GM Global APQP for Suppliers

Phone on
Vibrate
Ground Rules

This is your class, feel free

to ask questions at any time!

Manuel Yamada
Tel Aviv, Israel
April 12th, 2010

AGENDA

Introductions
APQP Process and Expectations
Project Plan
Customer vs Supplier Monitored APQP
APQP management in GQTS
APQP Requirements
GM Requirements
Q&A

Global APQP Vision

Become more proactive, by moving right side activities to the left
QSB for suppliers upfront after sourcing
Schedule early cross functional blitz audits on high risk suppliers

Streamline the APQP Process to be more effective

Identify key deliverables for each quality gate during the APQP
process
Track and report the results of the agreed deliverables, not just
PPAP and R@R

Supplier Responsibility

The goal of a successful

program launch and mass
production is to provide:

Quality @ Rate On Time

Background

Linkages of the ISO/TS 16949:2002, AIAG

APQP and Global Supplier Quality Manual
GM
Global
APQP
AIAG APQP

ISO/TS 16949
7.1
Planning of Product Realization

Background

GM APQP Global Process

Global APQP Team Goals & Results

Identify Quality Indicators
Develop Quality Tasks (17 total)

Develop Global Supplier Quality Manual, GM-1927

Reason: Global Sourcing and World Vehicles

Global APQP
GM-1927

GM
General Motors Corporation

Global Supplier
Quality Manual is
the General Motors
Common Global APQP
Manual
GMs common
direction for the
development and
implementation of an
APQP plan
Download from
GMSupplyPower

Advanced Product Quality Planning

Worldwide Purchasing

November 2000

GM 1927 Documents and Forms

Ordering:

Ordering information for all documents and manuals listed or referenced

throughout this manual (GM 1927) is contained on page II
Electronic Copies:

This manual and all documents that are part of this manual (this
includes any document with a GM 1927 number) can be found through
the internet at the GMSupplyPower website
The address is www.gmsupplypower.com, then follow these steps:

Log in
Select Quality Power
Select Library
Select Supplier Quality
Select APQP Manual & Documents

Global APQP
Summary Points
Global APQP driven by ISO TS 16949 and AIAG APQP

Common Global APQP Process for GM Worldwide

- All GM Divisions and Regions will use the Same Process
- Common Requirements for Suppliers
- Common Forms and Charts

Common Direction and One Voice from all GM Supplier

Quality Engineers
Supports Global SQ Communication Structure
- Supplier Program Status is shared between Regions
- All Information Available on GMSupplyPower website at
www.gmsupplypower.com

Global APQP
Customer Monitored APQP
Supplier Monitored APQP
Customer Monitored
SQE work closely with supplier
Supplier work closely with GM SQE
Supplier Monitored
SQE paper/electronic review of supplier
Supplier keep GM aware

GM Global APQP Monitoring

SQE is the responsible for invite and conduct Gate #1 (Kick-Off Meeting) for all parts on both Customer or
Supplier Monitored APQP

Customer Monitored SQE Responsibilities

Assure quality @ rate on time

Implement an advanced product quality

planning process with all sub-tier suppliers

of all quality related documents listed on APQP

Project Plan

Raise issues that might jeopardize a quality part

Participate in the remaining Supplier Gate

Execute the content and provide updates per the

APQP Project Plan

Drive the suppliers progress in the development

within the program timing either to suppliers or
GMs upper management, as appropriate

Customer Monitored Supplier Responsibilities

Invite and conduct all remaining Gate Reviews

Work closely with GM SQE
Supplier Monitored Supplier Responsibilities

Adhere to supplier manufacturing site protocol

Execute the content of the APQP Project Plan

Implement an advanced product quality

Attend PDT and associated program meetings

Drive/Enforce the process of suppliers quality

Responsible for meeting quality, timing and

Review meetings

when in the manufacturing facility

system development

Apply APQP Workbook Audits and upload all Key

Deliverables to GQTS

Supplier Monitored SQE Responsibilities

Monitor the suppliers adherence to program
timing and track open issues addressing

planning process with all sub-tier suppliers

capacity requirements

Provide parts for all GM build events

Present tasks and deliverables of APQP

Workbook internally in a management review and

submit the results to GM

Notify SQE when quality issues arise that might

affect program timing

Global APQP
Customer Monitored APQP vs

Supplier Monitored APQP

There is an inverse relationship
Customer monitoring means more
responsibility for the SQE
Supplier monitoring means more
responsibility for the Supplier

Global APQP Tasks changed as following:

01-Commodity Sourcing Strategy Mtg

01-Commodity Key Stakeholders Mtg

02-Technical Reviews

02-Technical Reviews

03-Risk Assessment / Sourcing

03-Supplier Eligibility

04-Supplier Gate Reviews

04-Gate Reviews

05-Timing Charts / Open Issues

05-Timing Charts / Open Issues

06-Feasibility / Assessment Letters

06-QSB

07-Flow Chart

07-Flow Chart

08-DFMEA

08-DFMEA

09-Design Reviews

09-Design Reviews

10-Gage, Tooling and Equipment Reviews

10-Tooling & Equipment Reviews

11-GP-11

11-Gage Development & Approval

12-PFMEA

12-PFMEA

13-Control Plan

13-Control Plan

14-GP-12

14-GP-12

15-PPAP

15-PPAP

16-Run @ Rate

16-Run @ Rate

17-Lessons Learned

17-Lessons Learned

 Corporate Planning sets time frames

Combination of the Best Processes

GPSC SUPPLIER QUALITY IMPROVEMENT PROCESS
GLOBAL SOURCING
IMPROVEMENT MEETING
QUALITY WORKSHOP
LEVEL II CONTROLLED SHIPPING

LEVEL I CONTROLLED SHIPPING

SUPPLIER QUALITY PROCESSES & MEASURES (GP-5)
PERFORMANCE MONITORING
CONTINUOUS IMPROVEMENT (GP-8)

TIME LINE
EARLY PRODUCTION
CONTAINMENT (GP-12)
RUN @ RATE (GP-9)
PRODUCTION PART
APPROVAL (PPAP)
PROTOTYPE SAMPLE
APPROVAL (GP-11)
PRE-PRODUCTION MEETING
ADVANCED PRODUCT
QUALITY PLANNING (APQP)
SOURCING DECISION
POTENTIAL SUPPLIER
ASSESSMENT

START OF
PRODUCTION

LIFE
OF PART

GM Global APQP

1. Commodity Sourcing Strategy Meetings

APQP Project Plan
Prototype

Pilot / Pre-Launch

Launch /
Production

Planning
Product Design and Development
Process Design and Development
Product and Process Validation
Feedback, Assessment and Corrective Action

2 Technical Reviews
Risk Assessment /
3 Sourcing
Supplier Gate
4 Reviews
Timing Charts /
5 Open Issues
Feasibility /
6 Assessment Letters

GR-1
GR-1

Sourcing
Activities
o------o

o------o

TR

Initial-TR

GR-1,2,3,4

GR-1,2,4

SOP

GR-2,3
o

Letter 4

o
o

o
o

Update

Production

o
o

RPN Reduction
DFMEA
o
o

GD&T

o
Prod Concept-TR

Letter 3

GR-1,2,3,4

Prototype

GR-1,2,4

Letter 2

KCDS Workshop

9 Design Reviews
Gage, Tooling and
10 Equipment Reviews

MVBs

Initial-TR

GR-1,2,3,4

DFMEA

8 DFMEA

MVBns

Update Risk

GR-1,3

Initial -TR

7 Flow Chart

Validation
Vehicle

GR-3

Gate
Reviews

GR-1

APQP Task
Commodity Sourcing
1 Strategy Mtg

Integration
Vehicle

GR-2

Structure
Vehicle

GM GVDP

GR-4

AIAG
APQP

o
Gage Concept Approval

o
Gage Design Approval

Gage Approval/R&R, Tool Completion

Execute
Execute
The Commodity Sourcing Strategy
Meeting is the
responsibility of the Buyer
11 GP-11
GR-2,3
o
o
o
o
RPN Reduction
Prototype
/ RPN Baseline
InternalInitial-TR
GM people
only
Production / RPN Reduction
12 PFMEA
GR-1,2,3,4
o
o
o
o
o
o
o
o
The first
time the SQEPrototype
becomes officially involved
GP-12 & Production in the APQP process
Initial-TR
13 Control Plan
GR-1,2,3,4
o
o
o
o
o
o
o
Commodity
Sourcing Strategy Meeting is thePlanfirst task that
by
the
Initial-TR
Execute is trackedExit
(Platform
Discretion)
14 GP-12
GR-3,4
o
o
o
o
APQP
Project Plan

15 PPAP

GR-4

o
Plan

16 Run @ Rate (GP-9)

GR-1,2,3,4

17 Lessons Learned

GR-1,2,3,4

o
o

Capacity Analysis

Capacity Analysis

o
Conduct Run@Rate

o
o

o
o

1. Commodity Key Stakeholders Meeting (CKSM)

Key points

Introduce and establish Key Stakeholder ownership, identify

program-specific strategies in the Engineering & Advance
Purchasing Sourcing Process (E&APSP) and ensure that the RFQpackage contains all information needed to receive comparable
quotes.

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 and start planning any required audits.

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
(suppliers must be capable to meet those specific requirements if
available).

1. Commodity Key Stakeholders Meeting (CKSM)

Available Data for Supplier Performance

- CT Bid List
- PSA/PCPA audit report
- GMSupplyPower (Six Panel Chart and Box Chart)

Supplier Commitment Letter is required for any

suppliers to be sourced with not Green status

Supplier Quality SOR

Supplier Quality Statement of Requirements

Supplier Quality has a Global

Statement of Requirements that
applies to all suppliers.
SOR Included in the GM RFQ.

Please sign, date and return page 5 of this document with your bid package as
record of your understanding of these requirements. Powertrain suppliers please
sign, date and return page 6 also.

1. All suppliers are expected to supply parts to General Motors with zero defects. Funding is to
be identified in the initial quote and subsequent quotes to reflect error occurrence detection (poka
yoke, error proofing devices, etc) and defect outflow prevention to customers. Controls
implemented at a later date are the financial responsibility of the supplier.

2. ISO/TS 16949 or QS-9000 - Quality System Requirements

All suppliers to General Motors must be certified to one of these standards and have a current
certificate available demonstrating compliance to GM supplements. These standards require
an extensive, formal, audited evaluation of suppliers quality and manufacturing methods.
The evaluation is conducted by a third party certified registrar.

Suppliers not certified to ISO/TS 16949 or QS-9000, or those suppliers constructing or

purchasing facilities to manufacture the parts being quoted, must include an outline of their
certification attainment plan with their quote for further consideration.

3. General Motors Procedures and Reference Documents

Supplier Quotations to GM
must include a signed copy of
the SOR, indicating compliance to
these requirements.

Suppliers are to adhere to the requirements contained in the following documents:

Advanced Product Quality Planning & Control Plan Reference Manual (AIAG)
Potential Failure Mode and Effects Analysis (FMEA) Reference Manual (AIAG)
Fundamental Statistical Process Control (SPC) Reference Manual (AIAG)
Measurement Systems Analysis (MSA) Reference Manual (AIAG)
Production Part Approval Process (PPAP) Manual (AIAG)
Key Characteristics Designation System (KCDS) GM-1805QN
GP-5 Supplier Quality Processes and Measurements Procedure. GM-1746
GP-7 Component Verification and Traceability Procedure. GM-1730
GP-8 Continuous Improvement Procedure. GM-1747
GP-9 Run @ Rate. GM-1960
GP-10 Evaluation and Accreditation of Supplier Test Facilities. GM-1796
GP-11 General Procedure for Pre-Prototype and Prototype Material. GM-1820
GP-12 Early Production Containment. GM-1920
GM-Supplier Technical Information GM-1825
Traceability Identifier Requirement TIR-15-300. GM-1731
Supplier Quality Weld Support Manual
Shipping Parts Identification Label Standard. GM-1724
Fixture Standards Requirement GM-1925
Operating Guide for Suppliers of Prototype Material NAO-0065

Signature of Supplier Representative

2. Technical Reviews
Review manufacturability, timing, design, manufacturing
capability, packaging, etc., issues related to a commodity.
NOTE: There may be situations where a TR is not held. SQE
must take responsibility for a review of the Quality info. This
should be done prior to performing the GPSC APQP
Assessment.
Attendees: Buyer, Engineer, SQE, Supplier, Manufacturing
Engineer, Other pertinent organizations
Outcome:
- Identifying suppliers that should not continue in the sourcing
process
- Initial GQSC APQP Assessment signed by the buyer, DRE and
SQE (this is required prior to signing the Sourcing
Recommendation form).
- Initial APQP Open issues list

Technical Review Checklist

Risk Assessment
Risk
Assessment

Customer
Monitored APQP

or
Supplier
Monitored APQP

3. Sourcing Eligibility
For a supplier location to be eligible to receive a new business
award from GM the manufacturing location to be sourced must
either be:
Green on the GM Creativity Team Bid List (CTBL) for Quality
for the specific commodity, OR

Have a supporting Quality Business Case (QBC) QUAD report

approved according to the criteria outlined in this task.
Supplier is requested to provide necessary information as
required and support audit requests at short notice.
- Identifying suppliers that should not continue in the sourcing
process
- Initial GQSC APQP Assessment signed by the buyer, DRE and
SQE (this is required prior to signing the Sourcing
Recommendation form).
- Initial APQP Open issues list

4. Gate Reviews
The purpose of the Gate Reviews is to review the progress of all
APQP Tasks as stated on the APQP Project Plan GM1927-1 and
track the status and progress of items listed on the APQP Timing
Chart GM1927-2.
These review meetings are intended as an APQP team review of
the part and process development and to capture the lessons
learned from each build event. The Gate Review #1 (Kick-Off
Meeting) is coordinated by the GM SQE for all APQP parts.
Used to review the progress of items according to the APQP
Project Plan (GM1927-1) and track the status and progress of
items listed on the APQP Timing Chart (GM1927-2)

109 Part J

4. Gate Reviews
Key points
Intended as a Readiness Review of the suppliers ability
to support specific GM build events and achieve both Full
PPAP and R@R according to the program requirements
Coordinated by the SQE
Conducted by the SQE on all parts tracked as
customer-monitored APQP
Conducted internally by the Supplier if the parts are
supplier monitored APQP
Aligned with GM build events

4. Gate Review

4. Gate Reviews
Key Deliverables
The Key Deliverable documents (see chart) are to be uploaded
into GQTS. All other APQP documents and forms (referenced in
the GM Global APQP Supplier Status Summary Workbook
GM1927-34) are to be retained at the supplier location.
The Key Deliverables related to PPAP (e.g. GM1411,
Dimensional Report, GM3660), must contain the GQTS PPAP
activity code as reference.

4. Gate Reviews
Key Deliverables
Gate
Deadline
(Time from
SORP in
weeks)

GVDP 5.0 timing

reference

ALL

-78

Key
Deliverables

Review

Within 30 days of
business nomination
advice / contract

Gate 1

Initiated after CVER

and completed 5
weeks after IVER

Gate 2

GM Global APQP Supplier Status Summary

Workbook
QSB Audit (Gap Analysis) or Greenfield
Checklist (Action Plan)
Timing Plan
Kick-Off Check list
PFMEA Check list
RPN Reduction Summary
Subcontractor Status
Supplier ADV Plan (ADVP&R) showing
execution status
QSB Audit (Compliance) or Greenfield Checklist
(Complete)
Run @ Rate Capacity Workbook
Dimensional Report
PPAP Worksheet (if not fully approved)
GP12 Audit

-52

Completed 10 weeks
prior Matching 1 GA

Gate 3

-35

Completed 3 weeks
prior PPV MRD

Gate 4

-15

Completed 1 week
prior MVBs MRD

PPAP

PPAP Approval

Run @
Rate

Run @ Rate Execution

PCPA

-8

Form/
Document

GM1927-34
GM1927-30
GM1927-31
GM1927-2
GM1927-14
GM1927-37
GM1927-21
GM1927-25
GM1829
GM1927-30
GM1927-31
GM1927-35
GM1927-32
GM1411
GM1927-33

R@R Module
GM1927-16

Gate Review # 1 - APQP Kick Off Meeting

Delivery

Kick off checklist (GM 1927-14)

Program team contact list (GM 1927-17)

APQP Timing chart

APQP open issue list

Initial PFD/PFMEA/PCP

Lessons learned

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

Major disruption prevention plan

APQP Kick Off Meeting

GM AND SUPPLIER PROGRAM CONTACTS

Who to
Contact?
GM1927-17
List the Key
Positions
needed to
Manage New
Programs

Part name:
GM Program:
Supplier Name:
Manufacturing Location Address:
Supplier Mfg. Plant Manager:

Position
Advance
SQE
Buyer

Name

Design
Engineer
VLE PPM
Proto PE

Part number:
Model Year:
DUNS #:
Phone:
GM
Phone (fax,mobile)

E-mail

Position
Project
Manager
Sales Mgr

Name

SUPPLIER
Phone (fax,mobile)

E-mail

Design
Engineer
Quality
Manager
Laboratory
Supv.

Manuf.
Engineer
GM Plant
Rep
GD&T
Readiness
Coord.
Containerization
Reliab.
Engineer
Paint
Engineer
Current
SQE

APQP Contact List.doc

Packaging
Engineer
1st Shift
Contact
nd
2 Shift
Contact
rd
3 Shift
Contact
SubContractor

GM1927-17

Gate Review # 2

Updated timing plans

Updated Open Issues

PFMEA checklist

RPN reduction summary

Subcontractor planning

Lessons Learned and best practice review

Major disruption prevention plan

Gate Review # 3

On-tracking timing chart, PFD/PFMEA/PCP, Quality

improvement activities, tier supplier improvement status etc

Open issue review Identify high risk open issues

QSB Audit (Compliance) or Greenfield Checklist (Complete)

Run @ Rate Capacity Workbook

Supplier ADV Plan (ADVP&R) showing execution status

PPAP plan and requirements

Gate Review # 4

Updated timing plans, PFD/PFMEA/PCP, Open Issues, Quality

improvement activities, tier supplier improvement status etc

Dimensional Report

PPAP Worksheet (if not fully approved)

GP12 Audit

Conduct Supplier Launch Day assessment

Gate Reviews 2,3,4

Meeting Subjects Include:

APQP Major/Open Issues List

APQP Timing Chart Updates
Progress of Tooling/Fixtures/Gages
Lessons Learned
Design Issues
RPN Reduction Plans
AIAG New Equipment Checklist (A-3)
AIAG Process Flow Checklist (A-6)
AIAG PFMEA Checklist (A-7)
AIAG Control Plan Checklist (A-8)
GP-12 Plan
Identify build issues/concerns

Gate Review Delivery

Global APQP for SQEs

Gate Review Delivery

5. Timing Charts / Open Issues

Key points
Supplier timing chart match GM master timing
requirement / MRD requirement
Supplier shall understand the logic consequence for
each activity and milestone

Supplier timing shall have high confidence of timing

achievability
Supplier shall identify potential risk by this report
card, and usage of escalation process
Use updated Open issue list as meeting minutes
and program management tool

APQP Timing Chart

APQP Timing Chart

Proactive Conformance to AIAG APQP Requirements and
GM Global APQP Tasks
Develop Detail Plans for Each Part / System
- Robust Part Designs
- Robust Processes with Error-proofing ZERO DEFECTS
Maintain Program Timing
- Design Completion
- Prototype Part Delivery
- Accurate Sample Submissions and Part Delivery

APQP Timing Chart

Key Elements:
- Data/Sample comparison
- ADVP&R
- Engineering approval
- Material substitution/approval
- Tier supplier plan
- New facility, M&E
- Tooling building
- Gage/fixture building
- FOS
- A-B-C Comparison (GS)
- ETO
- PPAP SPR & Submission
- PTR
- GP12 GP9
- Acceleration and pipeline/inventory
build up plan

APQP Timing Chart

APQP Timing Chart breakdown
Tooling list and timing chart
M&E timing chart
Sub-contractor timing chart
People Hiring and Training planning
Green/Brown field building planning
ADVP&R

Open Issue List

6. QSB (Quality Systems Basics)

Supplier is requested to work in QSB

implementation from the beginning of the
program development (Gate Review # 1)
Action plan for implementation to be updated
on a regular basis according to the actions
taken based on the plan dates
APQP QSB Task must be
compliant by Gate Review # 4

7. Flow Chart
Provide a Logical Pictorial Representation of the Process Flow that can
Purpose:
be used as the Foundation for PFMEAs. Control Plans, Work Station
Layouts, etc.

Review Process Flow Charts at Sourcing (if available), at Prototype, at

Production Part Approval and Regular Production
Ensure
that the Production Version is linked to the PFMEA and Control Plan
SQE
Responsibility:
Ensure that the Flow Chart Includes Inspection and Rework

Supplier Responsibility:
Create Preliminary Process Flow Chart using a Similar Process
Create and Maintain the Flow Chart through Prototype and into Production
Ensure the Flow Chart is Linked to the PFMEA and Control Plan
Communicate any Changes to the SQE

7. Flow Chart
Inspection

Rework
Scrap

Packaging
Shipping
KCC

Example: Initial process flow chart

Nonconforming part shall be reintroduced into the process stream at
or prior to the point of removal

9. Design Review
Key
points
Purpose: Ensure that the Design has been adequately Defined to Build Tools
and Gauges

Ensure engineering data is the latest version

Ensure supplier get SOR and engineering spec.

Ensure supplier understand the engineering data/spec
and testing method
Review KPC/PQC list and control method
ADVP should be approved by GM
BOM
Material substitution and approval

Minimum validation requirement for salable PPAP

Example: KPC/PQC and corresponding control method

N
O

KPC

Value

VE:30607.5mm
1

Length

WM:31187.5mm

Compr
ession
Load

VE/WM:
10.75mm
8~14N

KCC

Control Method

Extrusion: Cutting
Aging: Temperature; time
Finishing: End cutting

Extrusion: Automatic
cutting
Aging: PLC
Finishing: 100% DIM
check & SPC

Mixing: Ingredient quantity

Extrusion: Temperature;
Line speed
Aging: Temperature; time

Mixing: Bar code

Extrusion: PLC
Aging: PLC control
SPC

Example: Supplier DV/PV plan and result

Verify suppliers lab (GP10 Process) and closely follow

up the parts bench tests conducted by the supplier

Example: BOM

10. Tooling & Equipment Reviews

Purpose:
To conduct reviews of a Tooling and/or Equipment to ensure
that the manufacturing process is:
designed to the latest drawing change level
built

certified
so as to produce:
quality parts
at rate
according to GM program requirements

11. Gage Development and Approval

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

11. Gage Development and Approval

Supplier Responsibility:
Design, build, certify gage dimensionally (including a third party
certification), perform complete AIAG MSA (GR&R and Bias
study) and meet all requirements established by GM1925. A lean
gage (pull ahead CMM holding fixture) should be available for
first IVER build.

12. PFMEA
TOP 5 RPN Reduction Plan (Correct RPN value) !

ITS A LIVING DOCUMENT!

Top RPN Reduction Plan

13. Control Plan

Define the Method being used to Control all KPCs,
PQC and KCCs for Parts being Manufactured for
Vehicle Builds.

Prototype Control Plan

Pre-Launch (GP-12) Control Plan

Implementing from the first production part ship to

GM assembly line
Production CP: shall be verified by Pre-launch PCP

Control Plan
Key points
SQE shall define PCPA schedule and
frequency based on the risk priority of part and
process (Based on risk assessment)
Supplier and SQE shall verify final inspection to
ensure a robust inspection method

Its a living document to address any

change in product/process and reflect
updated control for quality issue

14. GP-12
Establish a Containment Plan during Start-up
and acceleration that will Quickly Identify
Quality Issues at the Suppliers Facility; i.e., a
Pre-Launch Control Plan
Prototype
Pre-Launch (GP-12)

Production: shall be validated by Pre-launch PCP

GP-12
GP12 Audit/Verification and take corrective action
Layered Audits by supervisor/Manager
Proactive Controlled Shipping Strategy and Execution
A. Failure to execute GP-12 will result in Controlled
Shipping Level 2 and other possible consequences.
B. Shipment of non-conforming material will result in
Controlled Shipping Level 2.

Duration of GP-12

GP-12 must be implemented for a period of time

or quantity of parts as specified by the customer or
until the Production Control Plan has been
validated, whichever is longer.
If time or quantity is not specified, GP-12 will
remain in effect through acceleration or a
minimum of 2 weeks, whichever is longer.

15. PPAP
Production Part Approval Process
Defines generic requirements for production and
bulk materials

Indicates the suppliers understanding of the

engineering design record and specifications
requirements
Indicates the process can consistently meet the
requirements at production rate

PPAP
Applicability

Applies to all internal and external

supplier sites of production and service
parts unless otherwise specified by the
authorized customer representative

PPAP
Key points
Supplier Production Trial Run
PPAP pre-production
PPAP SPR
PPAP is not one day job

Supplier Production Trial Run

- Supplier has to proof their process stability before PPAP
production

- Walk through the manufacturing process to verify the

PFD/PFMEA/Control Plan and error proofing
- Make sure KPC and KCC are clearly identified and
communicated at the shop floor
- Make sure operators are properly trained
- Review error proofing application in the process
- Verify the results of the production trial run to determine any
actions required before going to next step
- Verify GM engineering approval status and possible design
change status

Significant Production Run

For production parts, product for PPAP shall be taken

from a significant production run:

From 1 to 8 hours of production

To total a minimum of 300 consecutive parts

Produced at the production site, at the production rate,
using production tooling, gages, operators, etc.

Each unique manufacturing process shall be represented

Bulk material samples shall be taken from steady state
operation

Customer Notification
The organization shall notify the authorized
customer representative SQE of any planned changes
to design, process, or site
Upon notification and approval, and after change
implementation, submission is required unless
otherwise specified

PPAP Submission levels

Level 1 - Warrant only
Level 2 - Warrant with product samples
Level 3 - Warrant, product samples and data
(considered the default level)

Level 4 - Warrant and customer requirements

Level 5 - Warrant, product samples and data for
review at suppliers location
All required information shall be available or included in the
submission (levels 2-4) regardless of submission level!

16. Run @ Rate GP9

Verifies capability
Must meet: QTC on contract
Five working days per week
Required for all new parts
1 Day production at supplier site
= 1 Day usage in GM

Run @ Rate GP9

Key points
Begin from program Kick-Off (Initial GP-9)
Need to verify from time to time
- Tooling/M&E review
- FOS
- PPAP SPR
- After Salable PPAP (According to Hours per day)

No later than 8 weeks prior to SORP

Run @ Rate Approval Decisions

Pass (FULL PPAP)

Pending PPAP
Fail

17. Lessons Learned

Key points
SQE shall review Lessons learned from the every
beginning of a program
SQE shall ensure countermeasure in place to prevent
repeating same problem (Error-proofing, 100%
inspection, SPC)
SQE shall share Lessons Learned of similar
part/process with supplier

SQE shall drive supplier to implement Lessons

Learned as a systematic tool for continuous
improvement

Example: Design Lessons learned and best practice to achieve robust design

Driving GM to be the BEST!!!

Thank You

Global APQP for SQEs