GM 1927 Supplier Quality Manual PDF

General Motors Corporation
Global
Supplier Quality
Manual
Worldwide Purchasing
Global Purchasing and Supply Chain
June, 2012 I GM1927

Preface
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.
APQP
The 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.
Launch
The 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.
Current
The 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
June, 2012 II GM1927

Table of Contents
Preface...............................................................................................................................II
Table of Contents.............................................................................................................III
Manual Content Explanation............................................................................................V
Section 1 – Global APQP

Customer Monitored/Supplier Monitored Matrix..............................................................2
Global APQP RASIC.........................................................................................................3
Document Usage Guidelines.............................................................................................5
APQP Task Definitions
Task 1: Commodity Key Stakeholders Meeting...............................................................6
Task 2: Technical Reviews...............................................................................................7
Task 3: Sourcing Eligibility .............................................................................................8
Task 4: Supplier Gate Reviews.......................................................................................10
Task 5: Timing Charts/Open Issues................................................................................12
Task 6: Quality Systems Basics......................................................................................13
Task 7: Flow Chart.........................................................................................................14
Task 8: DFMEA..............................................................................................................15
Task 9: Design Reviews.................................................................................................17
Task 10: Tool & Equipment Reviews.............................................................................18
Task 11: Gage Development & Approval......................................................................19
Task 12: PFMEA............................................................................................................20
Task 13: Control Plan.....................................................................................................22
Task 14: GP-12 Early Production Containment.............................................................24
Task 15: PPAP................................................................................................................25
Task 16: Run @ Rate......................................................................................................27
Task 17: Lessons Learned...............................................................................................29
June, 2012 III GM1927

Section 2 – Global Launch
Document Usage Guidelines...........................................................................................31
Supplier Quality Launch Project Plan.............................................................................31
Launch Task Definitions
Task 1: Launch Management Team................................................................................32
Task 2: Global Launch Reporting...................................................................................34
Task 3: Supplier Launch Risk Analysis..........................................................................35
Task 4: Launch Issue Escalation.....................................................................................36
Task 5: Supplier Communication Conferences..............................................................37
Task 6: Supplier Layered Audits....................................................................................38
Task 7: APQP Team Reviews........................................................................................39
Task 8: Key Supplier Reviews........................................................................................40
Task 9: Supplier Launch Audit (SLA) Process..............................................................42
Task 10: Build Issue Tracking........................................................................................43
Task 11: Plant Daily Build Summary Report.................................................................44
Task 12: 3rd Party Containment (ESEP) - optional.........................................................45
Task 13: Boundary Samples - optional...........................................................................46
Section 3 – Global Current
Document Usage Guidelines by Global Region..............................................................48
Supplier Training.............................................................................................................49
Approved 3rd Party Providers...........................................................................................49
Current Task Definitions

Task 1: Continuous Improvement...................................................................................50
Task 2: Quality Systems Basics......................................................................................52
Task 3: Shutdown/Start Up Activity...............................................................................56
Task 4: Process Control Plan Audit................................................................................58
Task 5: Creativity Team Support....................................................................................60
Task 6: Global Emerging Issue/Alert Process................................................................63
Task 7: Major Disruption Prevention Activity...............................................................65
Task 8: Controlled Shipping 1........................................................................................68
Task 9: Controlled Shipping 2........................................................................................71
Task 10: Supplier Performance Review Meetings.........................................................75
Task 11: 3rd Party Provider Process................................................................................77
Task 12: Top Focus Process...........................................................................................84
Task 13: New Business Hold/Exit..................................................................................86
Revision History.............................................................................................................88
Glossary of Terms..........................................................................................................93
June, 2012 IV GM1927

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
Forms
GM 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 & Tags

Labels and tags referenced in the APQP process can be obtained as follows:
GMAP and GME – contact the SQE
GMLAAM – 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 Documents
All 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
June, 2012 V GM1927
V
Global APQP Process
Section 1
Global APQP
June, 2012 1 GM1927

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.
Customer Monitored Supplier Monitored

APQP Activity APQP APQP
Supplier GM Supplier GM
1 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) S R S R
Remaining Gate Reviews R A R I
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 – R (1) A R I
GM Design Responsible) S (2) S
9 Design Review (1 – Supplier Design Responsible, R (1) S (1) R (1) I
2 – GM Design Responsible) S (2) R (2) S (2)
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
Global APQP RASIC

June, 2012 2 GM1927
Global APQP Process
APQP Global Regional Dev. SQE Mfg SQE
CT SQE CT SQE
(multiple (1 region
region sourcing)
sourcing)
Pre-Sourcing (APQP Tasks 1, 2, 3)
On-time completion of Sourcing R R S S
Eligibility (APQP Task 3)
SQ Participation in CKSM (APQP Task 1) R R A S
SQ support at Technical Review (APQP R R A I

Task 2)
Completion of QBC QUAD Report (as A A S R
required)
SQ Signature on Recommendation R R C C
Sheet
Handover from Dev SQE to Mfg SQE S S R A
Post-Sourcing (APQP Tasks 4-17)
APQP Kick-off / Gate Review #1 S S S R
APQP Gate Review #2 (-78wks) - - S R
PPAP (-15wks) - - S R
R@R (-8wks) - - S R
Business Processes (GQTS, RLA, etc) - - S R
Key
Multiple Region Sourcing Sourcing involving GM Manufacturing plants in >1 region
1 Region Sourcing Sourcing for 1 plant or multiple plants within 1 GM region
Global CT (Creativity Team) SQE Globally responsible for CT in SQ, may also fill Dev SQE role
when co-located with Product Engineer
Regional CT (Creativity Team) SQE Regionally responsible for CT in SQ, may also fill Dev SQE role
when co-located with Product Engineer
Dev SQE - Development SQE 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
Mfg SQE - Manufacturing SQE Manufacturing SQE is located in the sourced Supplier's
Manufacturing country
R - Responsible Those solely and directly accountable for ensuring task
completion
A - Approving The party (or parties) that reviews and assures the work
product's quality
S - Supporting Individuals or groups who help to create the work product
I - Informed Those who are to be kept informed about proceedings
C - Consulted Those who help design the product or put in place quality
review criteria
Global APQP RASIC (Cont.)

June, 2012 3 GM1927
Global APQP Process
APQP Global CT SQE Regional CT SQE Development SQE Manufacturing SQE
(multiple region sourcing) (1 region sourcing)
Pre-Sourcing (APQP Tasks 1, 2, 3)
On-time completion of Sourcing R =Responsible to track all cross region R =Responsible to track single region S =Support by attending CSSMs and TRs, S =Support by attending TRs as required and
sourcings within the CT and ensure sourcings within the CT and ensure distributing information back to Global CT SQE completing timely audits and QUAD reports
Eligibility (APQP Task 3) appropriate SQ approvals from all regions appropriate SQ approvals from all and providing general follow-up as required to
are provided on time to guarantee regions are provided on time to ensure Sourcing date is met in accordance with
recommendation date guarantee recommendation date SQ requirements
SQ Participation in CKSM (APQP R =Responsible to drive for 100% R =Responsible to drive for 100% A =Attendee at CKSM, approve Engineering S =Support CKSMs where required and
sourcings to be CKSM compliant within sourcings to be CKSM compliant within and Purchasing inputs as acceptable to proceed practical if requested by the Dev SQE
Task 1) CT and ensure appropriate Dev SQE CT and ensure appropriate Dev SQE to RFQ and ensure completeness of SQ inputs
assignment and attendance assignment and attendance (i.e. inclusion of Product / Process specific SQ
SOR)
SQ support at Technical Review R =Responsible to ensure Dev SQE and/or R =Responsible to ensure Dev SQE A =Default attendee at Technical Review I =Optional attendee at TRs by conference call,
Mfg SQE is identified to attend the and/or Mfg SQE is identified to attend (unless delegated, with agreement, to Mfg Required attendee where TRs occur in Mfg
(APQP Task 2) Technical Review and receives timely the Technical Review and receives timely SQE); Review supplier inputs versus SQ SOR for Region, same Approver duties as Dev SQE in
communication from the Buyer communication from the Buyer approval OR follow-up to ensure corrected, this case
completed documentation
Completion of QBC QUAD Report A =Approver to confirm the Regional Mfg A =Approver to confirm the Regional S =Support to define audit requirements (as R =Responsible to complete audits (PCPA,
SQE completes the QUAD approvals as Mfg SQE completes the QUAD approvals per APQP Task 3) and ensure supplier PSA), Greenfield assessments and provide
(as required) required in line with APQP Task 3 as required in line with APQP Task 3 understands and provides necessary input data QUAD Approvals / Rejections from the Mfg
expectations expectations Region in line with APQP Task 3
SQ Signature on Recommendation R =Responsible to sign recommendations R =Responsible to sign C =to be consulted by the Global CT SQE prior C =to be consulted for confirmation via
on behalf of all regions confirming APQP recommendations on behalf of all to sign-off of the recommendation sheet Approved QUAD or, for DUNs locations Green
Sheet Task 3 requirements were met and regions confirming APQP Task 3 to the bidlist, by email acceptance, that a
regional buy-in was given to support requirements were met and regional supplier DUNs location is acceptable for
sourcing (even in the case of Green buy-in was given to support sourcing recommendation
supplier on bidlist) (even in the case of Green supplier on
bidlist)
Handover from Dev SQE to Mfg SQE S =Provide information and S =Provide information and R =Provide information and documentation A =Receive all Pre-Sourcing documentation
documentation from Pre-Sourcing documentation from Pre-Sourcing from the CKSM and Technical Reviews to the from the other functions to utilize in Post-
Mfg SQE Sourcing work
Post-Sourcing (APQP Tasks 4-17)
APQP Kick-off / Gate Review #1 S =Support Kick-Off by communicating S =Support Kick-Off by communicating S =Support Mfg SQE execution of APQP by R =Responsible to ensure supplier compliance
the award to the responsible APQP the award to the responsible APQP providing the direct information link to the to GM1927-34 ahead of the program deadline
Manager and ensuring the link between Manager and ensuring the link between Engineering and Program Homeroom, date including approval of mandatory GQTS
the Lead Buyer and Mfg SQE is the Lead Buyer and Mfg SQE is including but not limited to: attending Gate upload documents; responsible to engage
established established Reviews as requested, direct follow-up of support of Dev SQE as required and track
Engineering Open Issue actions, information follow-up; responsible to confirm
communication of Design Release level EWO part number and DUNs accuracy within GQTS
changes, confirmation and sharing of B1
Appendix volume revisions from DRE and
communication of program homeroom timing
revisions
APQP Gate Review #2 (-78wks) - - S =as above R =as above
PPAP (-15wks) - - S =as above, specifically including M1 GM1411 R =as above

sign-off support and GM 3660 sign-off follow-
up
R@R (-8wks) - - S =as above R =as above
Business Processes (GQTS, RLA, etc) - - S =Support Mfg SQE with part number R =Responsible to ensure accurate
information and root cause investigation of documentation within GQTS, including Key
part numbers missing in GQTS (release vs Documents by APQP Gate, PPAP, R@R and Red
contract) Launch Alerts. Responsible to escalate missing
Part Number / DUNs combination to Buyer
and Program Homeroom
Document Usage Guidelines

June, 2012 4 GM1927
Global APQP Process
F = Reference Only (information only, nothing to fill out)
MD = Mandatory Document (specific format required)
MI = Mandatory Information (format may vary, content mandatory)
1
RD = Recommended Document (not mandated, at a minimum content should be reviewed)
Mandatory
Document Number (Upload to Mandatory Recommended
GQTS)
APQP Project Plan GM1927-01 F
APQP Timing Chart GM1927-02 MI
Supplier Quality Statement of GM1927-03 MD
Requirements (SOR)
APQP Open Issues GM1927-05 MI
Commodity Key Stakeholders Meeting GM1927-06 RD
Checklist
APQP Supplier Assessment GM1927-07 MD
Technical Review Checklist GM1927-13 RD
APQP Kick-Off Meeting Checklist GM1927-14 MD
Process Control Plan Audit Worksheet GM1927-16 MD
GM and Supplier Program Contacts GM1927-17 MI
Process Capability Over Time GM1927-20 RD
RPN Reduction Summary Chart GM1927-21 MD
Directed Buy/Directed Source GM1927-23 MD
Checklist
Subcontractor Program Status Matrix GM1927-25 MD
Subcontractor Detailed Status Matrix GM1927-26 MI
Global Gage Request GM1927-29 MD
QSB Audit GM1927-30 MD
Greenfield & Brownfield Development GM1927-31 MD
Assessment Process
Dimensional Results GM1927-32 MD
GP12 Audit GM1927-33 MD
APQP Supplier Status Workbook GM1927-34 MD
Run @ Rate Capacity Workbook GM1927-35 MD
QSB Workshop Presentation GM1927-36 F
Global 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.
Task Number: 1
June, 2012 5 GM1927

Global APQP Process
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
June, 2012 6 GM1927

Task Number:
Task Name:
Task Owner:
2
Technical Review
Buyer
Global APQP Process
2
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

• 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
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.
• 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
June, 2012 7 GM1927
3
Global APQP Process
Task 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

• 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.
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.
June, 2012 8 GM1927

Global APQP Process
Task Number: 3 continued
Task Name: Sourcing Eligibility
Sourcing Approval Matrix:
Supplier Location CTBL TS16949 Required Audit Comments

Type Quality Quality
Rating Standard
Certified?
Greenfield (New N/A No, but PCPA on Sister Company Performance Data from Other Customers or
Construction) OR Sister Facility Yes. Facility Building Internal Data. QBC from Regional SQ Required. Buyer
Brownfield (Existing Like Product. Must Request Duns be Loaded into CSIDS when
Building) Available.
Greenfield (New N/A No, and PSA on Sister Company Performance Data from Other Customers or
Construction) OR Sister Facility No. Facility Building Internal Data. QBC from Regional SQ Required. Buyer
Brownfield (Existing Like Product. Must Request Duns be Loaded into CSIDS when
Building) 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 Green Yes PCPA Acceptable PCPA, QBC (Quad Report) from Regional
New CT Different Product SQ Required. 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
New CT Different Product Director.
Current Supplier to GM NR Yes PCPA Acceptable PCPA. Need Company Performance Data
New CT Different Product 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 NR Yes PCPA Need Company Performance Data from other Customers
with any GM locations or Supplier Internal Data. QBC from Regional SQ
Required.
New to GM, no business NR No PSA Need Company Performance Data from other Customers
with any GM locations or Supplier Internal Data. QBC from Regional SQ
Required.
New DUNS #, other Duns NR Yes PCPA Review data from other Duns locations. QBC from
currently ship to GM Regional SQ Required.
New DUNS #, other Duns NR No PSA Review data from other Duns locations. QBC from
currently ship to GM Regional SQ Required.
Not on CT Bidlist. N/A Yes None Current Local Bidlist Showing Green on Quality Metrics
Currently Shipping to or Local SQ Approval. – Only Valid for Additional
location that is not using Business to Current GM Customer Location.
GQTS.
Not on CT Bidlist. N/A Yes PCPA Current Local Bidlist Showing Green on Quality
Currently Shipping to Metrics. QBC from Regional SQ Required. – Only
location that is not using Valid for Additional Business to New GM Location.
GQTS.
Not on CT Bidlist. N/A No PSA Current Local Bidlist Showing Green on Quality
Currently Shipping to Metrics. QBC from Regional SQ Required. – Only
location that is not using Valid for Additional Business to New GM Location.
GQTS.
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.
• QUAD report form GM1927-71
• PSA audit
• PCPA GM1927-16
June, 2012 9 GM1927

4
Global APQP Process
Task 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
GVDP 5.0 timing Key Form/
(Time from Review
reference Deliverables Document
SORP in
weeks)
GM Global APQP Supplier Status Summary
ALL GM1927-34
Workbook
QSB Audit (Gap Analysis) or Greenfield GM1927-30
Within 30 days of Checklist (Action Plan) GM1927-31
business nomination Gate 1
Timing Plan GM1927-2
advice / contract
Kick-Off Check list GM1927-14
Initiated after CVER PFMEA Check list GM1927-37
-78 and completed 5 Gate 2 RPN Reduction Summary GM1927-21
weeks after IVER Subcontractor Status GM1927-25
Supplier ADV Plan (ADVP&R) showing
GM1829
execution status
Completed 10 weeks
-52 Gate 3 QSB Audit (Compliance) or Greenfield Checklist GM1927-30
prior Matching 1 GA
(Complete) GM1927-31
Run @ Rate Capacity Workbook GM1927-35
Dimensional Report GM1927-32
Completed 3 weeks
-35 Gate 4 PPAP Worksheet (if not fully approved) GM1411
prior PPV MRD
GP12 Audit GM1927-33
Completed 1 week
-15 PPAP PPAP Approval
prior MVBs MRD
Run @ Run @ Rate Execution R@R Module
-8
Rate PCPA GM1927-16
Customer for Deliverables: SQE, Buyer, Engineer, Readiness Coordinator, Manufacturing as appropriate.

• 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
June, 2012 10 GM1927

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.
• APQP Supplier Status Workbook GM1927-34
June, 2012 11 GM1927

5
Global APQP Process
Task Number: 5
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

• 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
SQ Review the APQP Timing Chart and APQP Open Issues List, minimum monthly.
E
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.
Sup Sub-component milestones shall be pulled ahead of Tier 1 assembly milestones by 6 weeks to
plie protect GM program timing.
r
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.
• APQP Timing Chart GM1927-2
June, 2012 12 GM1927

Task Number:
Task Name:
Task Owner:
6
Global APQP Process
QSB – Quality Systems Basics
Supplier
6
APQP QSB Task must be compliant on or before PPAP
Task Timing: Gate 1 (Gap Analysis) and Gate 3 (Compliance) Gate 3 (Beginning with Model Year 2010 programs)
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 Management
11. 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
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 For Greenfield suppliers, apply the Greenfield & Brownfield Development Assessment Process GM1927-31
/ DRE 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.
• QSB Presentation GM1927-36
• QSB Audit Form GM1927-30
June, 2012 13 GM1927

Task Number:
Task Name:
7
Process Flow Charts

Global APQP Process
• Greenfield/Brownfield checklist GM1927-31
7
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

• Information on each step of the manufacturing process Supplier
• Part-Specific Quality & Process SOR (if applicable) SQE
Resources: Supplier, SQE, Manufacturing Engineer
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.
• AIAG Advanced Product Quality Planning and Control Plan manual Process Flow Chart checklist A-6
June, 2012 14 GM1927

Task Number:
Task Name:
Task Owner:
8
DFMEA
Global APQP Process
Design Owner (GM Engineer or Supplier)

8
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

• 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:
Warranty Teamwork to: Compare with prior DFMEA

1. Bring Lessons
model start-ups and Continue with work
Marketing Learned into
FMEA format revise design to reduce risk (high
Prior model EWOs 2. Determine RPNs guidelines and data RPNs, high severity
and identify KCDS bases accordingly items, KCDS
Build concerns Designators
Designators)
Current SQE launch
& problem reflection
APQP SQE and Revise with new

Supplier input Lessons Learned from
validation and
GM Lessons
June, 2012 15 prototype builds Forward GM1927
to Task 12
Learned shared to use in development
with supplier of PFMEA
Global APQP Process
Task Name: DFMEA
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.
SQ Work with supplier to confirm that a DFMEA and System FMEA have been completed for all
E sub components by the responsible engineering function or the sub contractor.
Design Lead the workshops with GM DRE, SQE and Supplier Engineering and complete the DFMEA. In
Owner 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.
• 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
June, 2012 16 GM1927

9
Global APQP Process
Task 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

• 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
Design Schedule and conduct KCDS workshop. SQE, GM Engineer and supplier participate in workshop. The
Owner purpose of the workshop is to define critical product characteristics, and critical process control
characteristics.
Design Schedule and conduct GD&T review. The SQE, GM Engineer and supplier participate in the review.
Owner 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 For subcomponents, the same process is used to determine lead responsibility in conducting these
Owner 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.
• 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
June, 2012 17 GM1927

Task Number:
Task Name:
Task Owner:
10
Global APQP Process
Tooling and Equipment Reviews
Supplier
10
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

• Approved GD&T, KCDS Designators and Math Data Engineer
• 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
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 Review timing to obtain tools and equipment and functional test in line with program targets for, PPAP
Tooling and Run @ Rate. Verify that the supplier has planned (at minimum) and is working to complete and / or
Engineer tracking the following activities at appropriate time:
(SQTE), if • GM Engineering Design Releases
Available • 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 / At the tooling buy-off or PPAP approval, verify the existence of GM owned tooling and that it is properly
SQTE identified as GM property.
Su Review all timing and inform GM SQE about any changes from original project timing.
ppl
ier
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.
Su Complete the AIAG APQP New Equipment Checklist (A-3).
June, 2012 18 GM1927

Global APQP Process
ppl
ier
• AIAG Checklist A-3
June, 2012 19 GM1927

Task Number:
Task Name:
Task Owner:
11
Global APQP Process
Gage Development & Approval
Supplier
11
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

• 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
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 Review plans and timing to obtain gages in line with program targets for parts, PPAP and Run @ Rate.
Gage Engineer Ensure supplier is tracking and executing key tasks on time as Purchase orders issue, Gage Concept,
(SQGE), if Gage Design, Construction, Dimensional Certification and GR&R Validation. Conduct gage build
Available 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.
Suppl Review timing to ensure compliance and inform GM SQ Gage Engineer and SQE about any
ier 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.
• AIAG Measurement Systems Analysis Manual
June, 2012 20 GM1927
12
Global APQP Process
• General Motors Fixture Standards GM1925
• Gage Request Certification GM1927-29
Task Number: 12
Task Name: PFMEA
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

• 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:
DFMEA (KCDS Designators)

Teamwork to: Clearly identify PFMEA
1. Bring Lessons where in the process Continue with work
Warranty
Learned into flow the prevention to reduce risk (high
Marketing FMEA format of error occurrence RPNs, high severity
2. Determine RPNs and defect outflow items, KCDS
Prior model EWOs and identify will be addressed Designators)
Build concerns / PRRs KCDS Designators
Current SQE launch

& problem reflection Revise with new
Lessons Learned
APQP SQE and from validation,
Supplier input prototype pre-builds,
customer
GM Lessons complaints, and
Learned shared internal data for the
June, 2012
with supplier 21 GM1927
life of the part
Global APQP Process
Task Name: PFMEA
Responsible Methodology: continued

SQE 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.
SQ Ensure Part-Specific Quality & Process SOR (if applicable) is applied to support PFMEA
E development.
SQ Apply the GM1927-37 Checklist and review RPN Reduction Summary Plans GM 1927-21, and
E 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.
SQ Ensure supplier has completed PFMEA reviews with subcontractors.
E
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.
• 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
June, 2012 22 GM1927

Task Number: 13
Task Name:
Task Owner:
Control Plans
Supplier
Global APQP Process
13
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

• Control plans on similar components Supplier
• Process Flow Chart Supplier
• PFMEA Supplier
• Special Characteristics Supplier/Engineer
• 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
June, 2012 23 GM1927
Global APQP Process
recoverable format for a minimum of 3 years.
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.
• Process Control Plan Audit Worksheet GM1927-16
• AIAG Control Plan Checklist A-8
June, 2012 24 GM1927

Task Number:
Task Name:
Task Owner:
14
Global APQP Process
Early Production Containment (GP-12)
Supplier
14
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
Customer for Deliverables: GM Manufacturing or Assembly Facility, Supplier Quality, Purchasing

• Production Control Plan Supplier
• GP-12 timetable GM Customer
Resources: Supplier, SQE, Assembly Plant
SQE Ensure GP12 plan is available (agree on timing and exit criteria) 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.
Sup Require compliance to GP-12 from all subcontractors, as well as monitor and maintain their
plier records. This will require that subcontractors pull ahead their GP-12 to allow the Tier 1 GP12
timing compliance.
Verification for Exit
Sup Meet the defined exit criteria as per GM 1927-28. Supplier to request exit from GP-12 when eligible and
June, 2012 25 GM1927
Global APQP Process
plier provide supporting documentation and assessments on performance and corrective actions, if applicable,
to the appropriate Customer representative. Documentation may be in form of I-chart (GM1927-66) or other
format as per GM 1927-28
GM Verify that the supplier has met exit criteria per GM 1927-28, 4.0. (Minimum of two weeks supporting data.)
Ass Notify the supplier that they have met the criteria and that they are removed from GP-12. GP-12 exit
em letter (GM1927-39) optional.
bly
Cen
ter /
SQ
/
pla
nt
QE
• AIAG Advanced Product Quality Planning and Control Plan manual & Production Part Approval Process Manual
• GP 12 & GP-12 Audit GM1927-33
• GP 12 exit letter GM1927-39
June, 2012 26 GM1927

Global APQP Process
Task Number: 15
Task Name: Production Part Approval (PPAP)
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

• 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
Buyer Contract part, establish initial PPAP submission date and enter date into GPS.
SQE Determine submission level and quantity of samples.
June, 2012 27 GM1927
Global APQP Process
SQE Confirm PPAP submission date with the supplier and ensure supplier updates GQTS as required.
SQ Review the submission and determine the PPAP status in accordance with the AIAG PPAP
E 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.
June, 2012 28 GM1927

Global APQP Process
Task Name: Production Part Approval (PPAP)

SQ Apply the APQP Supplier Status Workbook - PPAP Approval Gate Decision GM1927- 34.
E
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.
Sup Submit PPAP package according to AIAG PPAP requirements for the appropriate submission
plier level on the date agreed on APQP timing chart GM1927-2
Supplier 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.
• AIAG Production Part Approval Process manual
• AIAG Statistical Process Control manual
• AIAG Measurement Systems Analysis (MSA) 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)
June, 2012 29 GM1927

Task Number:
Task Name:
Task Owner:
16
Run @ Rate (R@R)
Supplier
Global APQP Process
16
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

• 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.
June, 2012 30 GM1927
Global APQP Process
Task Name: Run @ Rate (R@R)

Supplier Conduct R@Rs on all parts requiring a R@R.
Supplier 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.
• GM1927-35
R@R Methodology
SQE conducts Supplier completes

Kick-off meeting Manufacturing Flow
Is Yes (Gate 1) and Diagram,
R@R Escalates if Shared Capacity Sheets,
Required? missing any Manufacturing Capacity
contract Estimate and
information submits to SQE
SQE conducts
No APQP meeting Customer
Customer
Supplier conducts
(Gate 3) and Or practice R@R during
Escalates if Supplier PPAP build and/or
missing any Monitored simulations.
supplier
information
SQE has Supplier
Quality and Supplier
Purchasing
Director approve
exemption Supplier conducts Supplier conducts
R@R using the R@R R@R using the R@R
Hourly Sheet with Hourly Sheet with
SQE present. SQE present.
SQE statuses
R@R as exempt EN
Supplier completes D Supplier completes
Capacity Workbook Capacity Workbook
and sends to SQE
Yes and sends to SQE
Is
R@R
SQE statuses SQE statuses
Status “Pass”?
R@R R@R
No
Supplier updates
APQP open issues
list with R@R issues
and SQE follows
Escalation process
June, 2012 31 GM1927

Task Number: 17
Global APQP Process
17
Task Name: Lessons Learned
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

• 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
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 MVBs
As solutions are identified, DFMEA, PFMEA, Flow Chart, and Control Plan are reviewed and updated.
Sup Contribute with additional lessons learned based on knowledge of the commodity.
plier
Sup Adhere to the Part-Specific Quality & Process SOR, (if applicable).
plier
June, 2012 32 GM1927
Global APQP Process
Sup Ensure a formal process is in place to update FMEA and control plans based on Lessons
plier Learned.
Supplier / Review Lessons Learned from the project and incorporate identified key items into Part-Specific Quality
SQE / DRE & Process SOR (if applicable) to ensure that future programs do not have the same issues.
GM Supply Power – Part-Specific Quality & Process SOR
June, 2012 33 GM1927

Global Launch Process
Section 2
Global Launch
June, 2012 34 GM1927

Document Usage Guidelines
F = 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 Recommended

Global Launch Report Template GM1927-40 MD
Supplier Conference Break-Out GM1927-41 RD
Questionnaire
Key Supplier Review Template GM1927-42 RD
Supplier Launch Audit form GM1927-43 MD
Supplier Performance Review GM1927-44 RD
Invitation Letter
Supplier Performance Review GM1927-45 RD
Presentation Template
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.
Supplier Quality Launch Plan PQRR PQRR PQRR PQRR PQRR PQRR
GM GVDP 5.0 33/20
Program Quality Gates PPV MVBns MVBs SORP STC LTR

-32
-21
-15 0 +1
+12
Pre-Production Build BIW BIW BIW M1 PPV PPV MVBns MVBns MVBs MVBs
CVER SVER IVER GA BIW GA Body GA Body GA
MRDs -54 -48 -45 -42 -39 -32 -25 -21 -15 -14
Supplier Milestone PPAP PPAP VTC PPAP R@R

M NS
Gate
Comp

Dates
Task # / -Wks to SORP -76 -72 -68 -64 -60 -56 -52 -48 -44 -40 -36 -32 -28 -24 -20 -16 -12 -8 -4 0 +4 +8 +12
Launch Management SQ Launch Manager SQ Assistant Launch Launch SQEs engaged
1 Assigned -75wks Mgr Assigned -52wks from -52wks
Team
2 Global Launch Reporting Bi-monthly minimum from -42wks
Supplier Launch Risk

3 Rank Suppliers and Develop Hi Risk List
Analysis
4 Launch Issue Escalation Track all issues at APQP G3, G4 and weekly from PPV
Supplier Communication Post Sourcing event Pre Launch event

5 -22wks
Conferences -46wks
6 Supplier Layered Audits APQP APQP

Gate 3 Gate 4
7 APQP Team Reviews Weekly scheduled reviews with APQP teams
Supplier site review Supplier Performance

8 Key Supplier Reviews Monthly reviews from -50wks to MVBns pre-MVBs Reviews as required
Supplier Launch Audit

9 Initial Audit Latest -8wks Re-audit +4wks
(SLA) Process
10 Build Issue Tracking Track all SQ Build issues from PPV
Plant Daily Build Summary

11 Issue daily summary starting PPV (on build days)
Report
3rd party Containment

12 Engage 3rd party from PPV
(ESEP) - optional
Boundary Samples -
13 Develop during MVB phase
optional
Figure 1 – Launch Manual Tasks aligned to GVDP 5.0 33/20 timing
June, 2012 35 GM1927

1
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 Leader assigned

-52wks Additional launch resources identified (if required)
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 (Major, New, MCE3 etc)
• SQ Launch Leader, and where required, additional launch resources.
Customer for Deliverables: Program Launch Manager, Manufacturing, Purchasing, Engineering, Supplier Quality

Program Information (Major, New, MCE3 etc) Program Team
Program Purchasing Manager Purchasing Program Management team
Resources: Supplier Quality, Plant Quality Engineering
SQ Launch
Understand the pipeline of new launches and assign dedicated SQ Launch Leaders to all Major, New,
Group
Derivative, MCE3 or CKD programs by -75wks to SORP.
Manager
SQ Launch Identify additional launch resources based on availability and program complexity and make a plan to
Leader engage them by -52wks to SORP.
SQ Launch
Participate in GLP program review with Plant and launch leadership.
Leader
SQ Launch Move SQ Launch Management Team resources on-site ahead of PPV (approximately -40wks prior to
Leader SORP).
Scope of work for SQ Launch Management Team includes (for detail refer to Tasks in this Manual):
• Maintain supply base risk ranking by DUNs throughout launch to drive mitigation measures and resource
allocation (Launch Manual Task 3).
• Monitor all builds events (IVER, 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).
• Support resolution of GCA, CTF, QAP, PRTS diamond 4 supplier issues (Support QE team).
• 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.
(termed Deep Dives in GMNA – Launch Manual Task 7).
• Support daily GCA, launch activity wrap up, and throughput meetings.
• Represent GPSC at major reviews and problem solving meetings such as: PQRRs, Core IRT’s, VPR, etc.
(as per Program Launch team expectations).
• Oversee structured Launch Issue Escalation process (Launch Manual Task 4).
June, 2012 36 GM1927

Task Name: Launch Management Team (excluding PT)
• Manage communication of Launch expectations to the Supply base (Launch Manual Task 5).
• 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
• Drive Key Supplier Review meetings, e.g. Supplier Performance Review (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). Risk mitigation process?
The Global Launch Process Owner’s Manual
June, 2012 37 GM1927

2
Task Number: 2
Task Name: Global Launch Report
Task Owner: Supplier Quality Launch Leader
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

• Program milestone dates Program Launch Manager
• Launch Alerts APQP SQE
• PPAP and Run@Rate promise dates & metrics APQP SQE / GQTS
Resources: Supplier Quality
SQ Launch Create report in line with global template prior to -42wks to SORP and issue minimum semi-monthly to
Leader relevant program and SQ management.
NOTE: some regions and programs reporting requirements may dictate weekly update post-PPV.
SQ Launch Create cover page using official program launch timing and information, including vehicle image if
Leader released (otherwise use carryover vehicle image).
SQ Launch If program is pre-PPV download Tool Construction Readiness slide from GSTS and include in
Leader presentation, if program is post-PPV use placeholder slide in place of Tool Construction Readiness.
SQ Launch If SORP is <23wks, develop Run@Rate glide path using commitment dates in GQTS and include in
Leader presentation, else if SORP is still >23wks use placeholder slide in place of Run@Rate glide path.
SQ Launch Capture all program Red Launch Alerts on a Red Launch Alert summary slide, cross checking criteria to
Leader ensure all alerts are appropriately identified.
SQ Launch Capture “new” part PPAP statistics in the main body of the presentation (including all part numbers first-
Leader use for the program).
APQP 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.
APQP SQE Issue & Manage Launch alerts in line with the Global Launch Alert criteria and escalate all Red Alerts to
the SQ Launch Leader for consideration in the Global Launch Report.
SMT Manage and Track APQP SQEs to ensure PPAP and Run@Rate are managed in GQTS within program
Manager milestones, and ensure appropriate Red Launch Alert escalation with recovery planning documentation
(i.e. 5 Phase).
• Global Launch Report template, GM1927-40
• Global Launch Alert criteria
June, 2012 38 GM1927

3
Task Number: 3
Task Name: Supplier Launch Risk Analysis
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

• APQP Assessment (1927-07) APQP SQE
• Supplier Bidlist Metrics Status APQP SQE
• Supplier Warranty Data Quality
• Identification of supplier risk drivers
(program timing delays, Greenfield plant, Brownfield plant) APQP SQE
• Open Significant Commercial Issues PPM
• Open Significant Design and Validation Issues PEM, SMT, APQP SQE
• Open EWOs or pending changes without implementation plans PEM, SMT, APQP SQE
• Manufacturing quality experience QE Manager
Resources: Supplier Quality, PPM, PEM, QE Manager, SMT
SQ Launch Compile list of high risk suppliers, respective commodities and issue(s) and confirm with APQP Teams,
Leader PPM and PEM to ensure completeness.
SQ Launch Based on high risk list, define preliminary list of suppliers for Launch Manual Task 5 break-outs, Task 6,
Leader Task 8and potentials list for Task 9.
Revisit risk ranking data periodically during the launch (set intervals or after major build phases) as a
SQ Launch
sense check to understand where risks may have been mitigated or new high risks are emerging. Realign
Leader
resources and focus accordingly.
APQP Supplier Status Workbook, GM1927-34
APQP Assessment, GM1927-7
APQP Timing Chart, GM1927-2
APQP Open Issues List, GM1927-5
June, 2012 39 GM1927

Task Number:
Task Name:
Task Owner:
4
Launch Issue Escalation
Supplier Quality Launch Leader

4
Task Timing: -75wks through SORP
Task Description: Standard process to communicate and escalate all Red Launch Alerts and Emerging Issues.
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

• Program milestone dates GVDP, Launch Readiness Website
• Launch Alerts APQP SQE
• APQP Valve Review delinquencies APQP SQE
• PPAP and Run@Rate promise dates APQP Teams / GQTS
• Launch CAB approved changes and TIDs PPM
SQ Launch Define standard expectations to communicate and escalate items considered as potential Red Launches
Leader (minimum requirement is entry in GQTS).
SQ Launch Monitor all Red Launch alerts for the program.
Leader
SQ Launch If program is within the reporting phase all Red Launch Alerts must be summarized and reported bi-
Leader monthly or weekly as part of the Global Launch Report.
SQE Escalate all potential Red Alerts to the SQ Launch Leader for inclusion in the Red Launch
Communication and escalation process.
SMT Manage and Track SQEs to ensure all potential Red Launches are captured and communicated.
Manager
SMT Follow all Red Launch Alerts in order to guarantee issue closure and implementation of appropriate
Manager corrective actions.
Global Launch Report template, GM1927-40
Launch Alert Criteria, GM1927-15
APQP Open Issues list, GM1927-5
June, 2012 40 GM1927

June, 2012 41 GM1927

5
Task Number: 5
Task Name: Supplier Communication Conferences
Task Owner: Post Sourcing Conference - GPSC PPM

Pre Launch Conference - SQ Launch Leader
Task Timing: Post Sourcing Conference no later than -46 wks

Pre Launch Conference no later than -22 wks
Further 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 (if required)
Key Deliverables:
• Clear and common understanding of all key function requirements in relation (i.e. Supply Chain, Quality,
Manufacturing) to launch across the supply base.
• Launch risk mitigation achieved via supplier executive attendance at the conference 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

Supplier Contacts List PPM
Supplier Launch Risk Analysis SQ Launch Leader
Resources: Launch Team, SQE, Engineering, Manufacturing, Materials, GM Executive Leadership, GPSC PPM,
and Suppliers
Conference Create agenda and identify internal functions and leaders to present functional material at the conference
Owner (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 Identify conference date and location, book facility and attendance of key executives and presenters,
Owner including Master of Ceremonies (3 months prior to conference).
Conference Develop attendee invitation list with contact details and issue invitations with RSVP deadline to all
Owner invitees (2-3 months prior to conference). Include capability for remote participation where required.
SQ Launch Use High Risk Supplier list, in consultation with SMT Managers, to develop list of 10-20 high risk
Leader suppliers for break-out sessions. Issue supplementary invitation to identified suppliers and SQEs for
break-out sessions and provide copy of the questionnaire (GM1927-41) for preparation (1-2 months prior
to conference).
Conference Book meeting room and invite cross-functional GM attendees for break-out sessions (2-4 weeks prior).
Owner
Conference Follow-up with functions for completed presentation material and collate and format into Master
Owner Presentation (1-3weeks prior to conference).
Conference Arrange nametags, refreshments and security access as required based on the final list of conference
Owner attendees (1-3 weeks prior to conference).
Conference Define support staff to manage ingress/egress of attendees, conference registration for attendees and
Owner other support as required (i.e. translators, 1-3 weeks prior to conference).
SQ Launch Collate results from the break-out sessions, track and follow-up closure of critical items with responsible
Leader SQEs and APQP Managers.
Supplier Conference Break-Out Questionnaire, GM1927-41
June, 2012 42 GM1927

6
Task Number: 6
Task Name: Supplier Layered Audits
Task Description: Standardized schedule of Supplier Layered Audits by SQ Team Leaders and Senior Level
Managers at Valve “A”
Key Deliverables:
• Measure effectiveness of APQP execution and ensure appropriate risk mitigation ahead of entering
Manufacturing Build phase.

• Program milestone dates Program Launch Manager
• Supplier Risk Analysis / Ranking Supplier Quality Launch Leader
• SQE audit and PPAP result Supplier Quality Engineer
SQ Launch Review supplier assessment results (SQ Launch Task 3) and group suppliers by SMT. Rank High
Leader 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 Provide list to SQ Team Leaders and Senior Level managers minimum 4 weeks ahead of requested
Leader audit completion date and follow-up for visit schedule (SQ Launch Leader may participate in visit
schedule as auditor).
SQ Launch Record audit results and track follow-up for any RED and YELLOW items until closure. Emphasize
Leader rapid closure of issues ahead of manufacturing build phase.
GM Layered Select audit based on relevance to the identified risk (unless a specific audit is mandated by SQ
Auditor Launch Leader ).,
APQP or SQ Follow-up RED and YELLOW items until closure and report results back to SQ Launch Leader.
Team 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.
APQP Supplier Status Workbook GM1927-34
QSB audit GM1927-30
Greenfield / Brownfield Development Assessment GM1927-31
GP-12 audit GM1927-33
GM1927-43 Supplier Launch Audit
Note: May substitute GM 1927-42 for supplier reviews
June, 2012 43 GM1927

7
Task Number: 7
Task Name: APQP Team Reviews (GMNA Deep Dive Reviews)
Task Description: Weekly deep dive reviews with APQP teams, tracking APQP Valve’s A & B, 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

GQTS Reports APQP Manager
Launch CAB approved changes and TIDs PPM
SQ Launch Schedule regular reviews starting ahead of Week -56. Agree on schedule and frequency of reviews
Manager with APQP Team Managers.
SQ Launch Develop standard reporting template in agreement with APQP Managers, including APQP Gate
Manager 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 Ensure consistent frequency of review for all program part numbers, including strategy for reviewing
Leader 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 Attend review as scheduled and present latest status on the agreed template. Focus on meeting
Supervisor metrics and early escalation of potential issues and Red Launch Alerts with countermeasures.
APQP Supplier Status Workbook, GM1927-34
Launch Alert Criteria
June, 2012 44 GM1927

June, 2012 45 GM1927

8
Task Number: 8
Task Name: Key Supplier Reviews
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

High Risk Supplier list SQ Launch Leader
Phase 1 – Monthly Supplier Presentation at GM site
SQ Launch Based on Risk Analysis from Task 3, identify the major high risk suppliers by SMT for monthly
Leader Key Supplier Review presentation at GM location.
SQ Launch Get endorsement of the list from responsible APQP Team Managers and define the Key Supplier
Leader Review owners by supplier (usually the SQE). The Key Supplier Review list can change at any
time with agreement of the SQ Launch Leader 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 Engage the Key Supplier Review owners to develop a monthly Key Supplier Review schedule,
Leader 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 Define invitation list for Key Supplier Review by supplier (suggested cross functional invitees
Team Manager 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 Follow-up Key Supplier Review owners to ensure consistency of scheduling and communication as
Team Manager well as issue closure.
SQE or SQ Schedule Key Supplier Review and issue invitation monthly to standard distribution minimum 1
Launch Leader 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 or SQ Chair review and arrange conference call details for remote participants as required.
Launch Leader
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.
June, 2012 46 GM1927

Task Number: 8 Continued
Task Name: Key Supplier Reviews
Phase 2 – Pre-MVBs GPSC Executive led visit to Supplier Plant
SQ Launch Based on the Risk Analysis from Task 3 and relative confidence gained through Phase 1 above,
Leader identify High Risk suppliers for GPSC Executive led reviews prior to MVBs (at supplier plant).
SQ Launch Define list of participating GPSC Executives and assign by supplier prior to -20wks. Inform
Leader 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 Nominate suppliers with multiple or major quality issues through PPV, MVBns and MVBs build
Leader phases for on-site review at GM Plant.
SQ Launch Review supplier list with Plant Management to determine which suppliers, if any, they wish to run
Leader Supplier Performance Reviews (SPR) with.
SQE or plant QE Issue SPR invitation letter (GM1927-44) to supplier and SPR standard presentation template
(GM1927-45).
SQE or plant QE Review presentation material with supplier informally in advance of SPR to ensure completeness.
SQE or plant QE Issue invitation to relevant GM Plant personnel, Quality personnel and Engineer.
SQE or plant QE Chair SPR meeting with supplier.
SQE or plant QE Capture open issues, follow-up and report out until closure.
KSR template GM1927-42
Supplier Performance Review Invitation Letter GM1927-44
Supplier Performance Review Presentation Template GM1927-45
June, 2012 47 GM1927

Task Number:
Task Name:
Task Owner:
9
Supplier Launch Audit (SLA) Process
Supplier Quality Launch Leader

9
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

APQP Supplier / Supplier Quality
Master Timing Supplier / Engineering / Supplier Quality
PRR History Supplier / Supplier Quality / Purchasing
Resources: Supplier, Supplier Quality, Product Engineering, Launch Team
Define list of candidate suppliers for SLA based on High Risk Supplier list and Supplier Performance
SQ Launch
during PPV and MVBns build phases (including feedback from Program Launch Team or Plant).
Leader
NOTE: SLA is a Deep Dive audit, it should be applied only to the highest risk suppliers.
SQ Launch Get agreement from responsible SMT Manager and confirm responsible SQE. As required, seek process
Leader expert engagement for audit support.
SQE Establish supplier visit schedule and report back to SQ Launch Leader .
SQE Ensure completion of the Supplier Launch Audit (SLA) form by the Supplier prior to the visit.
Prepare plant and complete Supplier Launch Audit (SLA) form in full prior to audit. Commit
Supplier appropriate resources to the audit, including leadership and functional attendance, to ensure
completeness of reporting and accurate assignment and ownership of Open Issues.
Report audit completion status to SQ Launch Leader and other internal customers. Ensure all Open
SQE Issues are appropriately captured and assigned and establish follow-up schedule – track all issues until
closure.
SQE Initiate Program Management PRRs and /or Red Launch Alerts as required based on audit findings.
Schedule follow-up audit after SORP as required to review major issues for closure or drive focus at
SQE
delinquent suppliers.
Commit to timely closure of all open issues and regular and transparent internal reviews to drive
Supplier
completion.
Supplier Launch Audit (SLA) form, GM1927-43
June, 2012 48 GM1927

10
Task Number: 10
Task Name: Build Issue Tracking
Task Owner: SQ Launch Leader
0
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

IRT Issues IRT Co-chair
GCA/QAP/CTF Issues Program Quality Manager
Launch CAB EWOs PPM
PRRs / Controlled Shipping GQTS / SQEs
Resources: SQ Launch Leader SQEs or Quality Engineers
SQ Launch Create tracking matrix template ahead of first in-plant build event.
Leader
SQ Launch Capture issues from daily summary meetings for SQ follow-up (including verifying correct
Leader 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 Define a review schedule and communicate to ensure SQEs are closing issues and reporting out in
Leader line with requirements (follow-up in APQP Team reviews or schedule alternate meeting).
SQ Launch Continue reviews through SORP until all issues are closed out and launch metrics are achieved.
Leader
June, 2012 49 GM1927

11
Task Number: 11
Task Name: Daily Build Summary
0
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

Daily manufacturing build summary Plant Launch Manager
Daily Quality metrics summary Program Quality Manager
IRT emerging issues Launch SQEs
SQ Launch Develop standard distribution list, including APQP and SQ Managers , responsible Directors and
Leader interested GPSC Executives, and issue standard daily report summarizing manufacturing validation
build activity
SQ Launch Capture issues for follow-up in the Issues Tracking Matrix and ensure closure and feedback to the
Leader plant
Required Data
• Weekly Production Plan and Status

• Quality results for DVT, GCA, and QAP
• PRR’s Open (list in table form and indicate those open longer than 15 days).
• PRR’s issued prior date – include all pertinent information including the SQE contacted to work the
issue.
• Issues being worked which may result in PRR or supplier action.
• Top Red Launch Alerts being tracked
• Future events (build events, PQRR’s, major leadership reviews, etc.)
June, 2012 50 GM1927

12
Task Number: 12
rd
Task Name: 3 Party Containment (ESEP) – optional (Task driven by plant QE organization)
1
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 supplier
This 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

Plant endorsement of ESEP Plant Launch Manager
In-plant location for 3rd party operation Plant Launch Manager
Resources: Supplier Quality, 3rd party quality services provider
SQ Launch Discuss containment strategy with Plant Launch Manager and determine if ESEP is an appropriate
Leader strategy to support manufacturing through the launch.
SQ Launch Identify potential 3rd party suppliers from approved Controlled Shipping provider list. Invite
Leader identified providers to make an ESEP plan and arrange for submission to the Plant Launch Manager
or delegate.
SQ Launch Work with Plant Launch Manager or delegate to get their decision on selected provider, communicate
Leader to supplier and make engagement plan.
SQ Team Send out general notification to all suppliers of ESEP process, including process introduction,
Manager standard templates, ESEP provider contact details and GM contact details for ESEP queries.
3rd party Execute ESEP as per process definition, engaging GM SQE for inspection process approval prior to
provider 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.
ESEP Authorization
ESEP Notification
June, 2012 51 GM1927

13
Task Number: 13
Task Name: Boundary Samples - optional
1
Task Owner: SQ Launch Leader
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

List of subjective parts in dispute Plant Quality
Full part specifications Release Engineer
Range of parts exhibiting reasonable production variation Supplier
Resources: Supplier Quality, Engineering, Quality, Manufacturing, Design Quality
SQ Launch Identify the need for Boundary Samples through plant requests or ongoing dispute over acceptable
Leader part level based on subjective assessment criteria.
SQ Launch Drive Boundary Sample development in the case of parts with disputed GCA mark-ups through the
Leader PPV and MVBns build phases.
SQ Launch Engage SQE, Supplier, Engineer, Design Quality and Plant personnel and schedule review at
Leader 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.
Boundary Sample Process Guide (available through GM Supplypower)
June, 2012 52 GM1927

Section 3
Global Current
June, 2012 53 GM1927

Document Usage Guidelines by Global Region
F = Reference Only (Information only, Nothing to fill out)
NA = Not applicable for specified region
MD = 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 NA
Process Control Plan Audit (PCPA) GM 1927-16 MD MD MD MD
RPN Reduction Summary GM 1927-21 MD MD MD MD
QSB Audit GM 1927-30 MD MD MD MD
Controlled Shipping Assessment Matrix GM 1927-51 MI MI MI MI
Controlled Shipping Assessment GM 1927-52 M M M M
Controlled Shipping Confirmation Reply Form GM 1927-53 MI MI MI MI
Controlled Shipping CS1/CS2 Verification Exit
Checklist GM 1927-54 RD RD RD RD
Controlled Shipping Level 1 Entry letter GM 1927-55 MI MI MI MI
Controlled Shipping Level 1 Exit Letter GM 1927-56 MI MI MI MI
Controlled Shipping Level 2 Entry Letter GM 1927-57 MI MI MI MI
Controlled Shipping Level 2 Exit Letter GM 1927-58 MI MI MI MI
Controlled Shipping Level 2 Exit Survey (Supplier) GM 1927-58a MI MI MI MI
Controlled Shipping Kick-off Meeting Worksheet GM 1927-59 MD MD MD MD
Cross Regional Support Request GM 1927-61 MI MI MI MI
CT Quality Action Plans GM 1927-62 RI RI RI RI
Global Emerging Issue Alert GM 1927-65 MI MI MI MI
Global Emerging Issue Alert Communications GM 1927-65a MI MI MI MI
I-Chart Controlled Shipping GM 1927-66 RI RI RI RI
New Business Hold Process Flow GM 1927-67 F F F F
Drill Deep & Wide PRR Read Across Matrix GM 1927-69 MI MI MI MI
Quad Report GM 1927-71 MD MD MD MD
Shop Floor Excellence (SFE) Audit GM 1927-72 MD MD MD MD
Shutdown/Start-up audit GM 1927-73 MD MD MD MD
Disruption Agenda Format GM 1927-75 MI MI MI MI
SPR Agenda Format GM 1927-76 MI MI MI MI
SPR Invite letter Format GM 1927-76a RI RI RI RI
Step Down Chart GM 1927-78 MD MD MD MD
Supplier Action Plans GM 1927-79 MI MI MI MI
Supplier Performance Assessment Matrix – SPAM GM 1927-80 RI RI RI RI
Top Focus Add/Remove Form GM 1927-82 RI RI RI M
Top Focus Process Notification Letter GM 1927-83 RI RI RI M
5 Whys 3 Times (Drill Deep & Wide Worksheet) GM 1927-84 MI MI MI MI
Drill Deep & Wide Audit GM 1927-85 MI MI MI MI
Drill 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,
June, 2012 54 GM1927

Training Available to Suppliers through 3rd Party Providers
Training (Workshops) APO GME LAAM NA
5S / Visual Workplace X
Applying SPC Tools X
Drill Deep & Wide X
Error Proofing X
Job Set Up Optimization & Error Proofing X
Label Error Proofing X
PFMEA X
Problem Solving X
Quality 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)
Job Set Up
Label 5S & Applying Error
Error Error Visual Problem SPC Proofing &
Proofing Proofing Workplace Solving Tools Optimization CS2
Approved Providers Training Training Training Training Training Training Training Implementation
The PIC Group X X X X X X X
Benchmark
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 X
CEI 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
Task Number:
June, 2012
1
55
1
GM1927
Task Name: Continuous Improvement
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

• 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
SQ Monitor and audit the supplier’s compliance to Continuous Improvement requirements (reference GP-8),
E and also continuous compliance to Part specific SOR / PCPA
SQE 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 Information
b. PFMEA
c. Process/Product Capability
d. 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
June, 2012 56 GM1927
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
Sup Effective Root Cause Analysis and Corrective Action Verification (Compliance with GP-5)
plie • The supplier is required to perform an effective analysis of technical root cause.
r • 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
• 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)
• SPC AIAG Documents
• FMEA, Process Control Plan (GM1927-16 and or 16a-name), Operator Standardized Work Instructions
• Drill Deep Wide Matrix (GM 1927-69)
• KCDS (GM1805, GMW15049)
June, 2012 57 GM1927

Task Number:
Task Name:
2
QSB – Quality Systems Basics

2
Task Owner: GPSC - Current Supplier Quality or Advance Supplier Quality
Task Timing: Throughout life of product APQP QSB Task must be compliant on or before PPAP Gate 3
(Beginning with Model Year 2010 programs)
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 product
3. Verification Stations
4. Standardized Operations
5. Standardized Operator Training – JIT
6. Error proof verification
7. Layered Process Audits
8. RPN Risk Reduction (Reverse PFMEA)
9. Contamination Control
10. Supply Chain Management
11. 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

Supplier Performance Report (6-Panel) Supply Power
Internal & External data analysis Supplier
Internal documentation (i.e. Training documentation) Supplier
Creativity 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
June, 2012 58 GM1927

Task Number: 2 Task Name: QSB – Quality Systems Basics (Continued)
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 For Greenfield suppliers, apply the Greenfield & Brownfield Development Assessment Process
/ DRE 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.
• 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.
June, 2012 59 GM1927

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.
STRATEGY CHAMPION ATTENDEES APROX. DURATION PRE-REQUISITES

Overview – Why are we SQE ALL 30 minutes Model Line/Area
here selection
1) Fast Response Plant Plant Leadership, Quality/ 2 hours Build Fast Response
(Problem Solving, Manager/ Manufacturing Engineers, Board & populate with
Lessons Learned) Manufacturing Facilities Support, issues for review in the
Lead Supervision workshop
2) Control of non- Quality Manufacturing & Quality 1 hour Current examples of

conforming Manager Plant Leadership & documents & or
product Engineers, Model Area standards to compare
Supervisor, team members
3) Verification Plant Manufacturing & Quality 2 hours Verification Station

Stations Manager/ Plant Leadership & initial template/ board
Manufacturing Engineers, Model Area populated with
Lead Supervisor, team members documents
4) Standardized Engineering Manufacturing & Quality 4 hours Shop Floor Marking

Operations (WPO- Manager Plant Leadership & Standards established.
5S, Std. Operation, Engineers, Model Area Current example of
Job Instructions, Supervisor, team members documents to compare.
Gaging)
5) Standardized HR/Personnel Manufacturing & Quality 1 hour Current Method to

operator training Manager Plant Leadership & Train to be reviewed
Engineers, Model Area against the 4-Step
Supervisor, team members Method
6) Error proof Engineering Manufacturing & Quality 1 hour Current examples of

verification Manager Plant Leadership & documents to compare
Engineers, Model Area
Supervisor, team members
7) Layered Process Plant Manufacturing & Quality 2 hours Current examples of

audits Manager/ Plant Leadership & documents to compare
Manufacturing Engineers, Model Area
Lead Supervisor, team members
8) RPN Risk Engineering Manufacturing & Quality 3 hours Current examples of

Reduction (Reverse Manager Plant Leadership & documents to compare
PFMEA) Care Engineers, Model Area
(Customer Supervisor, team members
Acceptance And
Review Evaluation)
9) Contamination Engineering Plant Leadership, Quality/ 3 hours Current examples of
Control Manager Manufacturing Engineers, documents to compare
Facilities Support,
Supervision
10) Supply Chain Quality Corporate, Site, Purchasing 1 hour Current examples of
Management Manager or & Quality Leadership and documents to compare
Corporate Support Staff
Supplier
Quality/
Purchasing
11) Managing Change Engineering Plant Leadership, Quality/ 3 hours Current examples of
June, 2012 60 GM1927
Manager Manufacturing Engineers, documents to compare
Facilities Support,
Supervision
Task Number: 2 Task Name:Quality Systems Basics (Continued)
After each workshop:
• 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 strategy
o 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
June, 2012 61 GM1927

Task Number:
Task Name:
Task Owner:
3
Shutdown / Startup Activity
GPSC – Current Supplier Quality

3
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

• 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: SQE

SQ Leadership
Buyer

Shutdown/Startup Audit Form (GM 1927-73) + Instructions Supply Power
(newest version, 80 Questions)
Master Dot Action Plan (GM 1927-79) Supply Power
High Risk Supplier Listing with CEO & Plant Manager, GQTS
Names, e-mail addresses (reasonable size)
June, 2012 62 GM1927

Resources: SQ Process/Data Group (where applicable)
Task Number: 3 Task Name: Shutdown / Startup Activity (Continued)
SQ Coordinator/SQ • Holds an initial conference call with the representatives to review objectives, the process and
Leader 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.
June, 2012 63 GM1927
Shutdown/Startup Audit Form (GM 1927-73)
Master Dot Action Plan (GM 1927-79)

4
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

PRR Analysis Summary GQTS
Supplier’s Internal Data Analysis Supplier
Process Flow Diagram Supplier
PFMEA Supplier
Process Control Plan Supplier
Resources: Supplier Representative, SQE
SQE Decides or is assigned to visit a supplier to:
Review a specific issue/concern
Review an overall performance concern
Gain 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.
June, 2012 64 GM1927
SQE
Chooses appropriate audit or audits to conduct.
Ensures that appropriate supplier representatives participate in the audit.
Ensures the Supplier understands documented concerns/non-conformances. 4
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 actions
Action plans, format and due dates
Follow-up time frame
Additional 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.
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.
Supplier Action Plan (GM 1927-79)

Continuous Improvement (GP-8)
June, 2012 65 GM1927

5
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.

CT Performance Report (6 Panel) Supply Power
Creativity Team Bid List (CTBL) GQTS
CT Metrics Tool (Monthly) Supply Power
Quality Progress Chart (CTBL) GQTS
PRR detail review GQTS
CT Roll out schedule CT
CT SQ Roles and Responsibilities Supply Power
QSB (Quality Systems Basics – GM1927-30) Supply Power
Quad Report (GM1927-71) Supply Power
PCPA (Process Control Plan Audit - GM1927-16) Supply Power
PSA (Potential Supplier Assessment) Supply Power
June, 2012 66 GM1927

Resources: Supplier Quality Engineer – Global Champion & Regional Assigned CT Support, Global /
Regional Buyers, CT members, Global / Regional Commodity Manager, Global / Regional Commodity Director,
Supplier
Task Number: 5 Task Name: SQE Creativity Team Support (Continued)
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 Provides CT agenda for each meeting, reviews CT business plans, rollout schedule (monthly), establish
Manager 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 Coordinates the sourcing package review before the GPSC ISC Sourcing meeting within the CT
Manager 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 Add and remove suppliers to the CT Bid list as agreed by the CT – SQ CT Global Champion reviews
June, 2012 67 GM1927
/ CT and approves or rejects actions to the CT Bid list weekly.
Members
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.
Task Number: 5 Task Name: SQE Creativity Team Support (Continued)
• 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
June, 2012 68 GM1927

6
Task Number: 6
Task Name: Global Emerging Issue/Alert Process
Task Owner: SQ Representatives
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.

• 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 float
6) Excessive repair time
7) Main assembly line downtime
8) 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.
June, 2012 69 GM1927

Problem description Assembly Center/SQ /QE
Global Customer Audit (GCA) Assembly Center
Direct Run Rate, Direct Run Loss, verification stations Assembly Center
C.A.R.E. Assembly Center
Shipping Hold Assembly Center
Vehicle Repair Float Assembly Center
Main 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)

Assessment Phase
QE/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 Manager
QE/SQ Determine if other GM locations are affected and notify Quality Leadership at each location
QE/SQ Assesses which of the following situations exits:
Situation A: Supplier is located in the same region as all GM receiving locations
Situation 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-5
Implementation 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 Action
Additional process controls (error proofing, layered auditing, etc.)
Regional SQ Travel to Supplier’s Location to confirm containment and corrective actions
June, 2012 70 GM1927
Supplier 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-5
Attend all Conference calls as required.
Participate in any/all follow up reviews/audits at the Supplying location.
GP-5
Global 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.
7
**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.
Task Number: 7
Task Name: Major Disruption Prevention – (as per GP-5)
Task Owner: GPSC – Current Supplier Quality
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

• 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
June, 2012 71 GM1927

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

• 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)
Resources: Supplier, Quality Engineer, GM Assembly Plant Personnel, and Supplier
SQ Select Suppliers for targeted Major Disruption prevention activity
Lea Train SQE’s relative to expectations and required audits
ders Assign SQE’s to selected suppliers
hip
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 • Conduct Supplier conference with Executive leadership of Supplier

Lea • Review Major Disruption Prevention Plan
ders • Clearly present expectations, deliverables, and consequences.
hip/
SQ
E
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
June, 2012 72 GM1927
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)
• GP-5
• GP-8
• GP-12
• Supplier Quality SOR GM1927-3, Part Specific Quality SOR (GM1927-03a-name)
• Drill Wide Matrix (GM 1927-69)
• 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
June, 2012 73 GM1927

8
Task Number: 8
Task Name: Controlled Shipping Level 1 (CS1)

Task Owner: Supplier Quality Engineer (SQE)
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
• I-Chart (GM 1927-66) to demonstrate product quality conformance (nonconforming vs.
quantity checked)
June, 2012 74 GM1927

• 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

Problem Reporting and Resolution (PRR) Mfg/Assembly Centers/SQE / GQTS
Request 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)
SQ Assessment Phase
E 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 Entry/ Implementation Phase
SQE 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.
June, 2012 75 GM1927

 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
Supplier 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 Monitor and Check Phase
Perform 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 charts
Determine 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)

SQE
Monitor supplier’s containment data (I-chart.)
Verify the supplier has a documented process control validation program in place (such as job setups, setup
error proofing, process error proofing, layered auditing, operator training & certification etc.)
Sup Meet the defined exit criteria.
plie Request exit from Controlled Shipping - Level 1 and provide supporting documentation and assessments on
r 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
SQ /Manufacturing Center, or coming out of the Supplier’s process.
E 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)
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)
June, 2012 76 GM1927
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*
9
Task Number: 9
Task Name: Controlled Shipping Level 2
Task Owner: Supplier Quality Engineer (SQE)
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)
June, 2012 77 GM1927

Key Deliverables:
• Certified Material to Assembly Plant
• 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 / GQTS
Request 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)
SQ Assessment Phase
E 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
the decision to place the supplier in CS1. This decision may also involve a SQ Manager.
SQ Entry/ Implementation Phase
E SQE 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 SQE
SQE 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:
June, 2012 78 GM1927

 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.
Sup
plie Implement CS 2 based on the requirements defined on the entry letter and confirmed by the SQE during
r& the kick off meeting.
CS Notify additional GM facilities that use the same part, inform them of the nonconformance, and provide
3rd containment activities as necessary.
Part Track breakpoints of nonconforming material. (Purge pipeline of suspect material, i.e. at Customer’s
y facility, in transit and at all storage locations.)
Pro Task Number: 9 Task Name: Controlled Shipping Level 2 (Continued)
vid
er
Sup Entry/ Implementation Phase

plie Commence the sort activities and display the results in a public and visible location.
r& The 3rd Party Provider performs an additional redundant inspection of all suspect non-conforming
CS products per the agreed upon process to ensure defect free parts are delivered to Customer.
3rd If applicable, 3rd party Provider Quality Engineer or Customer SQE to reviews the Supplier’s process and
Part quality history, and completes the Assessment.
y Supplier submits irreversible corrective action plans to the ISO/TS16949 registrar for review and/or
Pro assessment and authorizes ISO/TS16949 registrar to submit the review and/or assessment findings to the
vid Customer.
er
Monitor and Check Phase

Supplier Perform 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 charts
Determine 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.
June, 2012 79 GM1927
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)
SQE 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 again
Verify supplier’s root cause analysis and corrective actions.
Resolve any discrepancy in the interpretation of the inspection criteria between the supplier and the 3 rd
Party Provider
Interface between the supplier and the CS 2 Third Party provider to ensure the CS 2 process is conducted
without interruptions.
Sup Meet the defined exit criteria.
plie Request exit from Controlled Shipping - Level 2 and provide supporting documentation and assessments
r on performance and corrective actions to the appropriate Customer representative (Customer plant
SQ representative will be notified if required). Upon exit of CS2 the supplier should complete the CS2 Exit
E Survey 3rd Party Provider Services GM1927-58a and send to the GM Regional 3 rd 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)
GP-5
Kick-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)
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*
June, 2012 80 GM1927

10
Task Number: 10
Task Name: Supplier Performance Review Meetings
Task Owner: GPSC – Current Supplier Quality
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.

• 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
June, 2012 81 GM1927
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

Supplier Performance Report (6 panel) Supply Power
PRR Analysis Summary Supply Power / GQTS
GM Assembly Plant/3rd Party quality data Plant QE/3rd Party
APQP SQE
Launch SQE
Supplier’s Internal / External Data Analysis Supplier / SQE/QE
Drill 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)
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).
June, 2012 82 GM1927
SQE/QE
- Supplier CT Bid list (optional)
11
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.
• 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)
Task Number: 11
Task Name: 3rd Party Provider Process

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
June, 2012 83 GM1927
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,

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 / SQ
Pre-RFQ the potential new and old for each of the services GPSC Buyer / SQ
Determine approved list based on price / quality / service / experience GPSC Buyer / SQ
3rd Party Provider Agreement of services (ESEP / QCC, CSII, Workshops) 3rd Party Providers / GM Customers / SQ
/ Buyer
Supplier placed on ESEP / QCC or Controlled Shipping Level II GM Assembly Center
Supplier selection of GM Approved 3rd Party Provider CSII Supplier / GMSP Quality
Supplier selection of 3rd Party Provider Contract Established Supplier
Supplier Quality Performance needs improvement – workshop SQ / Supplier / GM Customer
Supplier selection GM Approved Workshop Provider or Specific Audit Supplier
Evaluation of new and old GM Approved 3rd Party Providers GPSC Buyer / SQ
PRR’s Problem Reporting Resolution GQTS
Controlled Shipping Level 1 and Level 2 GQTS
Resources: Supplier Quality, 3rd Party Provider, Supplier, Purchasing, GM Assembly Center / Plant Personnel
3rd Party Provider Methodology: (GM Approved CS2 Providers only)

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 3rd Party Providers
for Controlled Shipping Level 2 & Other Services (Workshops)
SQ / GM Buyer Creates and approves SOR (Statement of Requirements) for the 3rd Party Provider services that can be
(Regional) sent to potential providers.
Global Process Communicate Technical requirements / criteria for provider selection via Tech Review Checklist
SQ • Compliance to the Quality Statement of Requirements (SOR) for 3rd Party Providers
for Controlled Shipping Level 2
• Understanding of GP-5
• Pricing
• ISO 9001 Certification
• Geographic Footprint
June, 2012 84 GM1927
• Engineering Capabilities
• Training Capabilities
• Containment – CS2, Duration, Escapes, PRR Performance
• Special Services
• Requesting Approval in other countries
SQ / GM Buyer Coordinates with the GM buyer to conduct Pre-RFQ, Tech Review and agreement of SOR or scope of
(Regional) 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 Provide company presentation of the services that they offer, their current customers, shared best
Party Provider 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 Approved 3rd Party Providers will understand GM GP-5 procedure, understanding of Controlled
Party Provider / Shipping (CS) Level II process and timeline requirements and the requirements to provide standardize
Supplier 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 GM buyer / SQ will agree on services capped rates that the 3rd Party Providers can charge the supplier
Indirect Buyer for the services that they are contracted to perform. GM will determine either capped rates or the
(Global / specific rates for the different services.
Regional)
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 Maintains the Global GM Approved 3rd Party Providers listing and postings in GM SupplyPower
SQ 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 Review current Controlled Shipping services being provided, monitor exit timing and cost on-site
SQ review of the services being performed. Layered audit of the services provided to the supplier.
Newly Provider conducts required number of pilots for the services contracted for and includes layered
Approved 3rd audits along with customer survey or as determined by the regional SQ group to validate that the
Party Providers required services are being met.
(Regional)
3rd Party Other requirements include –
Provider -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,
3rd Party Provider Methodology: (GM Approved CS2 Providers only)
(Continued)
3rd Party
Provider -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 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 GM Customer could or shall write Customer Satisfaction PRR’s to the Controlled Shipping II
June, 2012 85 GM1927

Center / SQ / providers if the non-conforming material inspection has escaped the 3rd Party Provider containment
SQ Group 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
GP-5
Quality Statement of Requirement (SOR) for the 3rd Party Providers for Controlled Shipping Level 2 & Workshops
GM Approved 3rd Party Providers – CS2 & Workshops (GM SupplyPower – Quality Library)
3rd Party Provider Management Reference Manual – Controlled Shipping Level 2
Workshop Deployment Process – QSB/DDW/LEP Flowchart
QSB – Workshop Supplier Overview Materials, GM1927-30, GM1927-36
DDW – Workshop Materials, GM1927-84, GM1927-85 and GM1927-69
LEP – Workshop Materials (providers creates – must receive GM approval)
CS2 Exit Customer Satisfaction Survey 3rd Party Provider GM1927-58a
GM 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 website
ESEP Rasic Process Chart - posted in GMNA Quality website
ESEP Controlled Shipping Level II Interaction Flow Chart – posted in GMNA Quality website
ESEP Process For Metal Center Issues – posted in GMNA Quality website
ESEP Tracking Form & Kickoff Form – posted in GMNA Quality website
QCC (Quality Confirmation Center – GME) – refer to GME websites
Reference only –Global SQ Manual GM1927 - Launch Task 12, Third Party Containment (ESEP)
3rd Party Provider Methodology: (GM Approved Workshop Providers Only - QSB, LEP,
DDW only)
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 3rd Party Providers for Controlled
Shipping Level 2 & Other Services (Workshops)
(Regional) sent to potential providers.
SQ • Compliance to Quality Statement of Requirements (SOR) for 3rd Party Providers
for Controlled Shipping Level 2 & Other Services (Workshops)
• Understanding of GP-5
• Pricing
June, 2012 86 GM1927
SQ / GM Buyer Coordinates with the GM buyer to conduct Pre-RFQ, Tech Review and agreement of SOR or scope of
(Regional) service expectations and recommendation for services based quality, service, competitive price,
experience and proper resources as requested by the GM supplier base as needed.
Party Provider practices, survey results or awards, company global or regional footprint, skill set matrix of their
Workshops employees providing services, identify master trainer and lead trainers, certification plan and evidence
of demonstrated capability of the services quoting.
Party Provider Shipping (CS) Level II process. 3rd Party Provider and or GM will provide the workshop materials.
Workshops 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
Potential 3rd party provider and or GM.
Party Provider
Workshops
SQ / GM Buyer GM buyer / SQ will agree on services capped rates that the 3rd Party Workshops Providers can charge
(Regional) 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 Maintains the Global GM Approved 3rd Party Workshop Providers listing and postings in GM
SQ 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 GM Approved 3rd Party Workshop Providers must conduct Layered audit of the services they provide
Approved 3rd the GM supplier.
Party Providers
Workshops
(Regional)
Newly Workshop Provider conducts required number of pilots for the services contracted for and includes
Approved 3rd layered audits along with customer survey or as determined by the regional SQ group to validate that
Party Providers the required services are being met.
Workshops /
(Regional)
3rd Party 3rd Party Provider Methodology: (GM Approved Workshop Providers Only -
Workshop QSB, LEP, DDW only) (Continued)
Provider Other requirements include –
-Financial Stability and ability to provide adequate resources,
-Evidence of current ISO9001 certification,
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
June, 2012 87 GM1927
-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.
GP-5
3rd Party Provider Methodology: (ESEP (GMNA) / QCC GME)

GM Assembly Determines how many 3rd party providers need to be on the approved list for the specific GM
Centers / Assembly Center / GM Metal Center / GM Powertrain Assembly Center– regional for such services –
(GMPT, Metal ESEP (Enhanced Supplier Engagement Process) See GMNA Quality web-link of related ESEP
Center) / SQ / documents or QCC (Quality Confirmation Center) in GME.
GM Buyer http://quality.gm.com/mfg_quality/common_processes/nc_material/nc_material.html#top
(Regional) See Quality Statement of Requirements (SOR) for the Enhanced Supplier Engagement Process.
(Regional) sent to potential providers based on input from GM Assembly Centers, GMPT Assembly and GM
Metal Centers.
SQ / GM • Compliance to Quality Statement of Requirements (SOR) for the Enhanced
Assembly Supplier Engagement Process
June, 2012 88 GM1927
Center • Understanding of GP-5
• Pricing
GM Assembly Coordinates with the GM buyer to conduct Pre-RFQ, Tech Review and agreement of SOR or scope of
Centers / service expectations and recommendation for services based quality, service, competitive price,
(GMPT, Metal experience and proper resources as requested by the GM supplier base as needed.
Center) / SQ /
GM Buyer
(Regional)
Party Provider practices, survey results or awards, company global or regional footprint, skill set matrix of their
ESEP / QCC employees providing services, identify master trainer and lead trainers and evidence of demonstrated
capability of the services quoting.
Party Provider Shipping (CS) Level II process and timeline requirements and the requirements to provide standardize
ESEP / QCC work in a timely manner. Must comply with the Quality Statement of Requirements (SOR) for the
Enhanced Supplier Engagement Process.
GM Buyer / SQ Overall responsible for the ESEP Approved 3rd Party Provider process shall include the specific GM
/ SQ Group Assembly Center representative, GM Buyer, Supplier Quality, and SQ Group Manager / Director.
GM Assembly Upon all GM assembly centers agreement the GM Buyer will issue at purchasing PO# to contract the
Centers / ESEP / QCC provider the specific GM location and for the contracted time. Regional contracted rates
(GMPT, Metal will be controlled and quoted in their specific region with their own currency.
Center)
Global Process Maintains the Global GM Approved 3rd Party Providers ESEP / QCC listing and postings in GM
SQ SupplyPower Quality Library – 3rd Party Provider Management - Services
Assembly GM Assembly Center contacts supplier regarding being placed into ESEP / QCC process and the GM
Center / representative will contact the GM contracted GM Approved ESEP / QCC provider to begin
Supplier implementing problem free products to the specific GM Assembly Center(s).
Approved Provider will inspect, check, and /or test suspect material and sort to contain the defect utilizing a sort
ESEP / QCC log and ESEP / QCC sort tracking form. GM shall determine the inspection criteria and provide
Provider 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 3rd Party Provider Methodology: (ESEP (GMNA) / QCC GME) (Continued)
Center 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 will have capabilities to provide transportation of parts (if necessary), to electronically
Provider 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.
ESEP / QCC Provider must provide an implementation plan to include the following dates: ready to begin ESEP /
Provider QCC, location established to perform sorting / rework and logistics / communication with the GM
Assembly Center.
June, 2012 89 GM1927

ESEP / QCC Other requirements include –
Provider -Financial Stability and ability to provide adequate resources,
-Evidence of current ISO9001 certification,
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 Review current ESEP / QCC services being provided, monitor exit timing and cost on-site review of
Center / SQ 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)
GP-5
Task Number:
Task Name:
Task Owner:
12
Top Focus Process

GPSC – Current Supplier Quality
12
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
June, 2012 90 GM1927

targets with consequences identified for failure to meet these targets. Leadership engagement, accountability, and
escalation are key success factors.

• 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

Supplier Quality
Creativity Team

Supplier Performance Report (6 panel) Supply Power
PRR Analysis Summary GQTS
Resources: SQ Manager, Supplier Quality Engineer, Buyer, Supplier
Task Number: 12 Task Name: Top Focus Process (Continued)
SQE • Review performance data.
• Initiate Top Focus entry request.
• Develop Quad Report and Stepdown Chart.
• Perform Audits.
June, 2012 91 GM1927

•
•
•
•
•
Track progress, review improvements and audit for acceptability.
Execute Stepdown Consequences, as appropriate.
Share best practices. 13
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)
Task Number: 13
Task Name: New Business Hold

June, 2012 92 GM1927

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

Quad Report (GM 1927-71) SQE / GMSP
PRR Analysis Summary SQE - GQTS
Supplier Performance Report (6 Panel) GMSP Supplier Performance
Metrics
Warranty 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.
June, 2012 93 GM1927
Exit from NBH
• 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.
SQE Creates Quad Report with supporting NBH data.
SQE Obtain SQ Management approval for request – provide to SQ regional leadership.
SQ Present requested NBH (Adds only) at the SQ Executive Directors Staff Meeting
Leadership
SQ Exec. SQ Executive Director reviews with Purchasing Leadership and determines proper actions or status of
Director requested NBH (Adds only)
SQ Upon requested NBH Add received approval from SQ Executive Director / NBH Coordinator -
E 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 Creates NBH letter with required GM signatures, issues NBH PRR in GQTS, Provides distribution of
Coordinator 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 Creates NBH Removal letter with required GM signatures, Closes the NBH PRR in GQTS. Email sent to
Coordinator NBH distribution of the weekly NBH actions taken.
SQE / Reviews next updated CT Bid list for removal of NBH (Coded N= no or not on NBH or Coded Y=yes
Supplier currently on NBH) for the supplier specific duns code.
Supplier Notifies their specific ISO/TS16949 Registrar of the NBH Exit actions.
• 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

Revision History
Global APQP Process
January, 2004
June, 2012 94 GM1927
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 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.
June, 2012 95 GM1927

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.
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.
Appendices
Appendix 1 Complex Systems/Sub- Moved Document Usage Guidelines to the beginning of the
assemblies APQP Management APQP manual and made Complex Systems Appendix 1.
Plan
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 Warranty
Legend Legend updated to correctly show Internal and External versus GM only sources.
June, 2007
Various 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
June, 2012 96 GM1927
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,
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 removed

QSB —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
Appendices
Appendix 1 Complex Systems/Sub- Removed
assemblies APQP
Management Plan
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
June, 2012 97 GM1927

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
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

May, 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
June, 2012 98 GM1927

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
February, 2009
Section #2 Tasks 1-13
Section #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 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,
August, 2011

Section #2 Launch Manual Update – various minor changes to reflect current work practices.
November, 2011
June, 2012 99 GM1927
Section #2 Tasks 4
Launch Manual Update – Added reference to GM 1927-15.
June, 2012
Section #1 Tasks 14
Add optional GM 1927-39 GP12 Exit Letter.
Glossary of Terms
AAR: Appearance Approval Report
ADV: Analysis/Development/Validation
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)
June, 2012 100 GM1927

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.
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

June, 2012 101 GM1927
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.
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
June, 2012 102 GM1927

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
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

June, 2012 103 GM1927
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.
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
June, 2012 104 GM1927

GM 1927 Supplier Quality Manual PDF

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GM 1927 Supplier Quality Manual PDF

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General Motors Corporation

Global Purchasing and Supply Chain

June, 2012 I GM1927

Global Supplier Quality Directors

June, 2012 II GM1927

Section 1 – Global APQP

June, 2012 III GM1927

Current Task Definitions

June, 2012 IV GM1927

GM General Procedures (GPs)

Labels & Tags

June, 2012 V GM1927

June, 2012 1 GM1927

Customer vs. Supplier Monitored APQP

Customer Monitored Supplier Monitored

R Responsible - Task Owner (GM or Supplier)

Global APQP RASIC

SQ support at Technical Review (APQP R R A I

Global APQP RASIC (Cont.)

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 R =as above

Document Usage Guidelines

Obsolete Documents: GM1927-4, GM 1927-8, GM 1927-9, GM 1927-10, GM 1927-11,

June, 2012 5 GM1927

Task Owner: Buyer

Task Timing: Pre-Sourcing

Necessary Inputs: Source of Input:

Resources: Purchasing, Supplier Quality, Engineering

June, 2012 6 GM1927

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

Necessary Inputs: Source of Input:

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

Task Name: Sourcing Eligibility

Task Owner: SQE

Task Timing: Pre-sourcing

Customer for Deliverables: Purchasing

Necessary Inputs: Source of Input:

Resources: Purchasing, Supplier Quality and Supplier.

June, 2012 8 GM1927

Task Name: Sourcing Eligibility

Sourcing Approval Matrix:

Supplier Location CTBL TS16949 Required Audit Comments

June, 2012 9 GM1927

Task Name: Gate Reviews

Task Timing: As shown on APQP Project Plan

Necessary Inputs: Source of Input:

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

June, 2012 10 GM1927

Task Name: Gate Reviews

• APQP Supplier Status Workbook GM1927-34

June, 2012 11 GM1927

Task Name: Timing Chart and APQP Open Issues List

Task Owner: Supplier

Task Timing: Reviewed at Gate Reviews and throughout the program

Customer for Deliverables: Supplier Quality Engineer

Necessary Inputs: Source of Input:

June, 2012 12 GM1927

QSB – Quality Systems Basics

1. Fast Response • Standardized Work Instructions – SOS

Customer for Deliverables: Supplier Quality

Necessary Inputs: Source of Input