (Customer or Supplier Monitored) data submitted by the

supplier to ensure adequate actual installed capacity meets contract requirements.SQE Conduct the Gate 1 APQP Kick-off meeting and evaluate the supplier’s R@R plan.SQE Confirm that the Daily contracted capacity is accurate and is greater than or equal to GM’s daily

requirement (LCR). If there is a discrepancy or contract capacity information is missing, contact the buyer.

SQE Complete the Escalation Process for Gate 1 if any contract information missing and forward to SQ Manager.

SQE Conduct the Gate 3 APQP Review and determine R@R “PASS” metrics and advise supplier.SQE Complete the Escalation Process for Gate 3 if supplier did not complete all required information and

forward to SQ Manager.SQE Attend R@Rs designated as customer monitored. Ensure supplier uses the R@R Hourly Count Sheet.

Review documentation, subcontractor requirements, constraint operations and manufacturing process.SQE When supplier submits Capacity Workbook, status the R@R. If subcontractor letter is missing status must

be a “FAIL” until supplier is compliant.SQE Complete the Escalation Process for the R@R if it is a “FAIL” and forward to SQ Manager.SQE Enter R@R information in appropriate system.Supplier Develop a R@R plan and provide to the SQE at the Gate 1 APQP Kick-Off meeting.Supplier Confirm with the SQE that the Daily Contracted Capacity is accurate and is greater than or equal to GM’s

daily requirement (LCR).Supplier Complete the Capacity Workbook (Manufacturing Flow Diagram, Shared Capacity Sheet(s), and

Manufacturing System Capacity Estimate) and submit to the SQE prior to the Gate 3 APQP Review. The capacity analysis must show satisfactory results prior to ordering tooling and equipment.

Supplier Ensure understanding of the R@R “PASS” performance metrics.Supplier Conduct preliminary R@Rs and/or simulations prior to the planned R@R to confirm readiness. The

PPAP run of parts will be one of the trial runs.Supplier Complete verification for all subcontractors, and submit the letter one (1) month prior to the R@R.

September 21, 2009 27 GM1927

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Page 33: GM_APQP

Global APQP Process

Task Number: 16 continued

Task Name: Run @ Rate (R@R)

Responsible: Methodology continued : Supplier Conduct R@Rs on all parts requiring a [email protected] Completely fill out the R@R Hourly Count Sheet during the R@R for both the final operation and the

constraint operation.Supplier Complete the Capacity Workbook for all R@Rs and forward to the SQE within 24 hours.

Reference Documents: GM1927-35

September 21, 2009 28 GM1927

END

SQE conducts Kick-off meeting (Gate 1) and Escalates if

missing any contract

information

Customer Or

SupplierMonitored

Supplier conducts practice R@R during

PPAP build and/or simulations.

Supplier conducts R@R using the R@R

Hourly Sheet with SQE present.

IsR@R

Status “Pass”?

Supplier updates APQP open issues

list with R@R issues and SQE follows

Escalation process

SQE conducts APQP meeting (Gate 3) and Escalates if missing any

supplierinformation

Supplier completes Manufacturing Flow

Diagram, Shared Capacity Sheets, Manufacturing Capacity

Estimate and submits to SQE

Supplier completes Capacity Workbook and sends to SQE

SQE statuses R@R

IsR@R

Required?

SQE has Supplier Quality and Purchasing

Director approve exemption

SQE statuses R@R as exempt

Supplier conducts R@R using the R@R

Hourly Sheet with SQE present.

Supplier completes Capacity Workbook and sends to SQE

SQE statuses R@R

Yes

No Customer

Supplier

No

Yes

R@R Methodology

Page 34: GM_APQP

Global APQP Process

Task Number: 17

Task Name: Lessons Learned

Task Owner: Supplier

Task Timing: Commodity Key Stakeholders Meeting through Launch

Task Description: Maximize the knowledge gained from previous programs and not revisit the same quality or design issues.

Key Deliverables: DFMEA & PFMEA updated with Lessons Learned gained from this program. Part-Specific Quality & Process SOR for key commodities Part-Specific Quality & Process SOR updated with Lessons Learned throughout the APQP process

Customer for Deliverables: SQ, Engineering, PDT (Product Development Team), Supplier

Necessary Inputs: Source of Input: Existing Lessons Learned for same commodity SQE/Lessons Learned website Engineering Knowledge for commodities Engineer Process knowledge for same commodity SQE / Regional Databases

Resources: SQE, Engineering, Lessons Learned website

Responsible: Methodology:SQE Lessons Learned Update :

(Commodity Key Stakeholders Meeting): Ensure Part-Specific Quality & Process SOR (if applicable) is included in the RFQ package. The direction for the supplier is to use the information during design and process development.

(Technical Review): Provide an overview to suppliers on the lessons learned process and how it fits into APQP. Ensure that the potential suppliers understand the Part-Specific Quality & Process SOR (if applicable).

(Kick-off Meeting): Review any additional information that has been obtained on lessons learned from local or regional

databases. Ensure Lessons Learned issues are incorporated into the APQP Open Issues List GM1927-5. Ensure that the suppliers understand the Part-Specific Quality & Process SOR (if applicable). The goal is a zero tolerance for defects.

SQE Ensure in each of the subsequent Gate Reviews that supplier executes Lessons Learned process (Global APQP task #17) and apply to the Part-Specific Quality & Process SOR (if applicable).

Supplier Lessons Learned Update :Review solutions to issues identified in the Kick-off meeting and new items added to the list:(Gate Review 2): after CVER, SVER & IVER(Gate Review 3): during integration vehicle builds(Gate Review 4): during the Integration & Matching 1 GA(PPAP): during the PPV, MVBns(Run @ Rate): during the MVBsAs solutions are identified, DFMEA, PFMEA, Flow Chart, and Control Plan are reviewed and updated.

Supplier Contribute with additional lessons learned based on knowledge of the commodity.Supplier Adhere to the Part-Specific Quality & Process SOR, (if applicable).Supplier Ensure a formal process is in place to update FMEA and control plans based on Lessons Learned.Supplier / SQE / DRE

Review Lessons Learned from the project and incorporate identified key items into Part-Specific Quality & Process SOR (if applicable) to ensure that future programs do not have the same issues.

Reference Documents:

September 21, 2009 29 GM1927

17

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Global APQP ProcessGM Supply Power – Part-Specific Quality & Process SOR

September 21, 2009 30 GM1927

Page 36: GM_APQP

Global Launch Process

Section 2

Global Launch

September 21, 2009 31 GM1927

Page 37: GM_APQP

Global Launch Process

Document Usage GuidelinesF = Reference Only (information only, nothing to fill out)MD = Mandatory Document (specific format required)MI = Mandatory Information (format may vary, content mandatory)RD = Recommended Document (not mandated, at a minimum content should be reviewed)

Document Number Mandatory RecommendedGlobal Launch Report Template GM1927-40 MDSupplier Conference Break-Out Questionnaire

GM1927-41 RD

Key Supplier Review Template GM1927-42 RDSupplier Launch Audit form GM1927-43 MDSupplier Performance Review Invitation Letter

GM1927-44 RD

Supplier Performance Review Presentation Template

GM1927-45 RD

Obsolete Documents: N/A

NOTE: The tasks in the following section of the Manual are written considering the requirements of New, Major, Derivative, MCE3 or CKD program launches. Lower content programs (MCE2, MCE1 and Annuals) should consider tasks and resource requirements relative to program risk and apply only as required.

Figure 1 – Launch Manual Tasks aligned to GVDP 5.0 33/20 timing

September 21, 2009 32 GM1927

Supplier Quality Launch PlanProgram Quality Gates

Pre-Production Build MRDsSupplier Milestone Dates

-76 -72 -68 -64 -60 -56 -52 -48 -44 -40 -36 -32 -28 -24 -20 -16 -12 -8 -4 0 +4 +8 +12

1Launch Management Team

2 Global Launch Reporting

3Supplier Launch Risk Analysis

4 Launch Issue Escalation

5Supplier Communication Conferences

6 Supplier Layered Audits

7 APQP Team Reviews

8 Key Supplier Reviews

9Supplier Launch Audit (SLA) Process

10 Build Issue Tracking

11Plant Daily Build Summary Report

123rd party Containment (ESEP) - optional

13Boundary Samples - optional

GM

GV

DP

5.0

33/

20

Task # / -Wks to SORP

APQP Gate 3

BIW CVER

-54

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�-21MVBs

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�-15SORPPQRR

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�+12

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�MPPAP

�NSPPAP

�GateVTC�

R@R

�Comp

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-48

BIW IVER-45

PPVGA-32

MVBnsBody-25

MVBnsGA -21

MVBsBody-15

MVBsGA -14

M1GA-42

PPVBIW-39

SQ Launch Manager Assigned -75wks

SQ Assistant Launch Mgr Assigned -52wks

Launch SQEs engagedfrom -52wks

Bi-monthly minimum from -42wks

Pre Launch event -22wks

Monthly reviews from -50wks to MVBns

Initial Audit Latest -8wks

APQP Gate 4

Track all SQ Build issues from PPV

Issue daily summary starting PPV (on build days)

Rank Suppliers and Develop Hi Risk List

Engage 3rd party from PPV

Develop during MVB phase

Weekly scheduled reviews with APQP teams

Track all issues at APQP G3, G4 and weekly from PPV

Post Sourcing event -46wks

Re-audit +4wks

Supplier site reviewpre-MVBs

Supplier Performance Reviews as required

Page 38: GM_APQP

Global Launch Process

Task Number: 1

Task Name: Launch Management Team (excluding PT)

Task Owner: SQ Launch Group Manager and/or Global SQ Launch Manager (Platform Coordinator)

Task Timing: -75wks SQ Launch Manager assigned-52wks Assistant SQ Launch Manager assigned-52wks Launch SQEs assigned (where available)

Task Description: Staffing of an SQ Launch Management Team to support new vehicle launch and team responsibilities list.

Key Deliverables: Dedicated Launch Team FOCUSED on a Program Launch SQ Launch Manager, Assistant SQ Launch Manager and, where available, minimum 3 Launch SQEs (mature regions may allocate less resources as availability and relative launch risk dictates)

Customer for Deliverables: Program Launch Manager, Manufacturing, Purchasing, Engineering, Supplier Quality

Necessary Inputs: Source of Input:Program Information (Major, New, MCE3 etc) Program TeamPurchasing Launch Coordinator support Purchasing Program Management team

Resources: Supplier Quality, Plant Quality Engineering

Responsible Methodology:SQ Launch Group Manager

Understand the pipeline of new launches and assign dedicated SQ Launch Managers to all Major, New, Derivative, MCE3 or CKD programs by -75wks to SORP.

SQ Launch Manager

Identify source for template resources (Assistant SQ Launch Manager and Launch SQEs) based on availability and program complexity and make a plan to engage them by -52wks to SORP.

SQ Launch Manager

Conduct Kick-Off with Plant Manager, Launch Manager, SQ Director and affected Staff

SQ Launch Manager

Move SQ Launch Management Team resources on-site ahead of PPV (approximately -40wks prior to SORP).

Scope of work for SQ Launch Management Team includes (for detail refer Tasks in this Manual): Maintain supply base risk ranking by DUNs throughout launch to drive mitigation measures and resource

allocation (Launch Manual Task 3). Support all shifts (divide responsibilities between SQ Launch Management Team). Follow all builds (Matching, PPV, MVBns, MVBs, SSF and Acceleration). Provide daily summary of build progress and supply base performance during build events to GPSC

leadership (Launch Manual Task 11). Capture, communicate, and drive closure on major supplier related build issues (Launch Manual Task 10). Respond to diamond 4 supplier issues. Capture, communicate and drive closure on supplier fault CTF issues. Capture, communicate and drive closure on supplier fault GCA issues. Capture, communicate and drive closure on supplier fault QAP issues. Weekly or bi-monthly preparation of Global Launch Report (Launch Manual Task 2). Weekly or bi-monthly presentation of Global Launch Report to Program Team Reviews, Plant and

Manufacturing Launch Reviews and GPSC and Supplier Quality leadership reviews. Conduct weekly or bi-monthly analysis of PPAP, R@R, and RLA data contained in Global Launch Report. Support PIT and IRT weekly for Chassis, Body, Electrical, Trim, BSR (divide between SQ Launch

Management Team). Attend daily GCA, launch activity wrap up, and throughput meetings. Represent GPSC at major reviews and problem solving meetings such as: PQRRs, MRRMs, PQEP, LPIT,

Core IRT’s, etc. (as per Program Launch team expectations). Oversee structured Launch Issue Escalation process (Launch Manual Task 4).

September 21, 2009 33 GM1927

1

Page 39: GM_APQP

Global Launch ProcessTask Number: 1 continued

Task Name: Launch Management Team (excluding PT)

Manage communication of Launch expectations to the Supply base (Launch Manual Task 5). Participate in APQP Team Reviews (termed Deep Dives in GMNA – Launch Manual Task 7). Drive/Participate in problem resolution communication and follow-up globally (Launch Manual Task 10). Participate in Supply Chain material tracking calls for trouble suppliers / suppliers behind schedule

(shortage calls). Assist Supply Chain in understanding and overcoming roadblocks to getting parts to plant for MRDs where

there are supplier issues. Support CAB / EWO / TWO / EIT meetings, in consultation with PPM team (PPM team includes

Purchasing Launch Coordinator role). Drive Key Supplier Review meetings (Launch Manual Task 8). Drive Supplier Performance Review meetings as required (Launch Manual Task 8). Track/support Harmony Reviews, Grain buy-off and AAR approvals, as well as Boundary Sample

development if required (Launch Manual Task 13 - optional). Participate in and drive Layered Audits with critical suppliers (Launch Manual Task 6). Support plant with GP5/GP12 activities (containment strategy – ESEP as per Launch Manual Task 12,

optional and/or CS1 and CS2). Drive Deep Dive engagement at Top Risk and poor Launch performance suppliers (Supplier Launch Audit

- Launch Manual Task 9).

Reference Documents:The Global Launch Process Owner’s Manual

Task Number: 2September 21, 2009 34 GM1927 2

Page 40: GM_APQP

Global Launch Process

Task Name: Global Launch Report

Task Owner: Supplier Quality Launch Manager

Task Timing: Start -42wks

Task Description: Standard report updated minimum semi-monthly (every 2 weeks) from -42wks covering supply base PPAP, Run@Rate and Launch Alert summary specific to a Program Launch

Key Deliverables: Meet the program PPAP and Run@Rate glide path metrics

Customer for Deliverables: Program Launch Manager, Manufacturing, Purchasing, Engineering, Supplier Quality

Necessary Inputs: Source of Input: Program milestone dates Program Launch Manager Launch Alerts Manufacturing SQE PPAP and Run@Rate promise dates APQP Teams / GQTS

Resources: Supplier Quality

Responsible Methodology:SQ Launch Manager

Create report in line with global template prior to -42wks to SORP and issue minimum semi-monthly to relevant program and SQ management and post on GM Supplypower Quality library in Launch/Readiness folder under appropriate regional sub-folder. NOTE: some regions and programs reporting requirements may dictate weekly update post-PPV.

SQ Launch Manager

Create cover page using official program launch timing and information, including vehicle image if released (otherwise use carryover vehicle image).

SQ Launch Manager

If program is pre-PPV download Tool Construction Readiness slide from GSTS and include in presentation, if program is post-PPV use placeholder slide in place of Tool Construction Readiness.

SQ Launch Manager

If SORP is <23wks, develop Run@Rate glide path using commitment dates in GQTS and include in presentation, else if SORP is still >23wks use placeholder slide in place of Run@Rate glide path.

SQ Launch Manager

Capture all program Red Launch Alerts on a Red Launch Alert summary slide, cross checking criteria to ensure all alerts are appropriately identified.

SQ Launch Manager

Capture “new” part PPAP statistics in the main body of the presentation (including all part numbers first-use for the program) and “new and carry-over” part PPAP statistics including all program parts in the presentation back-up slides.

SQE Ensure suppliers maintain up-to-date PPAP and Run@Rate promise dates in GQTS from APQP Gate 3 onwards for all part numbers. Escalate immediately any Production Tooling delays, Full PPAP promise date past the PPAP Approved milestone (-15wks for GVDP 5.0 33/20) and issues preventing Run@Rate pass by SSF.

SQE Monitor Green, Yellow and Red Launch alerts in line with the Global Launch Alert criteria and escalate all Red Alerts to the SQ Launch Manager for inclusion in the Global Launch Report.

APQP Manager

Manage and Track Manufacturing SQEs to ensure PPAP and Run@Rate are managed in GQTS within program milestones, and ensure appropriate Red Launch Alert escalation with recovery planning for any delinquent items.

Reference Documents: Global Launch Report template, GM1927-40 Global Launch Alert criteria

September 21, 2009 35 GM1927

Page 41: GM_APQP

Global Launch ProcessTask Number: 3

Task Name: Supplier Launch Risk Analysis

Task Owner: Supplier Quality Launch Manager

Task Timing: -75 wks to -52 wks

Task Description: A standardized process used to rank supplier risk relative to program launch.

Key Deliverables: Develop list of High Risk suppliers

Customer for Deliverables: Program Launch Manager, Manufacturing, Purchasing, Engineering, Supplier Quality

Necessary Inputs: Source of Input: Plan For Every Part Supplier Quality Launch Manager APQP Assessment and APQP execution status Mfg SQE Supplier Bidlist Metrics Status Mfg SQE Supplier Warranty Data Quality Identification of supplier risk drivers (program timing delays, Greenfield plant, Brownfield plant) Mfg SQE Open Significant Commercial Issues PPM Open Significant Design and Validation Issues PEM Open EWOs or pending changes without implementation plans PLC (PPM)

Resources: Supplier Quality, PPM, PEM

Responsible Methodology:

SQ Launch Manager

Develop the “Plan for Every Part” matrix, include columns for key bid list metrics, supplier risk drivers and open significant issues, rank and analyze results to determine high risk supplier candidates based on Mfg SQE, PPM and PEM inputs. Risk Ranking criteria may include any or all of the Necessary Inputs above.

SQ Launch Manager

Compile list of high risk suppliers, respective commodities and issue(s) and confirm with APQP Teams, PPM and PEM to ensure completeness.

SQ Launch Manager

Based on high risk list, define preliminary list of suppliers for Launch Manual Task 5 break-outs, Task 6, Task 8and potentials list for Task 9.

SQ Launch Manager

Revisit risk ranking data periodically during the launch (set intervals or after major build phases) as a sense check to understand where risks may have been mitigated or new high risks are emerging. Realign resources and focus accordingly.

Reference Documents:APQP Supplier Status Workbook, GM1927-34APQP Assessment, GM1927-7APQP Timing Chart, GM1927-2APQP Open Issues List, GM1927-5

September 21, 2009 36 GM1927

3

Page 42: GM_APQP

Global Launch Process

Task Number: 4

Task Name: Launch Issue Escalation

Task Owner: Supplier Quality Launch Manager

Task Timing: -75wks through SORP

Task Description: Standard process to communicate and escalate all Level 1 or 2 Open Issues and Red Launch Alerts

Key Deliverables: Early identification of all Launch Risk issues to enable quick response and appropriate risk mitigation implementation

Customer for Deliverables: Program Launch Manager, Supplier Quality, PPM, Purchasing Manager and Product Engineering Managers

Necessary Inputs: Source of Input: Program milestone dates Program Launch Manager Launch Alerts (Red, Yellow, Green) SQE Level 1 or 2 Open Issues or APQP Gate Review delinquencies SQE PPAP and Run@Rate promise dates APQP Teams / GQTS Launch CAB approved changes and TIDs PLC (PPM)

Resources: Supplier Quality

Responsible Methodology:SQ Launch Manager

Define standard expectations to communicate and escalate items considered as potential Red Launches (minimum requirement is entry in GQTS).

SQ Launch Manager

Create a log to follow all Red Launch alerts for the program.

SQ Launch Manager

If program is within the reporting phase all Red Launch Alerts must be summarized and reported bi-monthly or weekly as part of the Global Launch Report.

SQE Monitor all Open Issue level 1 or 2 and escalate all potential Red Alerts to the SQ Launch Manager for inclusion in the Red Launch Communication and escalation process.

APQP Manager

Manage and Track SQEs to ensure all potential Red Launches are captured and communicated.

APQP Manager

Follow all Red Launch Alerts in order to guarantee issue closure and implementation of appropriate corrective actions.

Reference Documents:Global Launch Report template, GM1927-40APQP Open Issues list, GM1927-5

September 21, 2009 37 GM1927

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Global Launch Process

Task Number: 5

Task Name: Supplier Communication Conferences

Task Owner: Post Sourcing Conference - GPSC PPMPre Launch Conference - SQ Launch Manager

Task Timing: Post Sourcing Conference no later than -46 wks Pre Launch Conference no later than -22 wksFurther detail found in GLP Owner´s Manual

Task Description: Formal presentation to all suppliers at the customer location to establish requirements and expectations for the Launch, followed by break-out meetings for critical suppliers

Key Deliverables: Clear and common understanding of all key function requirements in relation to launch across the supply base Launch risk mitigation achieved via top Executive meeting in the customer’s site to gain commitment and to

assure focus on Launch Readiness from critical suppliers

Customer for Deliverables: Launch Team, Purchasing, Engineering, Supplier Quality, VLE, GM Assembly Plant, Supply Chain

Necessary Inputs: Source of Input:Supplier Contacts List PPMSupplier Launch Risk Analysis SQ Launch Manager

Resources: Launch Team, APQP, Current SQE, Engineering, Manufacturing, Materials, GM Executive Leadership, GPSC PPM, and Suppliers

Responsible Methodology:Conference Owner

Create agenda and identify internal functions and leaders to present functional material at the conference (3 months prior to conference). Potential presenters include Vehicle Line Executive/Director, Purchasing Program Director/Manager, Chief Engineer, Chief Manufacturing Engineer, Supplier Quality Director/Manager, Supply Chain Manager, Program Quality Director/Manager, Plant Manager, Launch Manager and Plant Quality Director/Manager.

Conference Owner

Identify conference date and location, book facility and attendance of key executives and presenters, including Master of Ceremonies (3 months prior to conference).

Conference Owner

Develop attendee invitation list with contact details and issue invitations with RSVP deadline to all invitees (2-3 months prior to conference). Include capability for remote participation where required.

SQ Launch Manager

Use High Risk Supplier list, in consultation with APQP Managers, to develop list of 10-20 high risk suppliers for break-out sessions. Issue supplementary invitation to identified suppliers and SQEs for break-out sessions and provide copy of the questionnaire for preparation (1-2 months prior to conference).

SQE Book meeting room and invite cross-functional GM attendees for break-out sessions (2-4 weeks prior).Conference Owner

Follow-up functions for completed presentation material and collate and format into Master Presentation (1-3weeks prior to conference).

Conference Owner

Arrange nametags, refreshments and security access as required based on the final list of conference attendees (1-3 weeks prior to conference).

Conference Owner

Define support staff to manage ingress/egress of attendees, conference registration for attendees and other support as required (i.e. translators, 1-3 weeks prior to conference).

SQ Launch Manager

Collate results from the break-out sessions, track and follow-up closure of critical items with responsible SQEs and APQP Managers.

Reference Documents:Supplier Conference Break-Out Questionnaire, GM1927-41The Global Launch Process Owner’s Manual

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Global Launch Process

Task Number: 6

Task Name: Supplier Layered Audits

Task Owner: Supplier Quality Launch Manager

Task Timing: Start -60wks

Task Description: Standardized schedule of Supplier Layered Audits by SQ Team Leaders and Senior Level Managers at APQP Gate 3 and 4 for High Launch Risk Suppliers.

Key Deliverables: Measure effectiveness of APQP execution and ensure appropriate risk mitigation ahead of entering Manufacturing Build phase

Customer for Deliverables: Program Launch Manager, Manufacturing, Purchasing, Engineering, Supplier Quality

Necessary Inputs: Source of Input: Program milestone dates Program Launch Manager Supplier Risk Analysis / Ranking Supplier Quality Launch Manager SQE audit and PPAP result Supplier Quality Engineer

Resources: Supplier Quality

Responsible Methodology:SQ Launch Manager

Review risk analysis results (SQ Launch Task 3) and group suppliers by SMT. Rank High Risk suppliers within each SMT, then develop Layered Audit supplier list. Review list before each round of Layered Audits to assess changes in relative risk levels between rounds.

SQ Launch Manager

Provide list to SQ Team Leaders and Senior Level managers minimum 4 weeks ahead of requested audit completion date and follow-up for visit schedule (SQ Launch Manager may participate in visit schedule as auditor).

SQ Launch Manager

Record audit results and track follow-up for any RED and YELLOW items until closure. Emphasize rapid closure of issues ahead of manufacturing build phase.

GM Layered Auditor

Select audit based on relevance to APQP Gate (unless a specific audit is mandated by SQ Launch Manager), ensuring focus on APQP Gate Review key deliverables (Gate 3 – QSB, Greenfield/Brownfield, Capacity Plan, ADV Plan; Gate 4 – Off-Tool Dimensional Status, GP-12 implementation).

APQP or SQ Team Manager

Follow-up RED and YELLOW items until closure and report results back to SQ Launch Manager. Measure effectiveness of APQP execution ahead of entering manufacturing builds.

SQE Complete initial audit ahead of Layered Audit and drive closure of all RED and YELLOW items ahead of Layered Audit.

SQE Record all RED and YELLOW items on Open Issues list and follow-up until closure.

Reference Documents:APQP Supplier Status Workbook GM1927-34QSB audit GM1927-30Greenfield / Brownfield Development Assessment GM1927-31GP-12 audit GM1927-33

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Global Launch Process

Task Number: 7

Task Name: APQP Team Reviews (GMNA Deep Dive Reviews)

Task Owner: Supplier Quality Launch Manager

Task Timing: Start -56wks

Task Description: Weekly deep dive reviews with APQP teams, tracking APQP Gate 3, APQP Gate 4, PPAP Non-Saleable, PPAP Gate and Run@Rate Complete Milestones and Red Launch Alerts

Key Deliverables: Adherence to the GM PPAP and Run@Rate metrics and flawless launch requirement

Necessary Inputs: Source of Input:GQTS Reports APQP ManagerLaunch CAB approved changes and TIDs PLC (PPM)

Resources: Supplier Quality

Responsible Methodology:SQ Launch Manager

Schedule regular reviews starting ahead of APQP Gate 3 deadline. Agree on schedule and frequency of reviews with APQP Team Managers.

SQ Launch Manager

Develop standard reporting template in agreement with APQP Managers, including APQP Gate Status (up until APQP Gate 4), PPAP glidepath, Run@Rate glidepath, GCA issues, QAP issues, Red Launch Alerts, Open PRRs, Controlled Shipping and Assistance Required.

SQ Launch Manager

Ensure consistent frequency of review for all program part numbers, including strategy for reviewing imported parts under the responsibility of overseas APQP teams (may drive rotating schedule to balance number of teams presenting against duration of reviews – consider risk factors).

APQP Manager Attend review as scheduled and present latest status on the agreed template. Focus on meeting metrics and early escalation of potential issues and Red Launch Alerts with countermeasures.

Reference Documents:APQP Supplier Status Workbook, GM1927-34Launch Alert Criteria

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Global Launch Process

Task Number: 8

Task Name: Key Supplier Reviews

Task Owner: Supplier Quality Launch Manager

Task Timing: Phase 1 -50wks to -22wks (Supplier monthly presentations at GM site)Phase 2 -18wks to -14wks (GM Executive visit to Supplier site)Phase 3 -10wks to EOA (Supplier Performance Reviews at GM Plant)

Task Description: Supplier Leadership presentation of program status for High Launch Risk commodities to cross functional GM management team

Key Deliverables: Launch risk mitigation through:

o direct engagement of supplier leadership; and o GM management monitoring of High Launch Risk commodities and suppliers

Customer for Deliverables: Program Launch Manager, Manufacturing, Engineering, Purchasing

Necessary Inputs: Source of Input:High Risk Supplier list SQ Launch Manager

Resources: Supplier Quality

Responsible Methodology:Phase 1 – Monthly Supplier Presentation at GM site

SQ Launch Manager

Based on Risk Analysis from Task 3, identify the major high risk suppliers by SMT for monthly Key Supplier Review presentation at GM location.

SQ Launch Manager

Get endorsement of the list from responsible APQP Team Managers and define the Key Supplier Review owners by supplier (usually the Manufacturing SQE). The Key Supplier Review list can change at any time with agreement of the SQ Launch Manager and APQP Manager if it is perceived that a specific supplier risk has been mitigated ahead of launch, or if new risks emerge.

SQ Launch Manager

Engage the Key Supplier Review owners to develop a monthly Key Supplier Review schedule, maintaining consistent day and time per month by supplier to maximize attendance and ensuring no clashes / overlaps (may involve grouping multiple reviews by SMT into consecutive timeslots to maximize resource efficiency).

APQP or SQ Team Manager

Define invitation list for Key Supplier Review by supplier (suggested cross functional invitees include: Engineer, Engineering SMT Manager or Director, Buyer, Purchasing SMT Manager or Director, Purchasing Program Manager, SMT Vehicle System Engineer, Sub-System Validation Engineer, Manufacturing Engineer, Vehicle Line Director, Vehicle Line Executive, Program Manager, Plant Launch Manager, Supply Chain).

APQP or SQ Team Manager

Follow-up Key Supplier Review owners to ensure consistency of scheduling and communication as well as issue closure.

SQE Schedule Key Supplier Review and issue invitation monthly to standard distribution minimum 1 week ahead of Key Supplier Review.

SQE Ensure supplier readiness and attendance at review – assess presentation prior to review with supplier where possible to ensure completeness and effectiveness of cross functional meeting.

SQE Chair review and arrange conference call details for remote participants as required.SQE Follow-up issues presented and identified through the Key Supplier Reviews to ensure they are

adequately captured and assigned on the Open Issues list and subsequently closed out in a timely manner in line with commitments and program requirements.

Supplier Prepare presentation material on the KSR template (GM1927-42) in advance and review with GM Mfg SQE prior to first review to confirm completeness.

Supplier Capture, assign and follow-up open issues identified through reviews.

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Global Launch Process

Task Number: 8 Continued

Task Name: Key Supplier Reviews

Responsible Methodology:Phase 2 – Pre-MVBs GPSC Executive led visit to Supplier Plant

SQ Launch Manager

Based on the Risk Analysis from Task 3 and relative confidence gained through Phase 1 above, identify High Risk suppliers for GPSC Executive led reviews prior to MVBs (at supplier plant).

SQ Launch Manager

Define list of participating GPSC Executives and assign by supplier prior to -20wks. Inform Executives and Mfg SQEs of assignments and expectations.

GPSC Executive Make an advance call to Supplier Executive, identified by the Mfg SQE as host for the review, to set expectations for the review.

GPSC Executive Make an advance call to the Buyer to understand any commercial issues or disputes, parts missing contract, commercial launch risks and to confirm contract capacity is greater than LCR.

GPSC Executive Meet with the Mfg SQE to review the 6-panel chart and understand existing build issues or launch risk issues.

GPSC Executive Provide direction in review for issue resolution and act as “road-block” buster as required.SQE Schedule review date and time with supplier in consultation with GPSC Executive, invite same

cross functional attendees as Phase 1 for supplier site review.Phase 3 – Supplier Performance Reviews at GM Plant

SQ Launch Manager

Nominate suppliers with multiple or major quality issues through PPV, MVBns and MVBs build phases for on-site review at GM Plant.

SQ Launch Manager

Review supplier list with Plant Management to determine which suppliers, if any, they wish to run Supplier Performance Reviews (SPR) with.

Launch SQE Issue SPR invitation letter (GM1927-44) to supplier and SPR standard presentation template (GM1927-45).

Manufacturing SQE

Review presentation material with supplier informally in advance of SPR to ensure completeness.

Launch SQE Issue invitation to relevant GM Plant personnel, Quality personnel and Engineer.Launch SQE Chair SPR meeting with supplier.Manufacturing SQE

Capture open issues, follow-up and report out until closure.

Reference Documents:KSR template GM1927-42Supplier Performance Review Invitation Letter GM1927-44Supplier Performance Review Presentation Template GM1927-45

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Global Launch Process

Task Number: 9

Task Name: Supplier Launch Audit (SLA) Process

Task Owner: Supplier Quality Launch Manager

Task Timing: Initial audit latest -8 wks and re-audit at +4 wks (if required) from SORP

Task Description: Detailed audit used to surface significant issues that could cause disruptions, rescheduling or delays at GM Assembly Plants or Ship to Commerce – used only for top risk suppliers

Key Deliverables: Completed Supplier Launch Audit (SLA) Form (GM1927-43)

Customer for Deliverables: Launch Team, Purchasing, Engineering, Supplier Quality, VLE, GM Assembly Plant, Supply Chain

Necessary Inputs: Source of Input APQP Supplier / Supplier QualityMaster Timing Supplier / Engineering / Supplier QualityPRR History Supplier / Supplier Quality / Purchasing

Resources: Supplier, Supplier Quality, Product Engineering, Launch Team

Responsible Methodology:

SQ Launch Manager

Define list of candidate suppliers for SLA based on High Risk Supplier list and Supplier Performance during PPV and MVBns build phases (including feedback from Program Launch Team or Plant). NOTE: SLA is a Deep Dive audit, it should be applied only to the highest risk suppliers.

SQ Launch Manager

Get agreement from responsible APQP Manager and confirm responsible Mfg SQE. As required, seek process expert engagement for audit support.

Mfg SQE Establish supplier visit schedule and report back to SQ Launch Manager.Mfg SQE Ensure completion of the Supplier Launch Audit (SLA) form by the Supplier prior to the visit.

SupplierPrepare plant and complete Supplier Launch Audit (SLA) form in full prior to audit. Commit appropriate resources to the audit, including leadership and functional attendance, to ensure completeness of reporting and accurate assignment and ownership of Open Issues.

Mfg SQEReport audit completion status to SQ Launch Manager and other internal customers. Ensure all Open Issues are appropriately captured and assigned and establish follow-up schedule – track all issues until closure.

Mfg SQE Initiate Program Management PRRs and /or Red Launch Alerts as required based on audit findings.

Mfg SQESchedule follow-up audit after SORP as required to review major issues for closure or drive focus at delinquent suppliers.

SupplierCommit to timely closure of all open issues and regular and transparent internal reviews to drive completion.

Reference Documents:Supplier Launch Audit (SLA) form, GM1927-43

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Global Launch Process

Task Number: 10

Task Name: Build Issue Tracking

Task Owner: SQ Launch Manager

Task Timing: From PPV through to SORP

Task Description: A standardized process to document and track to closure any Supplier Quality issues found during the MVB phase.

Key Deliverables: All Supplier Launch issues tracked through to closure ensuring a flawless Manufacturing launch.

Customer for Deliverables: SQE and SQ Launch Team

Necessary Inputs: Source of Input IRT Issues IRT Co-chairGCA/QAP/CTF Issues Program Quality ManagerLaunch CAB EWOs Change Management LeaderPRRs / Controlled Shipping GQTS / SQEs

Resources: Assistant SQ Launch Manager, Launch SQEs or Quality Engineers

Responsible Methodology:SQ Launch Manager

Create tracking matrix template ahead of first in-plant build event.

SQ Launch Manager

Capture issues from daily summary meetings for SQ follow-up (including verifying correct assignment to SQ), assign a tracking number and responsible SQE and communicate issue to SQE for action and report out. Include IRT issues, GCA issues, QAP issues, CTF issues, PRRs and Controlled Shipping.

SQ Launch Manager

Define a review schedule and communicate to ensure SQEs are closing issues and reporting out in line with requirements (follow-up in APQP Team reviews or schedule alternate meeting).

SQ Launch Manager

Continue reviews through SORP until all issues are closed out and launch metrics are achieved.

Reference Documents:The Global Launch Process Owner’s Manual

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Global Launch Process

Task Number: 11

Task Name: Daily Build Summary

Task Owner: Supplier Quality Launch Manager

Task Timing: Start at PPV and issue every plant build day through SORP

Task Description: Daily summary of manufacturing build activity issued to internal GPSC distribution

Key Deliverables: Communicate daily build activity and key metrics to:

o highlight issues and focus areas for SQ follow-up; and o communicate status of launch to Supplier Quality and Purchasing leadership

Customer for Deliverables: Supplier Quality Leadership, Purchasing Program Leadership, APQP teams

Necessary Inputs: Source of Input:Daily manufacturing build summary Plant Launch ManagerDaily Quality metrics summary Program Quality ManagerIRT emerging issues Launch SQEs

Resources: Supplier Quality

Responsible Methodology:SQ Launch Manager

Develop standard distribution list, including APQP and SQ Managers , responsible Directors and interested GPSC Executives, and issue standard daily report summarizing manufacturing validation build activity

SQ Launch Manager

Capture issues for follow-up in the Issues Tracking Matrix and ensure closure and feedback to the plant

Standard daily report minimum text / content (place in body of email):For (Mon/Tue/Wed/Thu/Fri)day mm/dd/yyyy (Program Code) Acceleration at (Assembly Plant) Daily Production: Target Actual Monday: mm/dd XXX XXXTuesday: mm/dd XXX XXXWednesday: mm/dd XXX XXXThursday: mm/dd XXX XXXFriday: mm/dd XXX XXX

GCA: Daily XX.X Bucket average XX.X (Glidepath target XX.X)

QAP: Daily XX.XBucket average XX.X (Glidepath target XX.X)

PRRs : (X)# Supplier Issue Description. Issue s : Critical Quality / Capacity / Commercial issues and actions

Support Needed:

Supplier Readiness / Engineering Issues:

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Global Launch Process

Task Number: 12

Task Name: 3rd Party Containment (ESEP) - optional

Task Owner: Supplier Quality Launch Manager

Task Timing: Start from PPV or MVBns build through End of Acceleration

Task Description: Engagement of 3rd party to be located on-site at GM Assembly plant throughout launch builds in order to execute immediate containment of any suspect material found on the GM Assembly line with costs transferred directly to the responsible supplierThis optional Task is applied only at the agreement and active engagement of the GM Assembly plant

Key Deliverables: Immediate 3rd party containment of any supplier quality issue found at the plant during launch with costs transferred to supplier

Customer for Deliverables: Launch Team, GM Assembly Plant

Necessary Inputs: Source of Input:Plant endorsement of ESEP Plant Launch ManagerIn-plant location for 3rd party operation Plant Launch Manager

Resources: Supplier Quality, 3rd party quality services provider

Responsible Methodology:SQ Launch Manager

Discuss containment strategy with Plant Launch Manager and determine if ESEP is an appropriate strategy to support manufacturing through the launch.

SQ Launch Manager

Identify potential 3rd party suppliers from approved Controlled Shipping provider list. Invite identified providers to make an ESEP plan and arrange for submission to the Plant Launch Manager or delegate.

SQ Launch Manager

Work with Plant Launch Manager or delegate to get their decision on selected provider, communicate to supplier and make engagement plan.

SQ Team Manager

Send out general notification to all suppliers of ESEP process, including process introduction, standard templates, ESEP provider contact details and GM contact details for ESEP queries.

3rd party provider

Execute ESEP as per process definition, engaging GM SQE for inspection process approval prior to commencement of any containment actions.

SQE Upon confirmation of supplier quality issue immediately co-ordinate with 3rd party provider to confirm and commence an approved inspection process and follow-up with supplier for root cause and corrective action implementation.

SQE Formalize Controlled Shipping Level 2 action against supplier within GQTS only once supplier fault is proven and GP-12 failure is confirmed.

Reference Documents:ESEP AuthorizationESEP Notification

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Global Launch Process

Task Number: 13

Task Name: Boundary Samples - optional

Task Owner: SQ Launch Manager

Task Timing: MVBs through SORP

Task Description: Review range of physical samples representing the anticipated manufacturing variation in order to establish limits for parts with subjective acceptance criteria (usually in relation to appearance and color)This optional Task is applied only as required to address cases of disputed parts with subjective acceptance criteria, where requested by the Plant or Supplier in the absence of an alternate acceptable solution

Key Deliverables: Agreement on physical samples representing upper and lower boundary conditions of acceptability, with parts

signed, dated and stored in an agreed location for quick access and reference

Customer for Deliverables: Plant Quality, Launch Team, Design Quality

Necessary Inputs: Source of Input:List of subjective parts in dispute Plant QualityFull part specifications Release EngineerRange of parts exhibiting reasonable production variation Supplier

Resources: Supplier Quality, Engineering, Quality, Manufacturing, Design Quality

Responsible Methodology:SQ Launch Manager

Identify the need for Boundary Samples through plant requests or ongoing dispute over acceptable part level based on subjective assessment criteria.

SQ Launch Manager

Drive Boundary Sample development in the case of parts with disputed GCA mark-ups through the PPV and MVBns build phases.

SQ Launch Manager

Engage SQE, Supplier, Engineer, Design Quality and Plant personnel and schedule review at mutually agreeable time with supplier commitment to provide a range of parts for review.

Supplier Produce parts from significant production run and select range for review representing reasonable production variation.

SQE Facilitate Boundary Sample review in line with process guide and capture follow-up actions. Schedule follow-up reviews as required until signed samples are developed.

Reference Documents:Boundary Sample Process Guide (available through GM Supplypower)

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Section 3

Global Current

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Document Usage Guidelines by Global RegionF = Reference Only (Information only, Nothing to fill out)NA = Not applicable for specified regionMD = Mandatory Document (document type required, specific format required)MI = Mandatory Information (document type required, format may vary, minimum content mandatory)RD = Recommended Document (document recommended, specific format required)RI = Recommended Information (document recommended, format may vary)

Document Number AP GME LAAM NAProcess Control Plan Audit (PCPA) GM 1927-16 MD MD MD MDRPN Reduction Summary GM 1927-21 MD MD MD MDQSB Audit GM 1927-30 MD MD MD MDControlled Shipping Assessment Matrix GM 1927-51 MI MI MI MIControlled Shipping Assessment GM 1927-52 M M M MControlled Shipping Confirmation Reply Form GM 1927-53 MI MI MI MIControlled Shipping CS1/CS2 Verification Exit Checklist GM 1927-54 RD RD RD RDControlled Shipping Level 1 Entry letter GM 1927-55 MI MI MI MIControlled Shipping Level 1 Exit Letter GM 1927-56 MI MI MI MI Controlled Shipping Level 2 Entry Letter GM 1927-57 MI MI MI MIControlled Shipping Level 2 Exit Letter GM 1927-58 MI MI MI MIControlled Shipping Level 2 Exit Survey (Supplier) GM 1927-58a MI MI MI MIControlled Shipping Kick-off Meeting Worksheet GM 1927-59 MD MD MD MDCross Regional Support Request GM 1927-61 MI MI MI MICT Quality Action Plans GM 1927-62 RI RI RI RIGlobal Emerging Issue Alert GM 1927-65 MI MI MI MIGlobal Emerging Issue Alert Communications GM 1927-65a MI MI MI MII-Chart Controlled Shipping GM 1927-66 RI RI RI RINew Business Hold Process Flow GM 1927-67 F F F FDrill Deep & Wide PRR Read Across Matrix GM 1927-69 MI MI MI MIQuad Report GM 1927-71 MD MD MD MDShop Floor Excellence (SFE) Audit GM 1927-72 MD MD MD MDShutdown/Start-up audit GM 1927-73 MD MD MD MDDisruption Agenda Format GM 1927-75 MI MI MI MISPR Agenda Format GM 1927-76 MI MI MI MISPR Invite letter Format GM 1927-76a RI RI RI RIStep Down Chart GM 1927-78 MD MD MD MDSupplier Action Plans GM 1927-79 MI MI MI MISupplier Performance Assessment Matrix – SPAM GM 1927-80 RI RI RI RITop Focus Add/Remove Form GM 1927-82 RI RI RI MTop Focus Process Notification Letter GM 1927-83 RI RI RI M5 Whys 3 Times (Drill Deep & Wide Worksheet) GM 1927-84 MI MI MI MIDrill Deep & Wide Audit GM 1927-85 MI MI MI MIDrill Deep & Wide Root Cause Workbook GM 1927-86 MI MI MI MI

All documents can be found at: https://www.gmsupplypower.com/apps/supplypower/NASApp/spcds/CDSRetrieval?lob=quality&subnav=library&togglefolder=1606

Obsolete Documents include the following: GM 1927-60, GM 1927-63, GM 1927-64, GM 1927-68, GM 1927-70, GM 1927-74, GM 1927-77,

GM 1927-81,

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Training Available to Suppliers through 3rd Party Providers

Training (Workshops) APO GME LAAM NA5S / Visual Workplace       XApplying SPC Tools       XDrill Deep & Wide XError Proofing       XJob Set Up Optimization & Error Proofing       XLabel Error Proofing       XPFMEA       XProblem Solving       XQuality Systems Basics     X X

Reference Only – Current information on training and providers can be obtained in GM Supply Power – Quality Library – 3rd Party Provider Management.

Approved 3rd Party Providers (Training/Implementation)

Approved Providers Training

Error Proofing Training

Label Error

Proofing Training

5S & Visual

Workplace Training

Problem Solving Training

Applying SPC

Tools Training

Job Set Up Error

Proofing & Optimization

TrainingCS2

ImplementationThe PIC Group X X X X X X   XBenchmark Technologies X     X X X    Luminous Group X X   X X   X  VQQ Inc. X X     X X    Eastern Michigan University X              PDC   X X   X     XCEI     X          EDS     X          

Reference Only – Current information on training and providers can be obtained in GM Supply Power – Quality Library – 3rd Party Provider Management.

https://www.gmsupplypower.com/apps/supplypower/NASApp/spcds/CDSRetrieval?lob=quality&subnav=library&togglefolder=20213

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Task Number: 1

Task Name: Continuous Improvement

Task Owner: Supplier

Task Timing: Throughout the life cycle of the product

Task Description: Defines the supplier’s responsibility to have an on-going process for continuous improvement of the product and related manufacturing processes; reference GP-8. The intent is to reduce variation and to ensure process stability and capability over time. There must be a performance attitude for zero defects.

Criteria for Application: Applies to all suppliers and products for the life of the part.

Key Deliverables: First Time Quality Trend Chart (I-Chart recommended GM 1927-66) Problem solving capability to establish root cause Process Capability Continuously Compliance to Supplier Quality SOR (1927-03 and or 1927-03a-name) Drill Deep Worksheet (GM 1927-84) RPN Reduction Summary (GM 1927-21) PFMEA, Process Control Plan, Operator Standardized Work Instruction – Revised Supplier Action Plan Form (GM 1927-79) Drill Deep Wide Matrix (GM 1927-69)

Customer for Deliverables: GM Assembly/Manufacturing Plants Supplier Quality Engineer Supplier Manufacturing Management

Necessary Inputs: Source of Input: Internal (FTQ, Process Capability, etc.) Supplier External Data Analysis (6-Panel, Warranty data, etc.) SupplyPower Parts Specific SOR (GM1927-03a-name) / SQE / SupplyPower PCPA (1927-16a-name) Lessons Learned Supplier

Resources: Supplier, SQE, Assembly Plant

Responsible Methodology:SQE Monitor and audit the supplier’s compliance to Continuous Improvement requirements (reference GP-8),

and also continuous compliance to Part specific SOR / PCPASQE Communicate specific concerns to the supplier for non-conformance, review action plans (as required),

escalate concerns to leadership (if required), and require the supplier to implement countermeasures (if necessary).

Supplier Identify Special Product and Process Characteristic Supplier shall identify product and process characteristics that require KCDS approach Inputs for this identification:

a. Customer Drawing Informationb. PFMEAc. Process/Product Capabilityd. Past or potential issue (Six Panel, Warranty Report, Internal Report)

Supplier Establish Process Controls for items identified Include KCDS items in Process Control Plan (PCP). Establish Key Control Characteristics (KCC) List.

Task Number: 1 Task Name: Continuous Improvement (Continued) Manage process capability and performance

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1. Variation control (SPC)2. Corrective action & process improvement

Update process capability / performance studies (FTQ, Cp/Cpk)Supplier Measure First Time Quality (reference GP-8)

First time quality is a measure of a process’ ability to make quality parts without scrap or rework. The rework of parts can result in undesirable variation and may take parts out of process if the rework was not initially comprehended in the process.

FTQ should be measured at: 1. End of line FTQ measurement (at a minimum); 2. Quality gates or verification stations for key processes

Quality gates or verification stations should include: Alarm limits established (e.g. 2 defects per hour) to drive immediate containment upstream in the process; A Pareto of failure modes for a specific timeframe; FTQ trend chart (I-Chart format recommended – GM 1927-66)

Supplier Continuously demonstrate process capability compliance to requirement in Supplier Quality SOR (GM1927-03, and or GM1927-03a-name), and have an ongoing process to reduce variation on characteristics identified as KPC’s

Supplier Effective Root Cause Analysis and Corrective Action Verification (Compliance with GP-5) The supplier is required to perform an effective analysis of technical root cause. Systemic root cause to be analyzed through the Drill Deep process using worksheet GM1927-

84. Verification and validation of corrective action should demonstrate the ability to turn the

problem on and off.Supplier RPN Reduction Process (reference QSB, GP-8) – to have a formal and documented RPN reduction

process which includes: A cross- functional team that meets regularly and updates FMEA and Control Plans Collection of external and internal data relative to rejects (scrap and rework) Incorporation of internal data (FTQ, scrap, etc.) and external data (PRR, etc.) into the FMEA

and validation that assigned RPN numbers are reasonable and accurate Identification and implementation of action plans with timing and accountability

Supplier Update and revise Quality Documentation – FMEA, Control Plan, and Standardized Work. The revisions are not only required when there are design or process changes, but are based on internal or external data.

Internal data should drive quarterly updates at a minimum External data should drive monthly updates at a minimum

Supplier Supplier should have a process in place, which would drive lessons learned into current and future application of FMEAs and Control Plans. The process should apply lessons learned by a look across of similar processes within the facility and within the company (Recommend Drill Wide Matrix – GM 1927-69) and compliance to Part Specific SOR / PCPA shared by SQE

Reference Documents: GP-8 QSB (Quality Systems Basics) GM1927-30 Audit and GM1927-36 Strategies Supplier Quality SOR GM1927-03 and or GM1927-03a-name GP-5 PRR I-chart (GM1927-66) Drill Deep Worksheet (GM 1927-84) RPN Reduction Summary (GM 1927-21) SPC AIAG Documents Supplier Action Plan Form (GM 1927-79) FMEA, Process Control Plan (GM1927-16 and or 16a-name), Operator Standardized Work Instructions Drill Deep Wide Matrix (GM 1927-69) KCDS (GM1805, GMW15049)

Task Number: 2

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Task Name: QSB – Quality Systems Basics

Task Owner: GPSC - Current Supplier Quality or Advance Supplier Quality

Task Timing: Throughout life of product

Task Description: QSB is a workshop at the supplier’s plant that teaches, develops, and facilitates implementation of the 11 basic strategies of quality. The intent is to share best practices and to understand the gap between the present state and the best practice. The workshop will include multi-disciplinary employees from all levels of the supplier to develop the foundation for each strategy using data available at the plant.

1. Fast Response (Includes Problem Solving, Lessons Learned)

2. Control of non-conforming product3. Verification Stations 4. Standardized Operations5. Standardized Operator Training – JIT 6. Error proof verification 7. Layered Process Audits 8. RPN Risk Reduction (Reverse PFMEA)9. Contamination Control10. Supply Chain Management11. Managing Change

Criteria for Application: Reactive, as a consequence/ exit criteria for Controlled Shipping or Top focus Proactive, to enhance a supplier’s quality system

Key Deliverables:Pass QSB Audit (Pass criteria = 90% compliance (Green) in each strategy).Completed action plan (Master Dot Methodology optional) for all Yellow or Red items

Customer for Deliverables: Supplier Quality, Supplier, and Trainer

Necessary Inputs: Source of InputSupplier Performance Report (6-Panel) Supply PowerInternal & External data analysis SupplierInternal documentation (i.e. Training documentation) SupplierCreativity Team Bid List GQTS

Additional Information: QSB Workshop Overview & Audit – GM Supply Power website (GM Supplypower.com Quality Library) Layered Audit video (Available from the SQE)

Fast Response, Verification Station Video (Available from the SQE)

Resources: Certified Trainer (Supplier Quality Engineer or Approved Third Party Provider)Multi-functional team from supplier (typically 12-15 people)Supplier’s Leadership

Task Number: 2 Task Name: QSB – Quality Systems Basics (Continued)

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Responsible Methodology:SQE Apply the QSB Audit (Gap Analysis) at Supplier Gate Review #1 using QSB audit form GM1927-30.

QSB is to be assessed against the manufacturing plant Quality Systems independent of product or specific manufacturing process.Rules for the application of the QSB Audits:

Customer Monitored APQP – Mandatory Supplier Monitored APQP – At SQE Discretion (recommended, if not passed within last 12

months Audit must be performed by GM SQE or a Third Party where agreed

SQE / Buyer / DRE

For Greenfield suppliers, apply the Greenfield & Brownfield Development Assessment Process GM1927-31 in place of QSB.

SQE Perform QSB workshop as per QSB Presentation GM1927-36 at supplier, if required.SQE Facilitates activities with GM Third Party Approved Provider (optional).

Monitor the Supplier Action Plan on a timely basis. Conducts QSB audit and provides status. Provides appropriate follow up. Participates or conducts workshop (optional).

SQE Perform the QSB Compliance Audit and Sign-off the Action Plan final implementation GM1927-30. In face of lack of full implementation, the open issues will be addressed by Master Dot (attached to the audit form) and the Program Management PRR rules will be applied.

SQE For Greenfield suppliers, Sign-off the Action Plan final implementation of the Greenfield & Brownfield Development Assessment Process GM1927-31.

Supplier Assumes responsibility and takes ownership of all activities to implement QSB.Advises the customer of implementation status and any foreseen impending problems.Provides action plans with appropriate detail, timing, ownership, etc.Implements action plan on a timely basis.

Supplier At the QSB Gap Analysis audit, or at the Greenfield & Brownfield Development Assessment Process audit, provide action plans with appropriate detail, timing, ownership, etc.

Supplier Implement and verify effectiveness of all the action plan items before Supplier Gate Review #3.Supplier Keep the customer updated regarding implementation status and any issues or concerns with

implementation.Reference Documents:

QSB Presentation GM1927-36 QSB Audit Form GM1927-30 Greenfield / Brownfield checklist GM1927-31 Supplier Action Plan Form GM1927-79

Pre-work SQE does the following:

- Identify suppliers to be trained. - Provide overview of QSB to suppliers individually or at a supplier symposium (purpose, content,

benefits, and successes).- Inform suppliers of why QSB is recommended or required.- Agree on a method of training (i.e. supplier pays third party trainer, GM provides training).

A QSB audit by a certified SQE shall be done to determine the necessity for a workshop. Supplier designates a champion for training and implementation process for each strategy. Supplier and Trainer make arrangements for a workshop(s) based on the audit results for each strategy on the

Audit Summary page.

Strategy = RED: Workshop Required for that strategy. For example the Summary page shows Fast Response and Risk Reduction RED, the workshop trainer only delivers training for those strategies)

Strategy = YELLOW: Agreement between the SQE and the Supplier if workshop training is required(An action plan for each Red/Yellow item is required)

Task Number: 2 Task Name:Quality Systems Basics (Continued)Conduct and deliver Workshop material as required.

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STRATEGY CHAMPION ATTENDEES APROX. DURATION PRE-REQUISITESOverview – Why are we here

SQE ALL 30 minutes Model Line/Area selection

1) Fast Response (Problem Solving, Lessons Learned)

Plant Manager/ Manufacturing Lead

Plant Leadership, Quality/ Manufacturing Engineers, Facilities Support, Supervision

2 hours Build Fast Response Board & populate with issues for review in the workshop

2) Control of non-conforming product

Quality Manager

Manufacturing & Quality Plant Leadership & Engineers, Model Area Supervisor, team members

1 hour Current examples of documents & or standards to compare

3) Verification Stations

Plant Manager/ Manufacturing Lead

Manufacturing & Quality Plant Leadership & Engineers, Model Area Supervisor, team members

2 hours Verification Station initial template/ board populated with documents

4) Standardized Operations (WPO-5S, Std. Operation, Job Instructions, Gaging)

Engineering Manager

Manufacturing & Quality Plant Leadership & Engineers, Model Area Supervisor, team members

4 hours Shop Floor Marking Standards established.Current example of documents to compare.

5) Standardized operator training

HR/Personnel Manager

Manufacturing & Quality Plant Leadership & Engineers, Model Area Supervisor, team members

1 hour Current Method to Train to be reviewed against the 4-Step Method

6) Error proof verification

Engineering Manager

Manufacturing & Quality Plant Leadership & Engineers, Model Area Supervisor, team members

1 hour Current examples of documents to compare

7) Layered Process audits

Plant Manager/ Manufacturing Lead

Manufacturing & Quality Plant Leadership & Engineers, Model Area Supervisor, team members

2 hours Current examples of documents to compare

8) RPN Risk Reduction (Reverse PFMEA) Care (Customer Acceptance And Review Evaluation)

Engineering Manager

Manufacturing & Quality Plant Leadership & Engineers, Model Area Supervisor, team members

3 hours Current examples of documents to compare

9) Contamination Control

Engineering Manager

Plant Leadership, Quality/ Manufacturing Engineers, Facilities Support, Supervision

3 hours Current examples of documents to compare

10) Supply Chain Management

Quality Manager or Corporate Supplier Quality/ Purchasing

Corporate, Site, Purchasing & Quality Leadership and Support Staff

1 hour Current examples of documents to compare

11) Managing Change Engineering Manager

Plant Leadership, Quality/ Manufacturing Engineers, Facilities Support, Supervision

3 hours Current examples of documents to compare

Task Number: 2 Task Name:Quality Systems Basics (Continued)

After each workshop:

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Analyze the current quality system, identify gaps, and create suggestions/forms/next steps to implement each strategy.

Shop floor strategies which focus in manufacturing or process areas should be applied on a pre-selected model line or area. Strategies which apply include Verification Stations, Standardized Operations and Training, Error Proofing, Layered Process Audits, Risk Reduction, and Contamination Control. The concept is to focus on 1 line or area first to:

o Develop and tune the process to how the supplier does business & meet the intent o Develop Champions in each strategyo Champion(s) develop a plan to roll out what they learned to other areas.

Follow-Up

GM may request / require the supplier to contract an approved GM third party to conduct the workshops. Supplier develops an Action Plan (Master Dot Methodology suggested) to track implementation of the key

strategies and improvements. SQE approves and monitors the Action Plan on a timely basis. Upon completion of Action Plan tasks, the SQE conducts a QSB audit to assess level of implementation. Supplier to provide an action plan with timing to roll out the shop floor strategies to the next line or area.

* SQE denotes GM Supplier Quality Engineer or approved GM SQ Representative

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Task Number: 3

Task Name: Shutdown / Startup Activity

Task Owner: GPSC – Current Supplier Quality

Task Timing: Throughout the life cycle of the product

Task Description: The purpose of the Shutdown/Startup Activity (SD/SU) is to implement standardized work for both the Supplier Quality Group and its suppliers, specifically focused around extended shutdown periods and subsequent startups. Examples include: Corporate (“summer”) shutdowns, Christmas shutdown, etc., but the task and tools can be used by any supplier when they are faced with any extended shutdown/startup, such as the elimination and/or restarting of a production shift or an extended weekend.

The goal of the Shutdown/Startup Activity is ZERO major disruptions caused by a supplier’s shutdown and subsequent restart of operations.

Key Deliverables: Completed Shutdown audit form Master Dot action plan for High risk suppliers

Criteria for Application: Extended shutdown periods, such as the “Summer Shutdown”, “Christmas Shutdown”,

Extraordinary Production Shutdown Selected high-risk suppliers based on established criteria. (Examples and not limited to

are the potential high risk suppliers criteria could include: Critical/Special Process (Heat Treating, Plating, Coating, etc.), High PPM, Emerging Issues, Plant Disruptions, High or High Cost Warranty, Tool Moves, Process Change, Launch Issues, CS1 or CS2 Supplier’s, Program Management PRR’s, High Financial Risk suppliers rated Red, new supplier to GM, and others)

Customer for Deliverables: SQESQ LeadershipBuyer

Necessary Inputs: Source of Input:Shutdown/Startup Audit Form (GM 1927-73) + Instructions Supply Power(newest version, 80 Questions)Master Dot Action Plan (GM 1927-79) Supply PowerHigh Risk Supplier Listing with CEO & Plant Manager, GQTSNames, e-mail addresses (reasonable size)

Resources: SQ Process/Data Group (where applicable)

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Task Number: 3 Task Name: Shutdown / Startup Activity (Continued)

Responsible Methodology:SQ Coordinator/SQ Leader

Holds an initial conference call with the representatives to review objectives, the process and key dates.

Identifies key criteria for selecting targeted suppliers for the SD/SU Audit activity, as suggested by customer plant Previous evidence or concern of poor startup at the supplier

Documents the SQE’s standardized work as part of the SD/SU Audit activity.SQ Team Identifies the suppliers to be targeted for the SD/SU activity based on the criteria provided

Assigns SQE’s to perform the standardized SD/SU work.SQE Obtains the contact information for the assigned supplier(s), including the CEO and Plant

Manager name, phone and e-mail address. Sends the standardized communication/e-mail to the supplier. THIS SHOULD BE OPTIONAL

(SEND THE AUDIT TO THE SUPPLIER SINCE SOME SQE TEAMS CONDUCT ON SITE REVIEW ONLY)

Supplier Performs a self-assessment of their shutdown/startup readiness using the SD/SU audit and supporting documentation provided by GM.

Completes the SD/SU audit form and returns to the assigned SQE with appropriate supporting documentation/evidence, or completes the web-based SD/SU online survey (if available).

Develops an action plan to resolve any issues identified in the self-assessment and implements containment and/or corrective actions. Sends the action plan to the assigned SQE.

SQE Judge the supplier’s performance (R-Y-G)self-assessment on the shutdown/startup audit form or survey, looks for evidence to support the supplier’s self assessment, and challenges the supplier if no evidence is provided.

Gives the supplier an overall R-Y-or G rating and updates the supplier’s status on a master tracking list

For Yellow suppliers, at a minimum, the SQE contacts the supplier to obtain clarification/evidence or further feedback on the open issues, and to request a supplier action plan if required.

For Red Suppliers, the SQE does an onsite review at the supplier location to resolve any red issues and review the supplier’s action plans.

Places the supplier into GP-12 or CS2 until all open issues are resolved. Reviews the supplier’s progress in resolving open issues and in implementing the action plan Updates the supplier’s R-Y-G overall status on the master-tracking list.

Supplier Reviews and rolls out GM Shutdown/Startup presentation internally. Implement GP-12 or CS2 as required.

Additional Information:

Previous Shutdown Audit, if applicable. Shutdown plan presentation.

Reference Documents:Shutdown/Startup Audit Form (GM 1927-73)Master Dot Action Plan (GM 1927-79)

* SQE denotes GM Supplier Quality Engineer or approved GM SQ Representative

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Task Number: 4

Task Name: Process Control Plan Audit & Part / Process Specific Audits

Task Owner: Supplier Quality Engineer

Task Timing: Throughout the life of the product

Task Description: The purpose of the Process Control Plan Audit is to ensure the supplier is following the documented Process Flow Diagram and executing the Process Control Plan that was the basis for PPAP. It is also to ensure the supplier is maintaining and updating said documents, including Process Flow Diagrams, PFMEAs, and Process Control Plans, while executing continuous improvement.

The purpose of the Part/ Process Specific Audits is to ensure that the supplier has specific controls in the process that are not covered in the Process Control Plan Audit. The Part / Process Specific Audits are designed to be used in combination with the Process Control Plan Audit.

Key Deliverables: Process Control Plan Audit (GM 1927-16) Part Specific or Process Specific Audits (GM 1927-16a-name) Supplier Action Plan (GM 1927-79), if required, approved by SQE

Customer for Deliverables: SQE, SQ Manager, Supplier

Necessary Inputs: Source of Input:PRR Analysis Summary GQTSSupplier’s Internal Data Analysis Supplier Process Flow Diagram SupplierPFMEA SupplierProcess Control Plan Supplier

Resources: Supplier Representative, SQE

Responsible Methodology :SQE Decides or is assigned to visit a supplier to:

Review a specific issue/concernReview an overall performance concernGain a better understanding of the supplier’s processes, etc.

SQE Reviews appropriate external performance data. Data should include 6 Panel Charts, PRRs, or a specific part/process concern.

SQE Contacts supplier’s Quality Manager to explain the nature of the visit and identify specific expectations relative to documents (such as part print, FMEA’s, Process Control Plan, etc.) that need to be ready for review.

SQE Identifies which product or process requires an audit.Chooses appropriate audit or audits to conduct.

SQE Ensures that appropriate supplier representatives participate in the audit.Ensures the Supplier understands documented concerns/non-conformances.Implements appropriate action, if necessary, to ensure conformance to requirements and reduce risk of major non-conformances; such as containment, CS1 or CS2.Summarizes expectations relative to:

Immediate corrective actionsAction plans, format and due datesFollow-up time frameAdditional requirements and expectations

Supplier Supplier implements any additional internal process controls required to reduce the risk of major non-conformance immediately, to insulate the GM Manufacturing facility or the Containment Gate.

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Task Number: 4 Task Name: Process Control Plan Audit & Part / Process Specific Audits (Continued)

Supplier Provides requested documents and participates in Audit.Understands concerns/non-conformances identified by the SQE.Implements any immediate containment/addition process controls as directed.Develops, documents, and provides action plan with appropriate detail, timing, ownership, etc.Implements action plan on a timely basis.

Reference Documents :

Supplier Action Plan (GM 1927-79)Continuous Improvement (GP-8)

* SQE denotes GM Supplier Quality Engineer or approved GM SQ Representative

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Task Number: 5

Task Name: SQE Creativity Team Support

Task Owner: GPSC – Supplier Quality

Task Timing: On-going process specific to Creativity Team

Task Description: SQE Creativity Team (CT) support is a process to drive quality in the Creativity Teams by providing the voice of Supplier Quality into the GPSC sourcing process. Through the creation of CT quality action plans, SQE’s engage the CT in strategic and up-front activities to grow, fix, or exit suppliers on the Creativity Team Bid List (CTBL). Additionally, CT quality action plans may be utilized to direct SQ resources and/or complement the Top Focus process. The SQE assigned to the Creativity Team provides the voice of the customer through feedback from Supplier Quality into the Creativity Team.

Key Deliverables: CT Quality Action Plans (GM 1927-62) Updated CT Bid List Grow-Fix-Exit Strategy (GFE) CT Metrics Tool Step-down Charts (GM 1927-78) Optional

Customer for Deliverables: Supplier, Supplier Quality, Creativity Team.

Necessary Inputs: Source of Input:CT Performance Report (6 Panel) Supply PowerCreativity Team Bid List (CTBL) GQTSCT Metrics Tool (Monthly) Supply PowerQuality Progress Chart (CTBL) GQTSPRR detail review GQTSSupplier’s Internal Data Analysis SupplierCT Roll out schedule CT CT SQ Roles and Responsibilities Supply PowerQSB (Quality Systems Basics – GM1927-30) Supply PowerQuad Report (GM1927-71) Supply PowerPCPA (Process Control Plan Audit - GM1927-16) Supply PowerPSA (Potential Supplier Assessment) Supply Power

Resources: Supplier Quality Engineer – Global Champion & Regional Assigned CT Support, Global / Regional Buyers, CT members, Global / Regional Commodity Manager, Global / Regional Commodity Director, Supplier

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Task Number: 5 Task Name: SQE Creativity Team Support (Continued)

Responsible Methodology:SQE SQ CT Global Champion reviews CT necessary inputs.SQE SQ CT Global Champion involvement within the CT to determine the Grow-Fix-Exit Strategy and the

commodity key drivers.SQE SQ CT Global Champion participates in the CT meetings, understands the CT business plan, presents

specific CT supplier quality and status of quality red supplier reductions including reporting of supplier reported major disruptions.

SQE SQ CT Global Champion maintains and is the master approver / rejecter or gate-keeper of the CT Bid list. Identifies non-green quality rated suppliers and those without TS16949 status in GQTS. Review actions specific to the CT weekly for the system CT Bid list updates.

SQE SQ CT Global Champion coordinates required new supplier audits with their SQ counter-parts in the other regions and own – supports the GPSC sourcing process (RFQ-Target Setting-Final Recommendations)

SQE SQ CT Global Champion maintains the necessary sourcing quality documents as specific to the CT that is assigned (PSA, PCPA and Quad Report – Quality Business Case)

SQE SQ CT Global Champion creates and maintains the Quality CT Action Plans which includes Grow / Fix Red suppliers to the specific CT – provide awareness to the CT and Purchasing Leadership.

SQE SQ CT Global Champion reviews sourcing packages within the CT (RFQ-Target Setting-Final Recommendations).

SQE SQ CT Global Champion uses the CT Meetings for poor performance supplier review presentations by the supplier that are Grow / Fix suppliers.

SQE SQ CT Global Champion uses any or all tools to improve the supplier quality performance which can include – adding to the Top Focus process, Supplier specific Master Dot Action Plans, 6Panels, and Supplier Step-down charts.

Commodity Manager

Provides CT agenda for each meeting, reviews CT business plans, rollout schedule (monthly), establish CT PPM targets each year (4th QTR) and CT performance, and establishes with the team inputs the G/F/E Strategy and the management of the CT Bid list with the SQ CT Global Champion.

Commodity Manager

Coordinates the sourcing package review before the GPSC ISC Sourcing meeting within the CT members (RFQ-Target Setting-Final Recommendations) which supports the G/F/E Strategy. Provides SQ agenda time to present CT quality data and supplier reviews.

SQE SQ CT Global Champion attains required sourcing approvals or reason for rejecting a sourcing decision (SQ in the supplier region) provides the SQ approval on the GPS Recommendation sheet.

SQE SQ CT Global Champion ensures non-green quality suppliers who will NOT be green by the time of the sourcing recommendation is NOT included in the Pre-RFQ. Communications the regional SQ assigned required – refer to the CT Quality Action plan tracking which also includes new suppliers to GM – Greenfield and Brownfield locations.

SQE SQ CT Global Champion must communicate and coordinate the proper documentation (regional SQ support) for Red Quality Sourcing Decision’s – Quad Report (Quality Business Case) must be approved by the Executive SQ Director located in the supplier region before the GPSC ISC Sourcing meeting.

SQE / Buyer / CT Members

Add and remove suppliers to the CT Bid list as agreed by the CT – SQ CT Global Champion reviews and approves or rejects actions to the CT Bid list weekly.

Supplier Poor performance Grow / Fix suppliers with the agreement of the CT will present at the CT Meetings their specific corrective actions to return to quality “Green” status on the CT Bid list. Supplier leadership provides documents and drives the improvement process.

SQE SQ CT Global Champion / regional SQ support reviews weekly supplier quality status CT Bid list – new Red Suppliers and changes to ISO/TS16949.

SQE SQ CT Global Champion / regional SQ support reviews the CT Metrics Tool updated once monthly after the PPM data is released (9th of month)

SQE SQ CT Global Champion / regional SQ support provides the Purchasing leadership when requested the required supplier quality data as needed for supplier executive reviews (as needed – 6panel charts, PRR history, PPM history detail, other).

SQE SQ CT Global Champion / regional SQ support follows the GM1927 – APQP Task 3 – Sourcing Eligibility.

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Task Number: 5 Task Name: SQE Creativity Team Support (Continued)

Reference Documents:

Quad Report (GM 1927-71) Supplier Quality Step down Chart (GM 1927-78) CT Quality Action Plan (GM 1927-62) CT Bid Lists GQTS CT Metrics Tool – GMSP SMT / Global CT Contacts List - GMSP 6 Panel charts GMSP GM1927 – APQP Task 3 – Sourcing Eligibility, GMSP QSB (Quality Systems Basics – GM1927-30) GMSP PCPA (Process Control Plan Audit - GM1927-16) GMSP PSA (Potential Supplier Assessment) GMSP

* SQE herein refers to GM Supplier Quality Engineer or approved GM SQ Representative

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Task Number: 6

Task Name: Global Emerging Issue/Alert Process

Task Owner: SQ Representatives

Task Timing: Throughout the life of the product

Task Description: The purpose of the Global Emerging Issue/Alert Process is to implement standardized work for GPSC Supplier Quality, GM Quality Organization and the GM supply base, specifically focused around communication and initial activities for emerging quality issues that may impact Manufacturing or Assembly Centers, or any other receiving locations in the same or other regions. The intent is to minimize potential impact of emerging quality issues through effective communication, containment activities, and established break points with certified product.

Criteria for Application: Part Quality Concerns that potentially impact the following areas:

1) Quality Gates. 2) Global Customer Audit (GCA)3) Direct Run Rate, Direct Run Loss, FTQ 4) C.A.R.E 5) Vehicle repair float6) Excessive repair time7) Main assembly line downtime8) Vehicle Shipping yard on ‘HOLD’ status

24hr CDP (Concern Detection Process)

Key Deliverables: Global Emerging Issue Alert (GM 1927-65) Conference call Schedule Certified Material/Break Points Controlled Shipping (if required) Email Issue Communication Template (GM1927-65a)

Customer for Deliverables: GM Manufacturing, Assembly centers/SPO/other receiving locations, Supplier Quality.

Necessary Inputs: Source of Input:Problem description Assembly Center/SQ /QEGlobal Customer Audit (GCA) Assembly CenterDirect Run Rate, Direct Run Loss, verification stations Assembly CenterC.A.R.E. Assembly CenterShipping Hold Assembly CenterVehicle Repair Float Assembly CenterMain Line Downtime Assembly Center

Resources: Supplier Management, Supplier Quality Engineer/Supervisor, Quality Engineering, 3rd Party Provider (if applicable), PC&L/MSO (if applicable),

Task Number: 6 Task Name: Global Emerging Issue/Alert Process (Continued)Responsible Methodology:

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Assessment PhaseQE/SQ A significant quality concern is identified at a GM manufacturing location which has potential for

meeting the one or more criteria described in the global major disruption definition.QE/SQ Determine potential severity and identify appropriate stakeholders/resources.QE/SQ Immediately communicate concern to local leadership and SQ Plant Support ManagerQE/SQ Determine if other GM locations are affected and notify Quality Leadership at each locationQE/SQ Assesses which of the following situations exits:

Situation A: Supplier is located in the same region as all GM receiving locationsSituation B: Supplier is located in the same region as the detecting GM location, but ships to an additional GM location in another region.Situation C: Supplier is located in different region from the detecting location

QE/SQ Issue PRR to supplier reference GP-5Implementation Phase

QE/SQ Situation A; Contact the supplier and immediately execute the following: Complete/distribute the Emerging Issue Report:

- Translate issue into print or boundary specifications.- Establish sort criteria.- Understand potential root cause.- Understand scope of problem (when did it potentially start).- Method to certify material.- Establish break point and method to identify certified material.- Contain and certify the pipeline.- Notify receiving locations of certification ID and estimated time of arrival of certified

material.QE/SQ Situation B, Follow activities for Situation A and also send the Emerging Issue Report to the single

point contact in the affected region (reference Cross Regional Support Matrix).QE/SQ Situation C, Follow activities for Situation A and also do the following:

Send the Emerging Issue Report to the single point contact in the region responsible for that supplier (reference Cross Regional Support Matrix.)Set up a conference call with the supplier and the responsible SQE representative to execute the steps referenced in Situation A.

QE/SQ Set up subsequent conference calls to complete activities.Monitor and Check Phase

QE/SQ Clearly understand the roles and responsibilities for subsequent tasks.QE/SQ Subsequent activities outside the scope of this task include:

-Verify the break point is still intact - Drill Deep Wide Worksheet analysis (GM1927-84)

-Verification of root cause -Corrective ActionAdditional process controls (error proofing, layered auditing, etc.)

Regional SQ Travel to Supplier’s Location to confirm containment and corrective actionsSupplier Communicate the Emerging issue to all affected Customer Locations.

Execute activities specified in “Situation A”.Drill Deep Wide Worksheet analysis (GM1927-84)Timely containment and response to PRR per GP-5Attend all Conference calls as required.Participate in any/all follow up reviews/audits at the Supplying location.

Reference Documents:GP-5Global Emerging Issue Alert (GM 1927-65)Email Issue Communication Template (GM1927-65a)Drill Deep Wide Worksheet analysis (GM1927-84)Global Emerging Issue Definition

* SQE denotes GM Supplier Quality Engineer, SQA, or approved GM SQ Representative. **Completion of the various activities in this task may require the collaboration of a number of

QE’s /SQEs. It is critical that these QE’s/ SQE’s understand their roles and deliverables.

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Task Number: 7

Task Name: Major Disruption Prevention – (as per GP-5)

Task Owner: GPSC – Current Supplier Quality

Task Timing: Throughout the life cycle of the product

Task Description: The intent of this task is to drive proactive activity into selected suppliers to identify and minimize risk of emerging issues and (Major Disruptions) through data analysis, process reviews, and leadership engagement.

Additional Description: The Major Disruption Prevention Plan consists of the following elements:

Conference for selected suppliers On-site visit at selected suppliers

Key Deliverables: Process Control Plan Audit (GM 1927-16) on highest risk process or product value stream. Dock Audit Problem Solving Process for Technical Root Cause Effective Systemic Root Cause Analysis (3X5 Whys Drill Deep GM 1927-84) (Read Across Drill Wide GM1927-69) Verification of Corrective Action Implementation Verification of Lessons learned (PRR Read Across) Utilization of Tools as Appropriate

RPN Reduction Process GP-12 CS1 and CS2 QSB (GM 1927-30) (85% no red items) Process Specific Audits Special Process Audits

Criteria for Application: History of PRR,s 6 Panel Data trending beyond acceptable targets for commodity Suppliers who have had quality Major Disruptions and/or emerging issues Unsatisfactory score for PCPA or QSB resulting in “Red Status” CT Metrics Tool Performance Launch issues

Customer for Deliverables: Creativity teamGM Assembly/Manufacturing PlantsSupplierSupplier Quality Management

Necessary Inputs: Source of Input: Supplier Performance Data (6 Panel Charts, etc.) Supply Power PRR detail review GQTS/Supplier GM Assembly/Manufacturing Plant metrics SQE Internal/External Data Analysis Supplier/SQE

Task Number: 7 Task Name: Major Disruption Prevention – (as per GP-5) (Continued)

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Resources: Supplier, Quality Engineer, GM Assembly Plant Personnel, and Supplier

Responsible Methodology:SQ Leadership

Select Suppliers for targeted Major Disruption prevention activityTrain SQE’s relative to expectations and required auditsAssign SQE’s to selected suppliers

SQE Review performance of assigned selected suppliers and identify parts/processes of high risk.Make arrangements to have supplier prepare Drill Deep (3X5 Whys) and PRR Read Across, (ref GP -5) for identified issues prior to SQE’s visit.Make arrangements to have supplier review their Major Disruption Prevention Plan during SQE’s visit.

Supplier Document the Systemic root cause of the identified issue on the (3X5 Whys Drill Deep) document consists of the following:

Manufacturing – Why did the manufacturing process not prevent the defect from being produced?

Quality – Why did the quality process not detect the defect and prevent it from escaping the process?

Planning – Why did the planning process not predict and prevent the defect? Documents implementation of lessons learned by completing the PRR Read Across matrix. Updates their Major Disruption Prevention Plan to: Predict potential areas of risk by reviewing internal/external data. Prevent the nonconformance through manufacturing controls. Protect/detect the nonconformance by enhancing the quality system. Develops and reviews action plan with SQE(GM1927-79)

SQ Leadership/SQE

Conduct Supplier conference with Executive leadership of Supplier Review Major Disruption Prevention Plan Clearly present expectations, deliverables, and consequences.

SQE Conducts on-site visit of assigned suppliers. Ensure supplier uses a disciplined approach in determining Technical Root Cause Analysis and

corrective action verification (Compliant with GP-5 Process). Conduct Drill Deep (3X5 whys) on selected issues/PRR,s to ensure a thorough understanding of systemic root causes. Use the Drill Deep Root Cause Pareto analysis tool to reveal Systemic issues and complete an action plan to address.

Conducts a Process Control Plan Audit on highest risk process or product value stream to verify the following:

Operator Instructions /standard work being followed. Control Plan Execution. Error Proofing effectiveness and verification. Corrective action implementation and effectiveness. FMEA’s control plans, and operator instructions have been updated. GP-12 or containment areas. Conducts a Dock Audit For selected high-risk parts, review material that has been labeled and is ready to ship for possible

defects. Referencing previous problems noted in PRR’s is advisable. Ensure that supplier has a routine process for doing dock audits. If concerns are identified, ensure appropriate actions are taken for the specific issues. This may

include Supplier Action Plan, GP-12, or execution of controlled shipping Level 1 or level 2. Completes a PCPA or QSB Action Plan and provides to the SQ Leadership. Conducts a QSB audit to verify the suppliers quality system supports the prevention of major

disruptions.

Task Number: 7 Task Name: Major Disruption Prevention – (as per GP-5) (Continued)

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Reference Documents: GP-5 GP-8 GP-12 Supplier Quality SOR GM1927-3, Part Specific Quality SOR (GM1927-03a-name) Drill Wide Matrix (GM 1927-69) Drill Deep Worksheet (GM 1927-84) RPN Reduction Summary (GM 1927-21) Supplier Action Plan Form (GM 1927-79) PCPA Audit (GM1927-16) QSB Audit (GM1927-30), QSB Workshop (GM1927-36) PCPA (GM1927-16a-name) Specific Process Audits (LINK) CT Metrics Tool (For GM Internal Use Only) (LINK)

* SQE herein refers to GM Supplier Quality Engineer or approved GM SQ Representative

Task Number: 8

Task Name: Controlled Shipping Level 1 (CS1)

Task Owner: Supplier Quality Engineer (SQE)

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Task Timing: Current Production, response to Supplier quality concerns

Task Description: Controlled Shipping Level 1 is a demand by Customer that a supplier put in place a redundant inspection process at the supplying location to sort for a specific and specified nonconformance, implement a root-cause and problem solving process, and isolate Customer from the receipt of nonconforming parts/material. The redundant inspection is in addition to normal controls, is enacted by the supplier and must be in addition to the normal production process controls. Suppliers that provide products to multi-regions will require that the GM SQ in the supplier region provide global lead during their regional supplier’s CS1 process.

Additional Description: The data obtained from the redundant inspection process is critical as both a measure of the effectiveness of the secondary inspection process and the corrective actions taken to eliminate the initial nonconformance. Recurrence for the same failure mode at the Customer Manufacturing Centers during the CS 1 process is another measure of the effectiveness of the corrective actions and containment process.

Criteria for Application (any of the items below may be considered): Repeat PRR’s Supplier’s current controls are not sufficient to ensure conformance to requirements Duration, quantity, and/or severity of the problem Internal/External Supplier data Quality Problem in the field (i.e. PRTS, Warranty, JD Power) Major Disruptions

Key Deliverables: Certified Material to the Customer facility Problem solving capability to establish root cause I-Chart (GM 1927-66) to demonstrate product quality conformance (nonconforming vs.

quantity checked) Documented and verified Corrective Action Additional process controls to prevent future occurrences Revised PCPs, PFMEA, Standardized work instructions as required CS1_CS2_Exit_Checksheet (GM 1927-54) Controlled Shipping Level 1 Entry letter (GM 1927-55) Controlled Shipping Confirmation Reply Form (GM 1927-53) Corrective Action Report from supplier Controlled Shipping Level 1 Exit Letter (GM 1927-56) Approved DDW and DDW Read Across (GM 1927-84 and GM 1927-69)

Customer for Deliverables: Customer Assembly/Manufacturing Centers, SQE

Necessary Inputs: Source of Input:Problem Reporting and Resolution (PRR) Mfg/Assembly Centers/SQE / GQTSRequest for Entry into CS1 Mfg/Assembly Centers/SQE / GQTS

Resources: Customer Plant Quality/Reliability Department, Customer Supplier Quality Engineer, Buyer, and Supplier

Task Number: 8 Task Name: Controlled Shipping Level 1 (CS1) (Continued)

Responsible Methodology:SQE Assessment Phase

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Manufacturing Center/SQE make a request for CS1, referencing the non-conformances identified either at the Customer Plant or at the supplier facilities.SQE reviews the request to ensure it complies with the criteria for application, and if applicable, makes the decision to place the supplier in CS1. This decision may also involve a SQ Manager.

SQE

Supplier

Entry/ Implementation PhaseSQE verbally notifies the supplier they are being placed in CS1 and that a confirmation letter will follow.SQE enters the CS1 record into GQTS to allow the system to deliver the entry letter to the supplier automatically. (For export compliance suppliers a written entry letter must be issued by the SQE – template in GMSP – Quality GM1927- 55)SQE conduct the CS 1 kick off meeting (via conference call or on site meeting) to:

- Review the non-conformance that resulted in the CS1 entry. - Review and approve the supplier’s containment process which includes:

Data collection utilizing an I-chart (GM1927-66). Communication back to Customer (including frequency). Control of non-conforming product. Lay out and inspection equipment

- Review and approve the supplier’s escalation/reaction plan for the containment activity. - Establish boundary samples (if applicable) and/or specifications for acceptance/rejection

of the parts.- Establish exit criteria for the CS1. Default criteria as follows:

20 consecutive working days of data (from the date of implementation of permanent corrective action) which verifies that the normal production controls are effective for controlling the discrepancies identified in the Controlled Shipping activity.

Documentation showing the root cause was identified and verified. Documentation indicating that corrective action was implemented and

validated. Copies of all documentation revised as required (Control plan, FMEA’s,

Process Flow, operator instructions, etc.) Documentation indicating that every effort was taken to implement error

proofing. Documented evidence DDW/Read across completed to close PRR

SQE requests the support of the Customer buyer if the supplier is uncooperative in implementing CS1 to Customer’s requirements.

Implement CS 1 based on the requirements defined on the entry letter and confirmed by the SQE during the kick off meeting.Notify additional GM facilities that use the same part, inform them of the nonconformance, and provide containment activities as necessary.Track breakpoints of nonconforming material. (Purge pipeline of suspect material, i.e. at Customer’s facility, in transit and at all storage locations.)Commence the sort activities and display the results in a public and visible location.

Supplier

SQE

Monitor and Check PhasePerform a redundant inspection of all suspect non-conforming products per the agreed upon process and ensure defect free parts/material are delivered to Customer ad document inspection results on the I chartsDetermine and demonstrate the root cause to the Customer SQE.Develop, implement and validate the permanent corrective actions, along with improved process controls (i.e., error proofing, layered audits, setup checklists, standardized work, operator training and certification program, etc.) and update all the applicable documents like PFMEA, PFD, etc.Conduct a daily management meeting at the sort location to review the results, ensure the corrective actions taken are effective, and plan required changes.

Task Number: 8 Task Name: Controlled Shipping Level 1 (CS1) (Continued)

Monitor supplier’s containment data (I-chart.)Verify the supplier has a documented process control validation program in place (such as job setups, setup

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error proofing, process error proofing, layered auditing, operator training & certification etc.)

Supplier

SQE

Verification for ExitMeet the defined exit criteria.Request exit from Controlled Shipping - Level 1 and provide supporting documentation and assessments on performance and corrective actions to the appropriate Customer representative (Customer plant representative will be notified if required).

Verify that the supplier has met all exit criteria. The Supplier is removed from CS1 after all exit criteria are met and the established time has expired without further non-conformances at the Customer Assembly /Manufacturing Center, or coming out of the Supplier’s process. Notify the supplier verbally that they have met the criteria and that they will be removed from CS1 upon receipt of the CS1 exit letter. Issue a Controlled Shipping Exit letter to the supplier into GQTS. (For export compliance suppliers a written exit letter must be issued by the SQE – template in GMSP – Quality GM1927- 56)

Reference Documents:GP-5 I-Chart (GM 1927-66)CS1_CS2_Exit_Checksheet (GM 1927-54)Controlled Shipping Level 1 Entry letter (GM1927-55)Controlled Shipping Confirmation Reply Form (GM1927-53)Controlled Shipping Level 1 Exit Letter (GM1927-56)Drill Deep & Wide (GM 1927 – 84)Drill Wide Matrix (GM 1927 – 69)Drill Deep & Wide Audit (GM 1927 – 85)

*SQE in this document refers to the SQE, QSE, or other approved Customer Representative**SQ Manager in this document refers to a SQ Manager or other Customer Manager*

Task Number: 9

Task Name: Controlled Shipping Level 2

Task Owner: Supplier Quality Engineer (SQE)

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Task Timing: Current Production, response to Supplier Quality concerns

Task Description: Controlled Shipping Level 2 is a Customer requirement to a supplier to put in place a 3rd party redundant inspection process to sort for a specific nonconformance, while maintaining Controlled Shipping Level 1, and implementing a root-cause problem solving process. The redundant inspection is in addition to normal controls and Controlled Shipping Level 1. Suppliers that provide products to multi-regions will require that the GM SQ in the supplier region provide global lead during their regional supplier’s CS2 process.

Additional Description: The 3rd party or a Customer representative will perform assessment audits. The data obtained from the 3rd party redundant inspection process as well as the audits are critical as both a measure of the effectiveness of the secondary inspection process and the corrective actions taken to eliminate the initial nonconformance.

Criteria for Application (any of the items below may be considered): Repeat PRRs Supplier’s current controls are not sufficient to ensure conformance to requirements Duration, quantity, and/or severity of the problem Internal/External Supplier data Controlled Shipping Level 1 failures Major Disruptions Quality Problem in the field (i.e. PRTS, Warranty, JD Power)

Key Deliverables: Certified Material to Assembly Plant Problem solving capability to establish root cause I-Chart (GM 1927-66) to demonstrate product quality conformance (nonconforming vs. quantity

checked by a 3rd party) Documented and verified irreversible corrective actions and additional controls to prevent future

recurrences Revised PCP’s, PMEA, Operator Instructions as required Approved DDW and Read Across (GM 1927-84 and GM 1927-69)

Customer for Deliverables: Customer Assembly/Manufacturing Centers, SQE

Necessary Inputs Source of Input:Problem Reporting and Resolution (PRR) Mfg/Assembly Centers/SQE / GQTSRequest for entry into CS2 Mfg/Assembly Centers/SQE / GQTS

Resources: Customer Plant Quality/Reliability Department, Customer Plant Supplier Quality Engineer, Buyer, Tier1 supplier, and 3rd Party Provider

Task Number: 9 Task Name: Controlled Shipping Level 2 (Continued)

Responsible Methodology:SQE Assessment Phase

Manufacturing Center/SQE make a request for CS2, referencing the non-conformances identified either at the Customer Plant or at the supplier facilities.SQE reviews the request to ensure it complies with the criteria for application, and if applicable, makes

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the decision to place the supplier in CS1. This decision may also involve a SQ Manager. SQE

Supplier & CS 3rd Party

Provider

Entry/ Implementation PhaseSQE verbally notifies the supplier they are being placed in CS2, that a confirmation letter (GM1927-53) will follow and that they must contract a GM approved 3rd party CS Provider (Posted in GM SupplyPower – Quality Library – 3rd Party Provider Management)

SQE enters the CS2 record into GQTS to allow the system to deliver the entry letter to the supplier automatically. (For export compliance suppliers a written entry letter must be issued by the SQE – template in GMSP – Quality GM1927- 57)

Supplier select and contacts a Controlled Shipping 3rd party (provider) and issues a purchase order for Controlled Shipping Level 2 activities within 24 hours of receiving the CS2 letter.

Supplier returns confirmation letter to the SQESQE conduct the CS 2 kick off meeting (via conference call or on site meeting) with the Supplier’s Quality Manager and Plant Manager to: Review the non-conformance that resulted in the CS2 entry.

- Review and approve the supplier’s containment process which includes: Control of non-conforming product. Lay out and inspection equipment

- Review and approve the CS 2 Third Party’s containment process which includes: Data collection utilizing an I-chart. Communication back to Customer (including frequency). Inspection instructions Material identification after inspection

- Review and approve the supplier’s escalation/reaction plan for the containment activity.

- Establish boundary samples (if applicable) and/or specifications for acceptance/rejection of the parts.

- Establish exit criteria for the CS2. Default criteria as follows: 20 consecutive working days of data (from the date of implementation of

permanent corrective action) which verifies that the normal production controls are effective for controlling the discrepancies identified in the Controlled Shipping activity.

Documentation showing the root cause was identified and verified. Documentation indicating that corrective action was implemented and

validated. Copies of all documentation revised as required (Control plan, FMEA’s,

Process Flow, operator instructions, etc.) Documentation indicating that every effort was taken to implement error

proofing. Documented evidence DDW/Read across completed to close PRR

SQE requests the support of the Customer buyer if the supplier is uncooperative in implementing CS2 to Customer’s requirements.

Implement CS 2 based on the requirements defined on the entry letter and confirmed by the SQE during the kick off meeting.Notify additional GM facilities that use the same part, inform them of the nonconformance, and provide containment activities as necessary.Track breakpoints of nonconforming material. (Purge pipeline of suspect material, i.e. at Customer’s facility, in transit and at all storage locations.)Task Number: 9 Task Name: Controlled Shipping Level 2 (Continued)

Supplier & CS 3rd Party

Provider

Entry/ Implementation PhaseCommence the sort activities and display the results in a public and visible location. The 3rd Party Provider performs an additional redundant inspection of all suspect non-conforming products per the agreed upon process to ensure defect free parts are delivered to Customer.

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If applicable, 3rd party Provider Quality Engineer or Customer SQE to reviews the Supplier’s process and quality history, and completes the Assessment. Supplier submits irreversible corrective action plans to the ISO/TS16949 registrar for review and/or assessment and authorizes ISO/TS16949 registrar to submit the review and/or assessment findings to the Customer.

Supplier

SQE

Monitor and Check PhasePerform a redundant inspection of all suspect non-conforming products per the agreed upon process and ensure defect free parts/material are delivered to Customer ad document inspection results on the I chartsDetermine and demonstrate the root cause to the Customer SQE.Develop, implement and validate the permanent corrective actions, along with improved process controls (i.e., error proofing, layered audits, setup checklists, standardized work, operator training and certification program, etc.) and update all the applicable documents like PFMEA, PFD, etc.Conduct a daily management meeting at the sort location to review the results, ensure the corrective actions taken are effective, and plan required changes. Provide the 3rd Party provider the elements required to perform the CS 2 inspection according to the requirements established by the SQE (inspection area, lighting, inspection tables, etc)

Monitor supplier’s containment data (I-chart.)Verify the supplier has a documented process control to ensure the problem (failure mode) reported by the Customer will never happen againVerify supplier’s root cause analysis and corrective actions.Resolve any discrepancy in the interpretation of the inspection criteria between the supplier and the 3rd Party ProviderInterface between the supplier and the CS 2 Third Party provider to ensure the CS 2 process is conducted without interruptions.

Supplier

SQE

Verification for ExitMeet the defined exit criteria.Request exit from Controlled Shipping - Level 2 and provide supporting documentation and assessments on performance and corrective actions to the appropriate Customer representative (Customer plant representative will be notified if required). Upon exit of CS2 the supplier should complete the CS2 Exit Survey 3rd Party Provider Services GM1927-58a and send to the GM Regional 3rd Party Provider representative.

Conduct PCPA Audit, if applicable.Verify that the supplier has met all exit criteria. (Assessment may be performed by the 3 rd party.) The Supplier is removed from CS2 after all exit criteria are met and the established time has been completed without further non-conformances at the Customer Assembly /Manufacturing Center or coming out of the Supplier’s process. Notify the supplier verbally that they have met the criteria and that they will be removed from CS2 upon receipt of the CS2 exit letter.Complete a CS2 exit checklist (as required) (Distribute exit check sheet to any additional Customer resources who have responsibility for letter creation and distribution, if applicable.)Issue a Controlled Shipping Exit letter to the supplier into GQTS the system will deliver the exit letter to the supplier automatically. (For export compliance suppliers a written exit letter must be issued by the SQE – template in GMSP – Quality GM1927- 58)

Reference Documents:GP-5Kick-off Meeting Worksheet (GM 1927-59)Controlled Shipping Level 2 Entry Letter (GM 1927-57)Controlled Shipping Confirmation Reply Form (GM 1927-53)

Task Number: 9 Task Name: Controlled Shipping Level 2 (Continued)

Reference Documents: (Continued)I-Chart (GM 1927-66)Controlled Shipping Assessment (GM 1927-52)Assessment Matrix (GM 1927-51)Supplier Action Report (GM 1927-79)September 21, 2009 74 GM1927

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Controlled Shipping Verification/Release/Exit worksheet GM 1927-54 (optional)Controlled Shipping Level 2 Exit Letter (GM 1927-58)Controlled Shipping Level 2 Exit Supplier Survey 3rd Party Provider (GM1927-58a)Drill Deep & Wide (GM 1927 – 84)Drill Wide Matrix (GM 1927 – 69)Drill Deep & Wide Audit (GM 1927 – 85)

*SQE in this document refers to the SQE, QSE, 3rd Party PQE, or other approved Customer Representative**SQ Manager in this document refers to a SQ Manager or other Customer Manager*

Task Number: 10Task Name: Supplier Performance Review Meetings

Task Owner: GPSC – Current Supplier Quality

Task Timing: Throughout the life of the product

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Task Description: Formal meetings between the leadership of the Supplier and the leadership of GM to review the Supplier’s quality performance and actions for driving improvement. This task describes 3 types of meetings, each with specific drivers, which engages leadership involvement to improve supplier performance.

Criteria for Application: Supplier Performance Review – focus is generally a supplier manufacturing Duns

performance to a specific GM Assembly/Manufacturing plant. Attendance includes the GM Plant QE and or QE lead, QE and or SQ Manager, the GM Plant Manager and/or Quality Manager, and the Supplier’s General/Plant Manager and Quality Manager.

Supplier Quality Improvement Meeting – focus is typically a supplier’s ultimate duns performance to GM. Attendance includes the GM Supplier Quality

Director(s)/Group Director, GM Supplier Quality Manager(s), the Supplier’s CEO/President, Corporate Quality Director, VP Manufacturing. Plant Disruption Review Meetings – focus is on the assembly plant disruption caused by a

supplier manufacturing Duns location. Attendance should include the GM Supplier Quality Director(s), GM Purchasing/Commodity Director and/or Manager, GM buyer, GM Supplier - Quality Manager(s), the Supplier’s CEO/President, Corporate Quality Director, VP Manufacturing. Assembly Plant Quality i.e QE, QE Manager, Quality Manager

Key Deliverables: Supplier presentation of problem definition, root cause and corrective action taken to protect

GM and its customers from failure modes and or quality defects as described in the SPR notification supplied by GM.

Supplier action plan. 5 Why and read across summary.

Customer for Deliverables: GM Assembly/Manufacturing Plant Quality, GM Supplier Quality Engineer/Manager/Director/GM Purchasing Commodity Manager/Director

Necessary Inputs: Source of Input:Supplier Performance Report (6 panel) Supply PowerPRR Analysis Summary Supply Power / GQTSGM Assembly Plant/3rd Party quality data Plant QE/3rd PartyAPQP SQELaunch SQESupplier’s Internal / External Data Analysis Supplier / SQE/QEDrill Deep/Read Across Supply Power / Supplier

Resources: Supplier Quality, Purchasing, Supplier, GM Assembly Plant Personnel

Task Number: 10 Task Name: Supplier Performance Review Meetings (Continued)

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Responsible Methodology :SQE/QE Pre-Meeting preparation.

Reviews 6-month PRR history, 6-panel charts, and other reports for targeted supplier to identify trends.

Creates a Pareto for quality non-conformances to identify repeat issues and/or major causes of customer dissatisfaction.

Issue notification letter inviting the supplier to the meeting. (Suggested format) Prepare a presentation package for review at the meeting with:

- Meeting agenda (suggested format)- Supplier Performance Report (6-panel)- Supplier’s performance metrics to the GM Assembly/Manufacturing Plant(s).- Supplier CT Bid list (optional)

SQE/QE Conduct Meeting. SQE/QE kicks off the meeting by presenting the agenda. The agenda should include:

- Safety evacuation procedure- Participant introductions (an attendance list to be completed by all participants)- Intent and expectations

SQE/QE SQE/QE reviews the Supplier’s performance and specific issues as appropriate (6 panel data, GM Plant impact, warranty /field performance)

Supplier Supplier presents their information, which should detail:- Pareto analysis of their failures – locations, products, modes- Root cause analysis of failures, if applicable- Specific corrective actions to address the failures- Systemic changes to address poor performance- Propose a quality improvement glide-path with sufficiency plans

SQE/QE For a plant disruption meeting, review the details of the disruption and the impact on the GM plant.

Supplier For a disruption meeting, review the root cause, the failures in their process, 5 why /read across and their corrective actions.

SQE/QE Reviews any open cost recoveries, review open items, assignments, owners and follow-up dates, establish date for follow-up meeting, if necessary.

Supplier Monitor and check. Drive and documents systemic improvements in the organization. Develops implements and tracks an action plan to resolve open issues.

SQE/QE Tracks progress, reviews improvements, and verifies implementation. Conducts follow-up as required.

Reference Documents: Supplier Action Plan (GM 1927-79) SPR Agenda (GM 1927-76) SPR Invite letter template (GM 1927-76a) Disruption Agenda (GM 1927-75) Supplier Presentation Template Drill Deep/Read Across (1927-69, 1927-84, 1927-85, 1927-86)

* SQE denotes GM Supplier Quality Engineer or approved GM SQ Representative

Task Number: 11

Task Name: 3rd Party Provider Process

Task Owner: GPSC – Supplier Quality

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Task Timing: On-going / Support GM Assembly Centers

Task Description: The 3rd Party Provider Approval Process is used to maintain qualified and approved 3rd party providers to support and protect the GM Assembly Centers, GM Powertrain and GM Metal Centers sites from receiving products that have been identified as not acceptable and require special inspection, and handling. Reference ESEP (Enhanced Supplier Engagement Process) in North America, QCC (Quality Confirmation Center) in GME while other regions may have the same or slightly different 3rd Party Containment also SQ Quality Manual 1927 – Task 12 Section Launch. The 3rd Party Providers are also used to improve supplier quality performance by offering the GM approved supplier specific workshops (LEP-Label Error Proofing, QSB-Quality Systems Basics, DDW-Drill Deep & Wide). GM shall conduct purchasing quotes for the services offered by suppliers as the market or need exist. GM will establish a maximum rate for specified services based on the purchasing quotes for ESEP / QCC services, Controlled Shipping Level II, various Workshops and audits. The 3rd Party is hired by the supplier and located at the supplier manufacturing site, another supplier location or ESEP / QCC provider site as agreed upon by the 3rd party provider and or the GM assembly customer. The contract for services is between the supplier and the 3rd party and is not GM, therefore GM will not be liable for any cost, damages or delays in the normal flow of production shipments. GM Approved 3rd Party Providers must not exceed the agreed upon capped service rates for the services they will provide the GM assembly center and GM suppliers – violation of exceeding quoted rates will result in removal from the GM Approved Third Party Provider listing. Regional SQ and the GM Assembly Centers (includes Powertrain, and Metal) will and can evaluate their regional 3rd Party Providers and remove providers from their approved list based upon their agreed local procedure or their criteria established by their region.

Key Deliverables: Immediate supplier response to GM quality concerns using GM Approved 3rd party

providers GM provides listing Approved 3rd Party Providers that supplier can select and enter in

contract with. Sustained quality containment and quality improvement using GM approved providers to

handle ESEP / QCC services, Controlled Shipping Level II or specific Approved GM Workshop or GM Audits.

Reduced cost of services based on services quoted and max. capped rates, hourly rates and or piece price rate charges.

Customer for Deliverables: GM Assembly Center or GM Plant, Supplier Quality,

Necessary Inputs: Source of Input:Provide list of potential new and current Approved 3rd Party Providers GPSC SQ / Buyer / Other Provide SOR of the services needed to GM buyer for RFQ GPSC Buyer / SQPre-RFQ the potential new and old for each of the services GPSC Buyer / SQDetermine approved list based on price / quality / service / experience GPSC Buyer / SQ3rd Party Provider Agreement of services (ESEP / QCC, CSII, Workshops) 3rd Party Providers / GM Customers / SQ

/ BuyerSupplier placed on ESEP / QCC or Controlled Shipping Level II GM Assembly CenterSupplier selection of GM Approved 3rd Party Provider CSII Supplier / GMSP QualitySupplier selection of 3rd Party Provider Contract Established SupplierSupplier Quality Performance needs improvement – workshop SQ / Supplier / GM CustomerSupplier selection GM Approved Workshop Provider or Specific Audit Supplier Evaluation of new and old GM Approved 3rd Party Providers GPSC Buyer / SQPRR’s Problem Reporting Resolution GQTSControlled Shipping Level 1 and Level 2 GQTS

Resources: Supplier Quality, 3rd Party Provider, Supplier, Purchasing, GM Assembly Center / Plant Personnel

3 rd Party Provider Methodology: (GM Approved CS2 Providers only)Responsible Methodology:SQ Regional Determines how many 3rd party providers need to be on the approved list – regional for such services

– Controlled Shipping Level II See Quality Statement of Requirements (SOR) for 3 rd Party Providers for Controlled Shipping Level 2 & Other Services (Workshops)

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SQ / GM Buyer (Regional)

Creates and approves SOR (Statement of Requirements) for the 3rd Party Provider services that can be sent to potential providers.

Global Process SQ

Communicate Technical requirements / criteria for provider selection via Tech Review Checklist Compliance to the Quality Statement of Requirements (SOR) for 3 rd Party Providers

for Controlled Shipping Level 2 Understanding of GP-5 Pricing ISO 9001 Certification Geographic Footprint Engineering Capabilities Training Capabilities Containment – CS2, Duration, Escapes, PRR Performance Special Services Requesting Approval in other countries

SQ / GM Buyer (Regional)

Coordinates with the GM buyer to conduct Pre-RFQ, Tech Review and agreement of SOR or scope of service expectations and recommendation for services based quality, service, competitive price, experience and proper resources as requested by the GM supplier base as needed.

Potential 3rd Party Provider

Provide company presentation of the services that they offer, their current customers, shared best practices, survey results or awards, company global or regional footprint that must have a local office in the country providing services, skill set matrix of their employees providing services, identify master trainer and lead trainers, certification plan and evidence of demonstrated capability of the services quoting.

Potential 3rd Party Provider / Supplier

Approved 3rd Party Providers will understand GM GP-5 procedure, understanding of Controlled Shipping (CS) Level II process and timeline requirements and the requirements to provide standardize work in a timely manner. Supplier and 3rd Party Provider will ensure effective corrective action for the PRR/failure mode that the CS II was initiated. Ensure that other GM problem solving or other problem solving / resolution tools are used such as DDW, Read Across, Red X, and or others. Providers must have a procedure for the certification of Provider Quality Engineers (PQE) or a PQE Certification process, layered audits shall be conducted by the 3rd party provider and or GM.

SQ / GM Indirect Buyer (Global / Regional)

GM buyer / SQ will agree on services capped rates that the 3rd Party Providers can charge the supplier for the services that they are contracted to perform. GM will determine either capped rates or the specific rates for the different services.

SQ Group Overall responsible for the Approved 3rd Party Provider process using the voice of the customer feedback / supplier history last 12 months, the requirements being met, the evaluation of the services provided to other OEM’s and or other customers. Customer surveys and letters from other customers regarding the 3rd Party Provider customer satisfaction status.

Global Process SQ

Maintains the Global GM Approved 3rd Party Providers listing and postings in GM SupplyPower Quality Library – 3rd Party Provider Management – Services. Maintains the Approved CS2 Providers in GQTS (Global Quality Tracking System)

Supplier Provide GM SQ and or GM customer the 3rd Party Provider Customer Satisfaction Survey feedback GM1927-58a regarding the services provided by the 3rd party provider.

Global Process SQ

Review current Controlled Shipping services being provided, monitor exit timing and cost on-site review of the services being performed. Layered audit of the services provided to the supplier.

Newly Approved 3rd Party Providers (Regional)

Provider conducts required number of pilots for the services contracted for and includes layered audits along with customer survey or as determined by the regional SQ group to validate that the required services are being met.

3rd Party Provider

3rd Party Provider

Other requirements include – -Financial Stability and ability to provide adequate resources, -Geographic footprint with the ability to implement containment activities in various geographic footprint / locations, Single-point coordinator that will deploy resources and manage communication with GM and the supplier, 3 rd Party Provider Methodology : (GM Approved CS2 Providers only) (Continued)

-Evidence of current ISO9001 certification, -Containment capabilities with performance data regarding performance to GM and other OEM’s for

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effective containment, duration of containment and failure to contain.-Engineering Capabilities that demonstrates quality engineering performance in the major OEM and tier 1 automotive market, ability to complete analysis and corrective actions for clients and effectiveness quality engineering work-Training & Education capabilities shall have employees with the appropriate level of education & training to perform effective provider containment/sorting services, quality engineering services, and maintaining quality data, and other required documents.

GM Assembly Center / SQ / SQ Group

GM Customer could or shall write Customer Satisfaction PRR’s to the Controlled Shipping II providers if the non-conforming material inspection has escaped the 3rd Party Provider containment process. Reference potential steps to exit criteria a GM Approved 3rd Party Provider can be done by conducting periodical assessment annually or at a frequency that has been determined by the specific GM region.The following 3rd Party Provider performance criteria may be used to evaluate the New 3rd Party Providers during the first 6 months or as determined by the GM region for CS2, Workshop-QSB, LEP and DDW; -Issue Customer Satisfaction PRR to 3rd Party Provider of CSII . PPM Improvement : Deterioration . Major Disruptions : more than 1 . Repeat CS2 : more than 2 times . Supplier Feedback Results : Red . SQ Layered Audit Results : Red

Reference Documents:GP-5Quality Statement of Requirement (SOR) for the 3rd Party Providers for Controlled Shipping Level 2 & WorkshopsGM Approved 3rd Party Providers – CS2 & Workshops (GM SupplyPower – Quality Library)3rd Party Provider Management Reference Manual – Controlled Shipping Level 2Workshop Deployment Process – QSB/DDW/LEP FlowchartQSB – Workshop Supplier Overview Materials, GM1927-30, GM1927-36DDW – Workshop Materials, GM1927-84, GM1927-85 and GM1927-69LEP – Workshop Materials (providers creates – must receive GM approval)CS2 Exit Customer Satisfaction Survey 3rd Party Provider GM1927-58aGM Approved 3rd Party Providers – ESEP / QCC Providers (GM SupplyPower – Quality Library)Quality Statement of Requirement (SOR) for the Enhanced Supplier Engagement Process (ESEP) / QCC (Quality Confirmation Center – GME) - posted in GMNA Quality websiteESEP Rasic Process Chart - posted in GMNA Quality websiteESEP Controlled Shipping Level II Interaction Flow Chart – posted in GMNA Quality websiteESEP Process For Metal Center Issues – posted in GMNA Quality websiteESEP Tracking Form & Kickoff Form – posted in GMNA Quality websiteQCC (Quality Confirmation Center – GME) – refer to GME websitesReference only –Global SQ Manual GM1927 - Launch Task 12, Third Party Containment (ESEP)

*SQE in this document refers to the SQE, QSE, 3rd Party PQE, or other approved Customer Representative**SQ Manager in this document refers to a SQ Manager or other Customer Manager*

3 rd Party Provider Methodology: (GM Approved Workshop Providers Only - QSB, LEP, DDW only)Responsible Methodology:SQ Regional Determines how many 3rd party providers need to be on the approved list – regional for such services,

QSB (Quality Systems Basics) Workshops, Label Error Proofing Workshops, Drill Deep & Wide Workshops. See Quality Statement of Requirements (SOR) for 3 rd Party Providers for Controlled Shipping Level 2 & Other Services (Workshops)

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SQ / GM Buyer (Regional)

Creates and approves SOR (Statement of Requirements) for the 3rd Party Provider services that can be sent to potential providers.

Global Process SQ

Communicate Technical requirements / criteria for provider selection via Tech Review Checklist Compliance to Quality Statement of Requirements (SOR) for 3 rd Party Providers

for Controlled Shipping Level 2 & Other Services (Workshops) Understanding of GP-5 Pricing ISO 9001 Certification Geographic Footprint Engineering Capabilities Training Capabilities Containment – CS2, Duration, Escapes, PRR Performance Special Services Requesting Approval in other countries

SQ / GM Buyer (Regional)

Coordinates with the GM buyer to conduct Pre-RFQ, Tech Review and agreement of SOR or scope of service expectations and recommendation for services based quality, service, competitive price, experience and proper resources as requested by the GM supplier base as needed.

Potential 3rd Party ProviderWorkshops

Provide company presentation of the services that they offer, their current customers, shared best practices, survey results or awards, company global or regional footprint, skill set matrix of their employees providing services, identify master trainer and lead trainers, certification plan and evidence of demonstrated capability of the services quoting.

Potential 3rd Party Provider Workshops

Potential 3rd Party Provider Workshops

Approved 3rd Party Providers will understand GM GP-5 procedure, understanding of Controlled Shipping (CS) Level II process. 3rd Party Provider and or GM will provide the workshop materials. The 3rd Party Provider will provide the sample of the workshop materials that is being presented if GM has not provided the required workshop material. 3rd Party Provider must have knowledge of GM problem solving or other problem solving / resolution tools that are used such as DDW, Read Across, Red X, and or others. Providers must have a procedure for the certification of Provider Quality Engineers (PQE) or a PQE Certification process, layered audits shall be conducted by the 3rd party provider and or GM.

SQ / GM Buyer (Regional)

GM buyer / SQ will agree on services capped rates that the 3rd Party Workshops Providers can charge the supplier for the services that they are contracted to perform. GM Regional will determine capped rates or the specific rates for the different services.

SQ Group Overall responsible for the Approved 3rd Party Workshop Provider process Global Process SQ

Maintains the Global GM Approved 3rd Party Workshop Providers listing and postings in GM SupplyPower Quality Library – 3rd Party Provider Management – Services. Maintains the Approved CS2 Providers in GQTS (Global Quality Tracking System)

Supplier Provide GM Global Process SQ and the 3rd Party Provider feedback regarding the services that the 3rd party workshop provider was contracted to conduct.

Newly Approved 3rd Party Providers Workshops (Regional)

GM Approved 3rd Party Workshop Providers must conduct Layered audit of the services they provide the GM supplier.

Newly Approved 3rd Party Providers Workshops / (Regional)

Workshop Provider conducts required number of pilots for the services contracted for and includes layered audits along with customer survey or as determined by the regional SQ group to validate that the required services are being met.

3rd Party Workshop Provider

3 rd Party Provider Methodology : (GM Approved Workshop Providers Only - QSB, LEP, DDW only) (Continued)Other requirements include – -Financial Stability and ability to provide adequate resources, -Geographic footprint with the ability to implement containment activities in various geographic footprint / locations, Single-point coordinator that will deploy resources and manage communication with GM and the supplier,

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-Evidence of current ISO9001 certification, -Containment capabilities with performance data regarding performance to GM and other OEM’s for effective containment, duration of containment and containment escapes,-Engineering Capabilities that demonstrates quality engineering performance in the major OEM and tier 1 automotive market, ability to complete analysis and corrective actions for clients and effectiveness quality engineering work-Training & Education capabilities shall have employees with the appropriate level of education & training to perform effective provider training workshop materials and maintaining other required documents.

Reference Documents:GP-5Quality Statement of Requirement (SOR) for the 3rd Party Providers for Controlled Shipping Level 2 & WorkshopsGM Approved 3rd Party Providers – CS2 & Workshops (GM SupplyPower – Quality Library)3rd Party Provider Management Reference Manual – Controlled Shipping Level 2Workshop Deployment Process – QSB/DDW/LEP FlowchartQSB – Workshop Supplier Overview Materials, GM1927-30, GM1927-36DDW – Workshop Materials, GM1927-84, GM1927-85 and GM1927-69LEP – Workshop Materials (providers creates – must receive GM approval)CS2 Exit Customer Satisfaction Survey 3rd Party Provider GM1927-58aGM Approved 3rd Party Providers – ESEP / QCC Providers (GM SupplyPower – Quality Library)Quality Statement of Requirement (SOR) for the Enhanced Supplier Engagement Process (ESEP) / QCC (Quality Confirmation Center – GME) - posted in GMNA Quality websiteESEP Rasic Process Chart - posted in GMNA Quality websiteESEP Controlled Shipping Level II Interaction Flow Chart – posted in GMNA Quality websiteESEP Process For Metal Center Issues – posted in GMNA Quality websiteESEP Tracking Form & Kickoff Form – posted in GMNA Quality websiteQCC (Quality Confirmation Center – GME) – refer to GME websitesReference only –Global SQ Manual GM1927 - Launch Task 12, Third Party Containment (ESEP)

*SQE in this document refers to the SQE, QSE, 3rd Party PQE, or other approved Customer Representative**SQ Manager in this document refers to a SQ Manager or other Customer Manager*

3 rd Party Provider Methodology: (ESEP (GMNA) / QCC GME) Responsible Methodology:GM Assembly Centers / (GMPT, Metal Center) / SQ / GM Buyer (Regional)

Determines how many 3rd party providers need to be on the approved list for the specific GM Assembly Center / GM Metal Center / GM Powertrain Assembly Center– regional for such services – ESEP (Enhanced Supplier Engagement Process) See GMNA Quality web-link of related ESEP documents or QCC (Quality Confirmation Center) in GME.http://quality.gm.com/mfg_quality/common_processes/nc_material/nc_material.html#topSee Quality Statement of Requirements (SOR) for the Enhanced Supplier Engagement Process.

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SQ / GM Buyer (Regional)

Creates and approves SOR (Statement of Requirements) for the 3rd Party Provider services that can be sent to potential providers based on input from GM Assembly Centers, GMPT Assembly and GM Metal Centers.

Global Process SQ / GM Assembly Center

Communicate Technical requirements / criteria for provider selection via Tech Review Checklist Compliance to Quality Statement of Requirements (SOR) for the Enhanced

Supplier Engagement Process Understanding of GP-5 Pricing ISO 9001 Certification Geographic Footprint Engineering Capabilities Training Capabilities Containment – CS2, Duration, Escapes, PRR Performance Special Services Requesting Approval in other countries

GM Assembly Centers / (GMPT, Metal Center) / SQ / GM Buyer (Regional)

Coordinates with the GM buyer to conduct Pre-RFQ, Tech Review and agreement of SOR or scope of service expectations and recommendation for services based quality, service, competitive price, experience and proper resources as requested by the GM supplier base as needed.

Potential 3rd Party Provider ESEP / QCC

Provide company presentation of the services that they offer, their current customers, shared best practices, survey results or awards, company global or regional footprint, skill set matrix of their employees providing services, identify master trainer and lead trainers and evidence of demonstrated capability of the services quoting.

Potential 3rd Party Provider ESEP / QCC

Approved 3rd Party Providers will understand GM GP-5 procedure, understanding of Controlled Shipping (CS) Level II process and timeline requirements and the requirements to provide standardize work in a timely manner. Must comply with the Quality Statement of Requirements (SOR) for the Enhanced Supplier Engagement Process.

GM Buyer / SQ / SQ Group GM Assembly Centers / (GMPT, Metal Center)

Overall responsible for the ESEP Approved 3rd Party Provider process shall include the specific GM Assembly Center representative, GM Buyer, Supplier Quality, and SQ Group Manager / Director. Upon all GM assembly centers agreement the GM Buyer will issue at purchasing PO# to contract the ESEP / QCC provider the specific GM location and for the contracted time. Regional contracted rates will be controlled and quoted in their specific region with their own currency.

Global Process SQ

Maintains the Global GM Approved 3rd Party Providers ESEP / QCC listing and postings in GM SupplyPower Quality Library – 3rd Party Provider Management - Services

Assembly Center / Supplier

GM Assembly Center contacts supplier regarding being placed into ESEP / QCC process and the GM representative will contact the GM contracted GM Approved ESEP / QCC provider to begin implementing problem free products to the specific GM Assembly Center(s).

Approved ESEP / QCC Provider

Provider will inspect, check, and /or test suspect material and sort to contain the defect utilizing a sort log and ESEP / QCC sort tracking form. GM shall determine the inspection criteria and provide boundary standards – the ESEP / QCC Provider and Supplier should be consulted to provide assistance. Work instructions for inspection, dimensional checking or testing are required whenever the ESEP / QCC resources are utilized – agreement by all parties is necessary. GM will verify the defects found by the ESEP provider.

Supplier Supplier is required to provide a break point to GM and the ESEP / QCC Provider for the material supplied is certified by them (supplier) which is defect free. This breakpoint needs to be for their entire pipeline and may be different for each GM plant supplied.

GM Assembly Center

3 rd Party Provider Methodology: (ESEP (GMNA) / QCC GME) (Continued) ESEP / QCC can cease at anytime that the GM Assembly Center has determined or typically not to exceed (2) two days of production material after the certified material is received to validate the effectiveness of the supplier breakpoint. If defects are found after the breakpoint from the supplier – the ESEP / QCC provider will continue until a NEW supplier established breakpoint is provided and validated.

ESEP / QCC Provider

Provider will have capabilities to provide transportation of parts (if necessary), to electronically communicate with the GM plant Production Control & Logistics group. Provider must adhere to the GM plant material delivery requirements to meet GM production schedules at the required line rates.

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ESEP / QCC Provider

Provider must provide an implementation plan to include the following dates: ready to begin ESEP / QCC, location established to perform sorting / rework and logistics / communication with the GM Assembly Center.

ESEP / QCC Provider

Other requirements include – -Financial Stability and ability to provide adequate resources, -Geographic footprint with the ability to implement containment activities in various geographic footprint / locations, Single-point coordinator that will deploy resources and manage communication with GM and the supplier, -Evidence of current ISO9001 certification, -Containment capabilities with performance data regarding performance to GM and other OEM’s for effective containment, duration of containment and containment escapes,-Education capabilities shall have employees with the appropriate level of education & training to perform effective provider containment/sorting services maintaining quality data, and other required ESEP data and documents

GM Assembly Center / SQ

Review current ESEP / QCC services being provided, monitor exit timing and cost on-site review of the services being performed. Layered audit and review of the services provided are subject to the GM Assembly Center, SQ and the supplier that the product is being contained for. GM Customer could or shall write Customer Satisfaction PRR’s to the ESEP providers if the non-conforming material inspection has escaped the 3rd Party Provider containment process. (Determined fault of the provider and not the supplier)

Reference Documents:GP-5Quality Statement of Requirement (SOR) for the 3rd Party Providers for Controlled Shipping Level 2 & WorkshopsGM Approved 3rd Party Providers – CS2 & Workshops (GM SupplyPower – Quality Library)3rd Party Provider Management Reference Manual – Controlled Shipping Level 2Workshop Deployment Process – QSB/DDW/LEP FlowchartQSB – Workshop Supplier Overview Materials, GM1927-30, GM1927-36DDW – Workshop Materials, GM1927-84, GM1927-85 and GM1927-69LEP – Workshop Materials (providers creates – must receive GM approval)CS2 Exit Customer Satisfaction Survey 3rd Party Provider GM1927-58aGM Approved 3rd Party Providers – ESEP / QCC Providers (GM SupplyPower – Quality Library)Quality Statement of Requirement (SOR) for the Enhanced Supplier Engagement Process (ESEP) / QCC (Quality Confirmation Center – GME) - posted in GMNA Quality websiteESEP Rasic Process Chart - posted in GMNA Quality websiteESEP Controlled Shipping Level II Interaction Flow Chart – posted in GMNA Quality websiteESEP Process For Metal Center Issues – posted in GMNA Quality websiteESEP Tracking Form & Kickoff Form – posted in GMNA Quality websiteQCC (Quality Confirmation Center – GME) – refer to GME websitesReference only –Global SQ Manual GM1927 - Launch Task 12, Third Party Containment (ESEP)

*SQE in this document refers to the SQE, QSE, 3rd Party PQE, or other approved Customer Representative**SQ Manager in this document refers to a SQ Manager or other Customer Manager*

Task Number: 12

Task Name: Top Focus Process

Task Owner: GPSC – Current Supplier Quality

Task Timing: Throughout the life cycle of the product

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Task Description: Top Focus is a process used to improve the quality performance of the supply base by utilizing audits, data analysis, and by driving systemic changes in the manufacturing and quality systems on the shop floor. The Process addresses systemic issues and is driven by supplier action plans and aggressive step down quality targets with consequences identified for failure to meet these targets. Leadership engagement, accountability, and escalation are key success factors.

Criteria for Application: Historically poor performing suppliers Negative impact on multiple GM Manufacturing/Assembly Centers based on quality

metrics (major disruptions, high PPM, high PRRs, Direct Run Loss, and GCA) Proactive continuous improvement activity for strategic suppliers

Key Deliverables: Process Control Plan Audit (PCPA) GM 1927-16, and or GM1927-16a-name Top Focus Process Notification Letter (Optional) GM 1927-83 Top Focus Add/Remove Form (Optional) GM 1927-82 Quad Report (GM 1927-71) Step Down Chart (GM 1927-78) Supplier Action Plans (GM 1927-79) Quality System Basic (QSB) Training GM1927-36 (Optional) Key Metric Wall Start and end date have to be defined Decision and review panel for regional Top Focus application

Customer for Deliverables: SupplierSupplier QualityCreativity Team

Necessary Inputs: Source of Input:Supplier Performance Report (6 panel) Supply PowerCreativity Team Bid List GQTSPRR Analysis Summary GQTSSupplier’s Internal Data Analysis Supplier

Resources: SQ Manager, Supplier Quality Engineer, Buyer, Supplier

Task Number: 12 Task Name: Top Focus Process (Continued)

Responsible Methodology:SQE Review performance data.

Initiate Top Focus entry request. Develop Quad Report and Stepdown Chart. Perform Audits.

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Track progress, review improvements and audit for acceptability. Execute Stepdown Consequences, as appropriate. Share best practices. Initiate controlled shipping to protect the GM Assembly Plants, when required. Engage supplier leadership. Engage SQ and Purchasing leadership as required. Initiate Top Focus exit request..

SQ Manager The SQ Manager/Supervisor conducts periodic performance reviews with the supplier, as required, to support the SQE.

Supplier Leadership commitment and accountability. Drive and document systemic improvements in the organization and quality system. Develop, implement, and track the action plan. Establish a “Key Metric Wall”. Track and meet key performance metrics. Meet the monthly Stepdown Chart targets. Establish a GREEN rating on the Creativity Team Bid List.

Reference / Additional Information / Documents:GM Supply Power (GMSP)

- QSB (Quality System Basics Audit) (GM1927-30)- Top Focus Add/Remove Form (Optional) GM 1927-82- Top Focus Process Notification Letter (Optional) (GM 1927-83)- Top Focus Training - GMSP- Quad Report Update (GM 1927-71)- Supplier Quality Step Down Chart (GM 1927-78)- Supplier Action Plan (GM 1927-79)- Process Control Plan Audit (PCPA) GM 1927-16, and or GM1927-16a-name- Quad Report (GM 1927-71)- Quality System Basic (QSB) Training GM1927-36 (Optional)

* SQE denotes GM Supplier Quality Engineer or approved GM SQ Representative

Task Number: 13

Task Name: New Business Hold

Task Owner: GPSC – Supplier Quality

Task Timing: Throughout the life of the product

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Task Description: New Business Hold is a process to escalate unresolved quality issues within the supplier's organization in order to get them successfully resolved. While on New Business Hold, that duns# will no longer be permitted to quote on new business.

Criteria for Application.(Representative examples. One or more of the following MAY result in New Business Hold):

Confirmed supplier plant disruption Unauthorized process or tool change Consequence on Step Down Chart Outcome of Supplier Performance Meeting Unresolved quality issues over an extended period of time

Key Deliverables: New Business Hold status on Creativity Team Bid List New Business Hold PRR issued in GQTS

Customer for Deliverables: Supplier

Necessary Inputs: Source of Input:Quad Report (GM 1927-71) SQE / GMSPCreativity Team Bid List GQTSPRR Analysis Summary SQE - GQTSSupplier Performance Report (6 Panel) GMSP Supplier Performance

MetricsWarranty data SQE

Resources: Supplier, Supplier Quality Engineer

Entry into NBH SQE creates/updates Quad Report, gathers supporting documentation, and submits to local

management for approval. (If a single point SQE is assigned to the supplier, they should initiate the Quad.)

SQ in the supplier region provides the Quad Report and supporting documentation to regional SQ Director for review and decision for potential review at the Global SQ Directors meeting. Potential NBH reviewed at the Global SQ Directors meeting – Executive SQ Director to review and discuss with the VP Purchasing or Commodity Executive Director.

If NBH action is rejected SQ in the region continues to work with the supplier to “Fix” performance issues and action items expected by the supplier as if they were placed into NBH.

If NBH action is accepted by the Executive SQ Director and Purchasing VP / Commodity Executive Director the SQ group that requested the NBH will be notified by the NBH Coordinator. SQ will contact the Commodity Creativity Team of the actions to place this supplier on NBH.

Lead or requesting SQ must contact the SMT Business Planner or Commodity Sourcing leader to request the proper amount of time to present to the Global Commodity Sourcing Group meeting.

Once the SQ group has presented and APPROVED the NBH Actions he/she must email the completed Quad Report to the NBH Coordinator. The Quad Report MUST include the Supplier CEO Name / Fax Number.

Upon approval, the GPSC NBH Coordinator creates the NBH letter and attains the appropriate executive signatures, communicates internally, inputs the NBH status into the Global Quality Tracking System (GQTS), and issues an official NBH notification letter to the Supplier.

Task Number: 13 Task Name: New Business Hold (Continued)

Entry into NBH (Continued) If sourcing table rejects, decision should be appealed to Executive Director of Supplier Quality. Regionally assigned SQ resource verifies that the supplier notified the QS/TS Registrar of New

Business Hold status.

Exit from NBH

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SQE monitors supplier’s progress to ensure exit criteria are being met. When the supplier has met the exit criteria, the SQE updates the Quad Report with supporting

documentation. SQ sends a notification or discussion with the GPSC Commodity Manager and or Creativity Team to

advise them that a New Business Hold removal is being initiated. SQ must contact the SMT Business Planner or Commodity Sourcing leader to request the proper

amount of time to present to the Global Commodity Sourcing Group meeting. Once the SQ group has presented and APPROVED the NBH Actions he/she must email the completed

Quad Report to the NBH Coordinator. The Quad Report MUST include the Supplier CEO Name / Fax Number.

Upon approval, the GPSC NBH Coordinator creates NBH removal letter and attains appropriate executive signatures, communicates internally, inputs the NBH status into the Global Quality Tracking System (GQTS), and issues an official NBH notification letter to the Supplier.

Responsible Methodology:SQE Creates Quad Report with supporting NBH data.SQE Obtain SQ Management approval for request – provide to SQ regional leadership. SQ Leadership

Present requested NBH (Adds only) at the SQ Executive Directors Staff Meeting

SQ Exec. Director

SQ Executive Director reviews with Purchasing Leadership and determines proper actions or status of requested NBH (Adds only)

SQE Upon requested NBH Add received approval from SQ Executive Director / NBH Coordinator - contacts the Creativity Team members of the actions and the SQE schedules the presentation at the specific commodity sourcing meeting for global notification and approval.

NBH Coordinator

Creates NBH letter with required GM signatures, issues NBH PRR in GQTS, Provides distribution of weekly NBH actions taken.

Supplier Reviews the NBH Quad Report and Exit criteria and notifies their specific ISO/TS16949 Registrar of the NBH actions.

SQE Monitors the supplier performance to meeting the defined NBH Exit Criteria on the Quad Report.SQE Upon supplier performance improvement and the supplier has met the NBH Exit Criteria update the

Quad Report. Review with your SQ management and upon SQ approval review within the CT. If all has approved must schedule the NBH Removal presentation at the specific commodity sourcing meeting.

SQE Upon approval from the commodity sourcing meeting – Must forward the Quad Report to the GPSC NBH Coordinator for processing.

NBH Coordinator

Creates NBH Removal letter with required GM signatures, Closes the NBH PRR in GQTS. Email sent to NBH distribution of the weekly NBH actions taken.

SQE / Supplier

Reviews next updated CT Bid list for removal of NBH (Coded N= no or not on NBH or Coded Y=yes currently on NBH) for the supplier specific duns code.

Supplier Notifies their specific ISO/TS16949 Registrar of the NBH Exit actions.

Reference Documents: Quad Report (GM 1927–71) SupplyPower NBH process flow chart (GM 1927-67) SupplyPower GP-5 (GM 1746) Supplier Quality Processes & Measurement Procedures - Section 7 (New Business Hold)

SupplyPower GQTS (Global Quality Tracking System) Creativity Bid list and PRR (Problem Reporting and Resolution)

GQTS

* SQE denotes GM Supplier Quality Engineer or approved GM SQ Representative

Revision HistoryGlobal APQP Process

January, 2004

Task 1 Commodity Sourcing Strategy Meeting—Under "Necessary Inputs" added warranty. Under "Methodology" section added types of warranty data to discuss at meeting. Under "Methodology" section added more

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information on PSA requirements and scoring method. Under "SQE Responsibility" section added that Part Specific SOR needs to be included in RFQ. Under "Additional Information" added AIAG QSA and Data sources for Warranty.

Task 2 Technical Reviews—“Under Necessary Inputs” eliminated Complex Systems/Subassemblies. Under "Methodology" section added Part Specific SOR to lessons learned review. Under the "SQE Responsibility" section added supplier understanding of Part Specific SOR. Under the "SQE Responsibility" section removed the word "recommended" that was listed next to the supplier understanding of SQ SOR. Under "Supplier Responsibility" section replaced "IPTV" with "warranty goals and expectations" and added warranty sufficiency plans.

Task 3 GPSC APQP Assessment & Sourcing—Under "Necessary Inputs" removed "QSA" reference to eliminate confusion (PSA and QSA are the same document). Under the "SQE Responsibility" section modified the follow-up requirements to correspond with changes to the GPSC APQP Assessment changes.

Task 4 Supplier Gate Reviews—Under "Deliverables" section removed sentence that referenced the Complex Systems appendix. Under "Methodology" section removed sentence from each Gate Review that referenced APQP Program management Complex Systems. Replaced "QWIK" with "Warranty Reduction Plans”. In Supplier Gate Review #3, removed reference to GM 1927-23M. Under "SQE Responsibilities" section added Part Specific SOR to lessons learned requirement.

Task 6 Feasibility and Manufacturing Assessment Letters—“Methodology” section, added GM Engineer as a recipient of Letters 2-4. Removed sentence that described letter as a formal transfer of responsibility from supplier's engineering to supplier's manufacturing organization.

Task 8 DFMEA—Under "Necessary Input" section replaced "criteria checklist" with "Part Specific SOR". Under the "Methodology" section added "high severity items" to DFMEA flow chart box.

Task 10 Gage, Tooling and Equipment Reviews—under "SQE Responsibility" section added sentence to verify the existence of GM owned tooling and that it is properly identified as GM property.

Task 11 GP-11 Pre-Prototype and Prototype—Under "Methodology" section added "or equivalent" to requirement that supplier's must ensure subcontractors follow GP-11. Under "Supplier Responsibility" section replaced "GM 1826-2" with "GP-11 Corrective Action Plan"

Task 12 PFMEA—Under "Necessary Inputs" section added Part Specific SOR to lessons learned input. Under "Methodology" section added "high severity items" to PFMEA box. Added "customer complaints, and internal data for the life of the part" to box that describes revision drivers. Under "SQE Responsibility" section added high severity failure modes to action plan requirement. Under "Supplier Responsibility" section add requirement for formal documented RPN reduction process, activity through the life of the part, subcontractor's involvement, and periodic reviews.

Task 13 Control Plans—Changed "may' to "should" for use of AIAG Control Plan format in the Definition section. Under the "Supplier Responsibility" section added requirement for layered audits and daily validation of error proofing. Also added review of subcontractor control plans.

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Task 14 Early Production Containment (GP-12)—Under "Definition" section added GP-12 applicability whenever mandated by GM on any parts that present significant risk to a customer plant. Under "Methodology" section add requirement for separate inspection area, irreversible corrective action, and 100% check.

Task 16 Run @ Rate (GP-9)—Under "Necessary Inputs" changed "Quoted" to "Contracted" tooling capacity. Under "Methodology" section added that SQE may decide to participate in sub-component Run @ Rate, as appropriate. Under "SQE Responsibility" changed "regional database" to "system" in the bullet referencing where to status customer-monitored Run @ Rates. Under "Supplier Responsibility" section removed "supplier monitored" from bullet referencing the status of Run @ Rates. Under "Additional Information" section removed wording regarding 2001 edition of GP-9. Under “Methodology”, SQE Responsibility”, and “Supplier Responsibility” sections added a reference to GM 1960-C1, C2, C3.

Task 17 Lessons Learned—Under "Deliverables" added Part Specific SQ SOR updates. Under "Methodology" section changed "Key Stakeholders" to "Commodity Sourcing Strategy" meeting. Added references to Part Specific SQ SOR’s. Under "Supplier Responsibility" section moved error-proofing validation to Task 13.

AppendicesAppendix 1 Complex Systems/Sub-

assemblies APQP Management Plan

Moved Document Usage Guidelines to the beginning of the APQP manual and made Complex Systems Appendix 1.

Appendix 2 Data Sources for Warranty Moved Complex Systems/Sub-assemblies APQP Management Plan to Appendix 1 and made Data Sources for Warranty Appendix 2.

May, 2005

Appendix 2 – Data Sources for WarrantyLegend Legend updated to correctly show Internal and External versus GM only sources.

June, 2007Various Changed references to QS900 and Quality Characteristics to match current terminology.

September, 2008

Task 1 Commodity Key Stakeholders Meeting—Task Name changed from Commodity Sourcing Strategy Meeting to Commodity Key Stakeholders Meeting; Task Description, Key Deliverables, Necessary Inputs and Methodology changed to meet GVDP 5.0 and Engineering & Advanced Purchasing Sourcing Process

Task 2 Technical Reviews— Task Description, Key Deliverables, Necessary Inputs and Methodology changed to meet GVDP 5.0 and Engineering & Advanced Purchasing Sourcing Process; Task 3 was integrated to this Task

Task 3 GPSC APQP Assessment & Sourcing was removed and integrated to Task 2;SQ NOD 004 was incorporated into the manual at this Task

Task 4 Gate Reviews— Task Name changed from Supplier Gate Reviews to Gate Reviews. Task Time,

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Description, Key Deliverables, Necessary Inputs and Methodology changed to meet GVDP 5.0 and Engineering & Advanced Purchasing Sourcing Process; PPAP and Run @ Rate Reviews were introduced; The APQP Supplier Status Workbook GM1927-34 was introduced to support Gate Reviews execution

Task 6 Feasibility and Manufacturing Assessment Letters —Was removedQSB —Was transferred from Current Section to APQP Section and updated

Task 7 Process Flow Charts — Task Description, Key Deliverables, Necessary Inputs and Methodology changed to meet GVDP 5.0

Task 8 DFMEA— Task Description, Key Deliverables, Necessary Inputs and Methodology changed to meet GVDP 5.0 and introduction of DRBFM activity

Task 10 Tooling and Equipment Reviews — Task Name changed from Gage, Tooling and Equipment Reviews to Tooling and Equipment Reviews; Gage activity was removed and transferred to Task 11; Task Description, Key Deliverables, Necessary Inputs and Methodology changed to meet GVDP 5.0

Task 11 GP-11 Pre-Prototype and Prototype — Was Removed.Gage Development And Approval — Was Removed from Task 10 and transferred to this Task in order to introduce the complete methodology to support the application of GM1925 (Checking Fixture Standard for purchased parts).

Task 12 PFMEA — Task Description, Key Deliverables, Necessary Inputs and Methodology changed to meet GVDP 5.0

Task 13 Control Plans — Task Description, Key Deliverables, Necessary Inputs and Methodology changed to meet GVDP 5.0 and Powertrain requirements

Task 14 Early Production Containment (GP-12) — Task Description, Key Deliverables, Necessary Inputs and Methodology changed to meet GVDP 5.0

Task 16 Run @ Rate (GP-9) — Complete methodology update

Task 17 Lessons Learned— Complete methodology update

AppendicesAppendix 1 Complex Systems/Sub-

assemblies APQP Management Plan

Removed

Appendix 2 Data Sources for Warranty Removed

February, 2009

Various - Global RASIC included as Global APQP section

Various – Added Global PFMEA Checklist to the Document Usage Guidelines

Task 4 Gate Reviews – Added clarification of Direct Buy component SQE roles at System/Assembly Gate Reviews- Changed Key deliverable from AIAG A-7 to GM1927-37

Task 6 QSB - Added Rules for QSB application

Task 10 Tooling & Equipment Review – Added the SQ Tooling Engineer roles where available

Task 11 Gage Development & Approval – Added complement information regarding detailed gage timing chart

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Task 12 PFMEA - Changed Key deliverable from AIAG A-7 to GM1927-37

Task 13 Control Plan – Included the information that functional requirements from SOR & part drawing must be enclosed by PCP

Global Launch ProcessMay, 2005

Task 1 Program Risk Assessment – Title changed from “Cross Functional Risk Assessment”; enhanced task description, methodology and deliverables to be more descriptive of process; added customer(s) for deliverables

Task 2 GP/SQA Launch Team Resource Plan Development – Title changed from GPSC/SQA Launch Team Staffing; Changed task owner for Launch Leader to Launch Director; enhanced task description and methodology to be more descriptive of process; added customer(s) for deliverables; clarified task owner responsibility

Task 3 Global Launch Matrix – Changed task timing to reflect actual publication process; enhanced task description and methodology to be more descriptive of process; added customer(s) for deliverables; updated data processing flow chart

Task 5 Daily Launch Issue Escalation Process – Former task 5 Launch Issue Escalation Process and task 6 Conference Calls combined to reflect practice

Task 6 Pre Launch Conference – Title changed from GPSC Executive Supplier Days (Pre-Launch Conference); enhanced task description, methodology and deliverables to be more descriptive of process; added customer(s) for deliverables

Task 7 Boundary Sample Review – Enhanced task description, methodology and deliverables to be more descriptive of process; added customer(s) for deliverables; include updated Boundary Sample RASIC Chart

Task 11 Problem Solving Process – Enhanced methodology to be more descriptive of process; included references to GM Problem Solving Processes in Additional Information

November, 2006

Task 5 Daily Launch Issue Escalation Process – Former task 5 Launch Issue Escalation Process and task 6 Conference Calls combined to reflect practice

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Task 6 Pre Launch Conference – Title changed from GPSC Executive Supplier Days (Pre-Launch Conference); enhanced task description, methodology and deliverables to be more descriptive of process; added customer(s) for deliverables

Task 7 Boundary Sample Review – Enhanced task description, methodology and deliverables to be more descriptive of process; added customer(s) for deliverables; include updated Boundary Sample RASIC Chart

Task 11 Problem Solving Process – Enhanced methodology to be more descriptive of process; included references to GM Problem Solving Processes in Additional Information

February, 2009

Section #2 Tasks 1-13Section #2 Complete Launch Manual re-write - to reflect current work practices and global process

agreements made during Q4 2008 Launch Process calls supported by GMNA, LAAM, GME, GMAP and GMPT

September, 2009

Section #3 Tasks 1-13Section #3 Complete Current Manual re-write - to reflect current work practices and global process

agreements made during Q3 2009 Current Revision supported by the Global Task Team and Global SQ Process team as supported by GMNA, LAAM, GME, GMAP and GMPT.

Task 11 / Contents Removed obsolete process Executive Champion Process (ECP) and replaced with 3rd Party Provider Process, Task 11 and Table of Contents page IV. Removed word “Spill” replaced with “Disruption” in the contents page IV, document guidelines listing.

Updated Glossary of Terms pages 93 – 97.

Revised Document Usage Guidelines – Page 48.Obsolete Documents includes the following: GM 1927-60, GM 1927-63, GM 1927-64, GM 1927-68, GM 1927-70, GM 1927-74, GM 1927-77, GM 1927-81,

Glossary of Terms

AAR: Appearance Approval Report

ADV: Analysis/Development/Validation

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ADV P&R: Analysis/Development/Validation Plan and Report. This form is used to document a Supplier’s ADV Plan and track execution

AIAG: Automotive Industries Action Group, an organization formed by General Motors, Ford and Daimler-Chrysler to develop common standards and expectations for automotive suppliers.

AP: Advance Purchasing or Asia Pacific

APQP: Advanced Product Quality Planning

APQP Project Plan: A one-page summary of the GM APQP process that describes the tasks and the timeframe in which they occur.

AQC: Attribute Quality Characteristic

ASQE: Advanced Supplier Quality Engineer

BIW: Body in White. Usually the bare metal shell of the body; includes doors and deck lid prior to paint and trim.

BOM: Bill of Materials

BOP: Bill of Process

Brownfield Site: An expansion of an existing facility.

CKSM: Commodity Key Stakeholders Meeting

CMM: Coordinate Measuring Machine

Cpk: Capability Index for a stable process

CTC: Component Timing Chart (DRE document)

CTS: Component Technical Specifications

CVER: Concept Vehicle Engineering Release

DAQ: Design Appearance Quality (Color Harmony / Appearance Group)

Defect outflow detection: A phrase used in the Supplier Quality Statement of Requirements that refers to in-process or subsequent inspection used to detect defects in parts.

DFFA: Dimensional Fit Function & Appearance

DFM/DFA: Design for Manufacturability / Design for Assembly

DFMEA: Design Failure Modes and Effects Analysis. It is used to identify the potential failure modes of a part, associated with the design, and establish a priority system for design improvements.

DPV: Defects per vehicle

DR: Documentation Required

DRE: Design Release Engineer

DSO: Design Sign Off

E&APSP: Engineering & Advance Purchasing Sourcing Process.

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Error Occurrence Prevention: A phrase used in the Supplier Quality Statement of Requirements that refers to poke yoke or error-proofing devices used to prevent errors in the manufacturing process from occurring.

ESEP: Enhanced Supplier Engagement Process using GM approved 3rd Party Providers for containment sorting & rework

EWO: Engineering Work Order

FTQ: First Time Quality

GA: General Assembly

GD&T: Geometric Dimensioning & Tolerancing

GM: General Motors

GMAP: General Motors Asia Pacific

GME: General Motors Europe

GMIO: General Motors International Operations

GMNA: General Motors North America

GMSP: GM Supply Power

GP: General Procedure

GPDS: Global Product Description System

GPS: Global Purchasing System

GPSC: Global Purchasing & Supplier Chain

GQTS: Global Quality Tracking System

GR&R: Gage Repeatability and Reproducibility

Greenfield Site: A new supplier facility that is built to support a program.

GSTS: Global Status & Timing System

GVDP: Global Vehicle Development Process

IPTV: Incidents per Thousand Vehicles

IVBR: Integration Vehicle Build Release

IVER: Integration Vehicle Engineering Release

KCC: Key Control Characteristics. It is a process characteristic where variation can affect the final part and/or the performance of the part.

KCDS: Key Characteristic Designation System

Kick-Off Meeting: The first APQP supplier program review.

KPC: Key Product Characteristic. It is a product characteristic for which reasonably anticipated variation could significantly affect safety, compliance to governmental regulations, or customer satisfaction.

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LAAM: (General Motors) Latin America, Africa & Middle East

LCR: Lean Capacity Rate. It is the GM daily capacity requirement.

MCE: Mid Cycle Enhancement

MCR: Maximum Capacity Rate. It is the GM maximum capacity requirement.

MDC: Mule Design Complete

MOP: Make or Purchase

MPC: Material Production Control

MPCE: Material Production Control Europe

MRD: Material Required Date; date material must be delivered in order to allow a build event to begin.

MSA: Measurement Systems Analysis

MU: Mock-Up. Mock-ups can be actual functioning parts, sub-assemblies or assemblies or non-functional wood, expanded polystyrene, plastic or metal representations of parts, subassemblies or assemblies. The design source can be responsible for providing mock-ups.

MVBns: Manufacturing Validation Build non-saleable

MVBs: Manufacturing Validation Build saleable

NBH: New Business Hold

N.O.D.: Notice of Decision

NOA: Notice of Action

OEM: Original Equipment Manufacturer

PAD: Production Assembly Documents

PC&L: Production Control & Logistics

PDT: Product Development Team

PET: Program Execution Team

PFMEA: Process Failure Modes and Effects Analysis. It is used to identify potential failure modes associated with the manufacturing and assembly process.

PPAP: Production Part Approval Process

Ppk: Performance index for a stable process

PPM: 1) Program Purchasing Manager, 2) Parts Per Million (Calculation of discrepant parts /receipts as defined in GP5)

PPV: Product & Process Validation

PQC: Product Quality Characteristic

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PQRR: Program Quality Readiness Review

PR/R: Problem Reporting & Resolution

PSA: Potential Supplier Assessment, a subset of the Quality System Assessment (QSA)

QCC: Quality Confirmation Center (GME form of ESEP – enhanced supplier engagement process using GM approved 3rd party providers for containment sorting and rework)

QSA: Quality System Assessment

QSB: Quality Systems Basics

QRD: Quality Reliability Durability

QTC: Quoted Tool Capacity

RASIC: Responsible, Approve, Support, Inform, Consult

R@R: Run at Rate

RFQ: Request For Quotation

RPN: Risk Priority Number related to FMEA development

RPN Reduction Plan: An action plan that describes what is being done to reduce the risk priority number for items listed in the DFMEA or PFMEA.

SDE: Supplier Development Engineer

SFMEA: System Failure Mode and Effects Analysis

SMT: Systems Management Team

SOA: Start of Acceleration

SORP: Start of Regular Production

SOR: Statement of Requirements

SOS: Start of Sales

SPC: Statistical Process Control

SPO: (General Motors) Service and Parts Operations

SQ: Supplier Quality

SQE: Supplier Quality Engineer

SQIP: Supplier Quality Improvement Process

SSF: Start of System Fill

SSTS: Sub-system Technical Specifications

Sub-Assembly / Sub-System: An assembly of sub-components delivered to the GM main production line for installation to the vehicle as a single unit.

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Subcontractor: The supplier of a sub-component to a Complex System/Subassembly supplier (Tier 2, 3, etc).

SVE: Sub-System Validation Engineer

SVER: Structure Vehicle Engineering Release.

Team Feasibility Commitment: An AIAG APQP form that is provided with the Request for Quotation. It is used to document the supplier’s concerns with the feasibility of manufacturing the part as specified.

TKO: Tooling Kick-Off

TWO: Temporary Work Order

UG: Unigraphics

VDP: Vehicle Development Process

VLE: Vehicle Line Executive

VLT: Vehicle Line Team

VOC: Voice of the Customer

VOD: Voice of Design

VPI: Vehicle Program Initiation

VTC: Validation Testing Complete

VTS: Vehicle Technical Specification

WO: Engineering Work Order

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