GMAPQP手册.docx

GM Advance Product Quality Planning Manual

Table of Contents
GM ADVANCE PRODUCT QUALITY PLANNING 1
WORK INSTRUCTIONS 2
VALVE A 3
General Requirements 3
Design Review 3
Commercial Issues 4
Plant Layout and Process Flow 4
DFMEA 4
Lessons Learned and Warranty 5
Gage and Tooling Equipment Review 7
Validation and ADVP & R 8
PFMEA and Error Proofing 8
Process Control Plan 8
Dimensional Plan 9
Materials/DCS File Logs 10
Design Appearance Quality 10
Containerization 10
Tiered Supplybase 11
PPAP 11
R@R 12
GP-12 12
QSB 12
VALVE B 14
General Requirements 14
Design Review 14
Commercial Issues 15
Plant Layout and Process Flow 15
DFMEA 15
Lessons Learned and Warranty 16
Gage and Tooling Equipment Review 16
Validation and ADVP & R 16
PFMEA and Error Proofing 17
Process Control Plan 17
Dimensional Plan 17
Materials/DCS File Logs 17
Design Appearance Requirements 18
Containerization 18
Tiered Supply-Base 18
PPAP 19
R@R 19
GP-12 19
QSB 19
PPAP 21
General Requirements 21
Commercial/Open Issues 21
PFMEA & Error Proofing 21
Design Appearance Requirements 21
Tiered Supply-Base 22
R@R 22
GP-12 22
R@R 23
General Requirements 23
Design Reviews, Math, and GD&T 23
PFMEA & Error Proofing 23
Tiered Supply-Base 23
GP-12 23
APPENDICES 24
Appendix A - APQP General Timing 25
Appendix B – Assessment Rasic 26
Appendix C – Global APQP RASIC 27
Appendix D – Required Documents, References, & Resources 28
Design Review 28
Commercial Issues 28
Plant Layout and Process Flow 28
DFMEA 28
GM SQE 28
Lesson Learned and Warranty 28
Gage and Tooling Equipment Review 28
Validation and ADVP&R 28
PFMEA and Error Proofing 28
Process Control Plan 28
Dimensional Plan 28
Material & DCS Logs 29
GM DE & Materials Eng. 29
Appearance/Grain/Cloth 29
Containerization 29
Tiered Supplybase 29
PPAP 29
R@R 29
GP 12 29
QSB 29
Appendix E – Glossary 30

GM Advance Product Quality Planning
GM’s vision is to Design, Build, and Sell the World’s Best Vehicles, in order to do that we must have a robust plan. That plan must include great designs, great manufacturing processes and great quality systems. We have learned that the critical components to a successful quality system are communication and standardized work. The purpose of this manual is to communicate GM’s expectations and provide standardized work during the product development cycle.
This manual is intended as a supplement to the AIAG Advance Product Quality Manual, which provides the framework and detail for good advance quality planning. The manual is designed to help GM personnel and suppliers understand the expectations specifically related to GM launches.
In order to help support GM’s vision, the planning process has been split into four reviews, Valve A, Valve B, PPAP and R@R. In the following sections there are four procedures defining ‘who, what, and when’ for each of the review. Each procedure includes standardized work showing the requirements, escalation options, reference documents, and methodology behind each task.

Work Instructions
The following are the work instructions for the task requiring a status of Red, Yellow, or Green. They are intended to show the SQE and Supplier what the ‘ideal’ state for each task is. The ultimate goal is to reach the ‘ideal’ state for each task in order to support program timing for delivering a quality part by the required PPAP date. Deviations from the ‘ideal’ state are listed in the work instructions. The appropriate category shall be selected and loaded into GQTS by the supplier regardless if the part(s) are statused as Supplier or Customer Monitored. If the parts(s) are statused as Customer-Monitored, the SQE will approve the supplier’s submission. A worksheet (GM 1927-34) has been provided for the SQE and supplier to use as a summary sheet. Also, included in the work instructions are Resources and References, regional documentation requirements, and suggested methodologies to help the team achieve the required content.

Valve A
General Requirements
Timing:
· Valve A is targeted to be completed three (3) weeks prior to Tool Kick-Off (TKO). TKO is commodity specific and is based on the official program timing template generated through the Program Timing Office.
· The individual tasks shall be cadenced appropriately from sourcing to the Valve A event. See Appendix A for recommended cadence of events.
Ownership:
· All events (Valve A, Valve B, PPAP and R@R) shall be coordinated by the supplier with input from SQE.
· Valve A shall be attended at a minimum by:
o Supplier: Program Management, Quality, Manufacturing, and Engineering
o GM: SQE, Design Release Engineer, and Purchasing
o Optional attendees: Dimensional Engineering, GD&T group, and Appearance Engineer
Deliverables:
· A supplier kick-off meeting shall be conducted at award of the business. The GM 1927- 14 should be used as reference and best practice for the meeting agenda and content discussion. GM SQE shall communicate program timing deliverables at that time. The supplier shall maintain a contact list for each program over the life of the program. The list shall include at a minimum: Name, Position, Cell Phone, email, 24-hour contact, and escalation priority (i.e. who should be called 1st, 2nd, etc) for all necessary supplier personnel.
· Each program shall have one open issues list that includes all program issues; this would include, but is not limited to, all commercial, design, engineering, quality and manufacturing issues.
· APQP specific timing items shall be maintained on one overall program management timeline with additional program critical information such as timing for tooling, testing etc.
· Red, Yellow, or Green status shall be identified for each item listed per Appendix A and documented according to GM1927-34 in the APQP module.
Design Review
· Engineering has confirmed that math data is released and is accessible to supplier.
· Math data and related files include all appropriate notes on other necessary items such as materials, test specifications, software requirements, etc.
· Released engineering data has been compared to the SOR/SSTS and CTS; all discrepancies have an adequate action plan for resolution.
· Supplier to confirm availability of the math data and notes and has confirmed feasibility for production.
· Key Characteristic Designation System (KCDS) meeting is scheduled or has been completed
· Supplier to review GD&T documentation for the following:
o The datum schemes are consistent with both product use and process intent.
o Plans for gage development are consistent with the datum scheme.
o Tolerances are understood and verified achievable by the supplier.
o In cases of new technology or tighter tolerances than historically achieved, an action plan is needed to monitor the progress of capability performance throughout the process development phase.
· Escalation Drop Downs
o G – Adequate math data and GD&T released – Supplier has confirmed feasibility
o Y – Adequate design data not available – recovery plan in place
o Y – Datums or tolerances not agreed to – recovery plan in place
o Y – Feasibility not confirmed – recovery plan in place
o Y – KCDS not completed but scheduled
o R – Adequate design data not available – recovery plan not in place
o R – Datums or tolerances not agreed to – recovery plan not in place
o R – Feasibility not confirmed – recovery plan not in place
Commercial Issues
· Supplier received piece price and tooling contract to the latest available level of Math Data
· Supplier has received tooling PO
· SQE to verify that supplier has no additional commercial issues, i.e. issues with directed-buy suppliers pricing, etc.
· Escalation Drop Downs
o R – No tooling PO
o R – Additional commercial issues
o Y – Contracts need to be updated
o G – No commercial issues
Plant Layout and Process Flow
· Plant Layout
o Supplier to provide current plant layout for the entire facility including planned area where new program will be housed, the shipping, receiving, inventory, suspect/scrap material hold areas, etc.
o Supplier to provide detailed view of area where program will be housed, if applicable should include cell configuration, in-process & finished goods inventory area, scrap area, etc.
o GM SQE should review layout to make sure there are no concerns, i.e. over lapping rework and finished goods storage, if there are issues supplier needs to provide a plan to address/control
· Process Flow
o Supplier to provide a diagram for production and pre-production process both should include shipping , receiving , and rework , and should coordinate with the PFMEA and Control Plan; preliminary diagram should include GP-12
o Process flow should include every operation within the process of making this part in accordance with the AIAG APQP and Control Plan Manual
· Escalation Drop Down
o R – Supplier does not have a plan/space to house the new program
o Y – Supplier has to move existing programs to house new program
o G – Supplier has no issues with housing new program
DFMEA
· General Requirements
o Supplier has done all necessary design analysis for part and tool manufacturability, i.e. mold flow analysis, tool material hardness, etc, for the particular commodity
o Supplier has applied the DFMEA to all relevant areas
o Supplier & GM have reviewed all warranty issues and incorporated all corrective actions into the DFMEA
o Supplier has evaluated the design to determine if potential failures will be addressed via process control or the assembly equipment
· GM – Design Responsible
o Supplier has worked with GM DRE to build DFMEA
o Supplier has reviewed the DFMEA corresponding to the current design from the GM DRE
· Supplier – Design Responsible
o Supplier has reviewed the SOR/SSTS and CTS for all design, governmental, reliability, appearance, serviceability, and any other applicable requirements and incorporated into DMFEA
o Supplier has reviewed the latest AIAG FMEA Edition and applied all applicable requirements
o Supplier has considered all influences the awarded part has on mating parts and the influence of mating parts on the awarded part and incorporated into DFMEA
o Supplier has provided the DFMEA corresponding to the current design to the GM DRE and the DFMEA is approved by the GM DRE
· Escalation Drop Down
o G – DFMEA Complete to current EWO GM responsible
o G – DFMEA Complete to current EWO Supplier responsible
o R – DFMEA Not Complete to current EWO GM responsible
o R – DFMEA Not Complete to current EWO Supplier responsible
Lessons Learned and Warranty
· Supplier has reviewed all similar products across all vehicles, OEMs, and manufacturing facilities and incorporated all information into Lessons Learned document or database; information can come from customer complaints, in-house quality reviews, GP-12, warranty complaints, GM SORs, GM Process Specific Audits, etc.
· Supplier has used information from Lessons Learned and incorporated into the control plan, PFMEA, DFMEA, operator instructions, and all other applicable areas; if supplier is not design responsible they should inform product engineering of any important information
· Supplier has a procedure to address warranty issues, should include how warranty returns are handled, contact info for key personnel, protocol for how potential warranty issues are communicated to the customer, steps as to how corrective action is fed back to lessons learned database, control plan, PFMEA, etc.
· Escalation Drop Downs
o R – Supplier has no Lessons Learned database or Warranty Issues procedure and has no plan for one
o Y – Supplier has no Lessons Learned database or Warranty Issues procedure and has plan for one
o Y – Supplier has Lessons Learned database and Warranty Issues procedure and has not incorporated information
o G – Supplier has Lessons Learned database and Warranty Issues procedure and has incorporated information

Gage and Tooling Equipment Review
· General Requirements
o Supplier has received toolable P-released, or at a minimum T-released, math data; if T-released there should be a recovery plan for P-released math
o Supplier has received final contracted part GD&T and reviewed tolerances with GM SQE, DE, and Dimensional Engineer and is in agreement
o If assembling, supplier has component part GD&T
o Supplier has reviewed and agreed to all SQ Part Specific SORs for gage and tooling requirements, should have been done prior to sourcing
o Supplier has done all necessary design analysis for part and tool manufacturability, i.e. mold flow analysis, tool material hardness, etc, for the particular commodity
· Tooling Review Requirements
o Supplier has ensured that all Part or SQ SOR tooling requirements are comprehended in the tooling equipment plan and has clearly defined all tooling equipment function and verified that all SOR requirements are satisfied
o Supplier has comprehended all component and assembly GD&T into assembly equipment
o Supplier has provided error proofing plan for equipment, process flow, PFMEA, and PCP and documents are approved by SQE; For VAA suppliers, approval needed from SQE and Manufacturing Engineer
o Supplier has provided timing chart detailing equipment build, shipment, set-up timing, expected date of first shots, PPAP, and R@R; equipment timing is to include all line items required for the part to meet all fit, finish, and function requirements
o Supplier has completed and returned all relevant process specific audits, answers are to be based on what will be incorporated in the tooling equipment
· Gage Review Requirements
o Supplier has set-up and conducted an initial design review with the gage source, meeting attendees should at minimum include the GM DE, SQE, and craftsmanship engineer; for VAAs the manufacturing engineer should be invited as well
o Discussion for meeting should include points where any KPCs or PQCs ports will be placed on the gage
o Supplier will set-up and conduct a 90% complete design review at the gage source, at a minimum meeting attendees should include the GM DE, SQE, and craftsmanship engineer; for VAAs the manufacturing engineer should be invited as well; SQE to approve gage design
o Supplier has ensured that all GD&T requirements are capable of being checked on gage by some feature, and where not being checked by a feature supplier shall provide a plan as to how the requirement will be verified
o Supplier has provided timing for gage completion and level if gage build is staged
· Escalation Drop Downs
o G – Tooling Design complete
o G – Gage design complete
o Y – Tooling design not complete; no impact to PPAP target
o Y – Gage design not complete; no impact to PPAP target
o R – Tooling design not complete; impact to PPAP target
o R – Gage design not complete; impact to PPAP target
Validatio