Preface
This Reference Manual represents the collaborative efforts of a GM worldwide team engaged to develop a GM Common APQP process. Prior to this, each General Motors Supplier Quality organization facilitated the implementation of the APQP process using divisional and regional specific methodologies.
The global team harmonized and standardized the various divisional and regional APQP processes and developed this GM APQP Manual (GM1927). 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.
This document is the second revision to the initial release and has been updated to reflect the most recent requirements set by General Motors for all Global Suppliers. As part of this update, a Revision History section has been added to provide a brief description of the October 2002 changes.
Approvals for this revision are as follows:
M. Wolf M. Moretti
Worldwide Purchasing Latin American Operations Supplier Quality Supplier Quality
T.Nejman M. Aldea
Powertrain Asian Pacific Operations Supplier Quality Supplier Quality
W. Kraatz M. Sch?enleber
North American Vehicle Operations European Operations
Supplier Quality Supplier Quality
I
Table of Contents Preface…………………………………………………………………………..I Table of Contents …………………………………………..………..….……..II Manual Content Explanation …………………………………..………..…....IV Customer Monitored/Supplier Monitored Matrix ………………...……….…..V APQP Proce ss Model Flow ……………………………………………….…..VI Revision History……………………………………………………………...VII
APQP Task Definitions
Task 1: Commodity Sourcing Strategy Meeting (1)
Task 2: Technical Reviews .................. . (3)
Task 3: Risk Assessment & Sourcing (5)
Task 4: Supplier Program Reviews (7)
Task 5: Timing Charts/Open Issues (12)
Task 6: Feasibility & Manufacturing Assessment Letters (13)
Task 7: Flow Chart (15)
Task 8: DFMEA (16)
Task 9: Design Reviews (18)
Task 10: Gage, Tool & Equipment Reviews (20)
Task 11: GP-11 Pre-prototype & Prototype Material (23)
Task 12: PFMEA Development (25)
Task 13: Control Plan (27)
Task 14: GP-12 Early Production Containment (29)
Task 15: PPAP (31)
Task 16: Run @ Rate (GP-9) (33)
Task 17: Lessons Learned (36)
Appendices
Appendix 1—Document Usage Guidelines by Global Region (38)
GM 1927-1 APQP Project Plan
GM 1927-2 APQP Timing Chart
GM 1927-3 Supplier Quality Statement of Requirements (SOR)
GM 1927-4 Required Quality Information Letter
GM 1927-5 APQP Open Issues Form
GM 1927-6 Commodity Sourcing Strategy Meeting Checklist
GM 1927-7 WWP APQP Assessment
GM 1927-10 Lessons Learned Process Overview
GM 1927-12 Lessons Learned Criteria Checklist
GM 1927-13 Technical Review Checklist
II
Appendix 1—GM 1927 Documents (continued)
GM 1927-14 APQP Kick-Off Meeting Checklist
GM 1927-15 APQP Kick-Off Meeting Presentation
GM 1927-16 Process Control Plan Audit Worksheet
GM 1927-17 GM & Supplier Program Contact List
GM 1927-18 Typical Stakeholders Meeting Agenda
GM 1927-19 Manufacturing Feasibility Letters
GM 1927-20 Process Capability Over Time
GM 1927-21 RPN Reduction Summary Chart
M GM 1927-22M Program Management RASIC
M GM 1927-23M Directed Buy Checklist
M GM 1927-24M Supplier Program Reviews
M GM 1927-25M Subcontractor Program Status Matrix
M GM 1927-26M Subcontractor Detailed Status Matrix
GM 1927-27 Fixture Design Matrix
GM 1927-28 Global Powertrain PFMEA Risk Ranking Form Note: M indicates documents specific to suppliers of Complex Systems/Sub-assemblies Appendix 2— Complex Systems/Sub-assembly APQP Management (40)
Plan
Appendix 3—Glossary of Terms (44)
Manual Content Explanation
Each section is referenced by a task number and includes the following:
?Task name
?Task Owner(s)
?Task Timing (approximate)
?Task Description
?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 the task and purpose
?SQE Responsibilities—brief description of actions required
?Supplier Responsibilities—brief description of actions required
?References and additional information.
Appendices
The Appendices contain all GM specific APQP forms and documents that are to be used throughout the implementation of the APQP process. Directions for specific application of each form or document are explained in APQP Task Definitions 1 through 17.
Document Procurement
GM Global APQP
All specific GM APQP forms and documents referenced in this GM Global APQP manual
(GM 1927) are contained in this document and can be copied for use. This manual and all documents can also be obtained through GM’s SupplyPower at https://www.doczj.com/doc/ea1646962.html,.
GM General Procedures (GPs)
All GM General Procedures (GPs) referenced can be obtained by contacting Boise Cascade Office Products at 1-888-216-0371, Fax 1-888-216-0603.
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 https://www.doczj.com/doc/ea1646962.html,. 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.
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 may monitor and approve the APQP activities.
Customer Monitored Supplier Monitored
APQP APQP
R Responsible (GM or Supplier)
A Approve - GM approves deliverables
S Support completion of deliverables (GM or Supplier)
I Inform– GM reviews deliverables at discretion of SQE
C Consult
N/A Not Applicable
May be reviewed by GM as part of PPAP (Depending on submission level)
V
Advanced Product Quality Planning (APQP)
Top Flow Down
A. Buyer conducts Commodity
Sorucing Strategy Meeting1
B. Purchasing sends out RFQ
C. Buyer conducts Technical reviews2
D. Buyer/SQE/Engineer conduct
WWP APQP Assessment
/sourcing3
→Supplier Quality SOR in RFQ
→Lessons learned added to RFQ17→WWP APQP Assessment3
→Sourcing Recommendation3
→Preliminary Timing chart5, Process flow chart7, PFMEA12 and Control
plan13
→Team Feasibility commitment6
A. SQE schedules APQP kick-off
meeting4
B. SQE hosts APQP kick-off meeting4
C. Supplier provides updated draft of
Timing chart5, Open Issues5,
Process flow chart7, PFMEA12,
control plan13, etc.
D. Initial Design9 and Gage, Tooling
and Equipment reviews10
→Initial Timing chart5, Open issues
list5, Process flow chart7, PFMEA12
and Control plan13
→Schedule dates for required
workshops (KCDS)9
→Updated Lessons Learned17
A. SQE attends design reviews and
conducts scheduled workshops9
B. SQE reviews gage, tool &
equipment concept10
C. SQE reviews prototype draft of
process flow chart7, PFMEA12 and
Control Plan13
D. GP-11 plan approved by
appropriate GM department11
E. Gate Review #24 is conducted
→Updated Process flow chart7,
PFMEA12, and Control plan13
→Gage, tooling & equipment
concept10
→Feasibility Letter #16
→Updated Timing chart5 & Open
issues list5
A. SQE attends design reviews9 and
promotes lessons learned17
B. SQE reviews gage and tool
designs10
C. SQE guides update of post-
prototype Process flow chart7,
PFMEA12, Control plan13
D. SQE reviews error proofing & RPN
reduction plans12
E. GP-11 parts, modules and systems
approved11
F. Risk Assessment3 updated by SQE
G. Gate Review #34 is conducted
→Updated Process flow chart7,
PFMEA12, Control plan13, Timing
chart5 and Open issues list5
→Completed gage & tool designs10
→Feasibility letter #26
→GP-12 plan14
→Updated WWP APQP Assessment3
A. SQE conducts advanced PPAP15
and tool shop reviews10
B. SQE reviews and statuses PPAP
package15
C. Run@Rate16 (GP-9) is performed
D. Gate Review #44 is conducted
→PPAP15 and Run@Rate16 Status →Feasibility Letter #36
→Updated Timing chart5 and Open Issues list5
A. Supplier performs GP-8 and
updates control plan13
B. GP-12 is completed14
C. Lessons learned captured and
DFMEA/PFMEA are updated17
D. APQP is concluded
→
Updated control plan13
→DFMEA8/PFMEA12 updated with
lessons learned
VI
October 2002 GM 1927
Revision History
October 2002
Tasks 1-17
Task 1 Commodity Sourcing Strategy Meeting—name revised from Key Stakeholders Meeting to Commodity Sourcing Strategy Meeting to align with Global Sourcing process naming. ADVP&R Cover Sheet
added to Deliverables if required per the SOR.
Task 2 Technical Reviews—―Under Necessary Inputs‖ eliminated redundant listing requirements that are included in the Required Quality Information form GM 1927-4 that is part of the RFQ package.
Task 3 WWP APQP Assessment & Sourcing—Name revised from Risk Assessment to WWP APQP Assessment. Clarifications made for suppliers of Complex Systems/Sub-assemblies.
Task 4 Supplier Gate Reviews—name revised from Supplier Program Reviews to Supplier Gate Reviews to correlate with the terms used in the https://www.doczj.com/doc/ea1646962.html, APQP tracking system. Referenced made
pertaining to Directed Buys. Task numbers referenced next to requirements due at each of the 4 Gate
Reviews.
Task 5 Timing Chart and APQP Open Issues List—minor name revision and other minor clerical revision.
Task 6 Feasibility and Manufacturing Assessment Letters—―Deliverables‖ section, clarified AIAG APQP and Control Plan Manual Appendix E as source for the Team Feasibility Commitment
Task 7 Process Flow Charts—revised name from Develop, review and update Process Flow Charts to Process Flow Charts.
Task 8 DFMEA—Task Owner revised from GM Design/Release Engineer to Design responsible engineer.
Replaced GM Design/Release Engineer with Design responsible engineer through the task write-up.
―Necessary Input‖ section added Requirements as stated in SOR/SSTS/CTS and Key Product
Characteristics (if already identified)
Task 9 Design Reviews—revised name from Conduct Design Reviews to Design Reviews. Supplier Responsibility section, included requirement for GM W3059 and GM W3116. Additional Information
section, added GM W 3050, GM W 3116, ITEZ1401 Procedure for ITDC.
Task 10 Gage, Tooling and Equipment Reviews—revised name from Conduct Gage, Tooling and Equipment Reviews to Gage, Tooling and Equipment Reviews. Functional Test Requirement included in each
section. Supplier Responsibilities section, minor revisions including requirement for completing the
AIAG APQP New Equipment Checklist (A-3). PED 114 manual added to Additional Information
section.
Task 11 GP-11 Pre-Prototype and Prototype—Clarified task write-up and included GP-11 GM 1820 document form numbers in the Additional Information section.
Task 12 PFMEA—revised name from PFMEA Development to PFMEA. Included the usage of the Global Powertrain PFMEA Risk Ranking Chart GM 1927-28. Additional Information section, added the
Global Powertrain PFMEA Risk Ranking Chart GM 1927-28
Task 13 Control Plans—Necessary Inputs section added Special Characteristics and Lessons Learned. SQE Responsibilities section, revised requirements.
Task 14 Early Production Containment (GP-12)—minor revisions
VII
8
October 2002 GM 1927
October 2002
Tasks 1-17 continued
Task 15 Production Part Approval Process (PPAP)—revised name from Production Part Approval PPAP to Production Part Approval Process (PPAP. Methodology section, removed requirement of a specific
number of parts for subcomponents necessary for PPAP. Removed Directed Buy PPAP date
statements. Additional Information added Engineering Source Approval for Functional Performance
GM-E364
Task 16 GP-9 Run @ Rate—revised name from Conduct GP-9 Run @ Rate to GP-9 Run @ Rate. Updated the Task write-up to include the GP-9 June 2001 required forms. Significant clarifications in each section. Task 17 Lessons Learned—revised name from Lessons Learned Communication & Update to Lessons Learned.
Included the required use of the GM Lessons Learned website.
Suffixed Documents
GM 1927-1 APQP Project Plan Revised to correlate with program development terms
GM 1927-2 APQP Timing Chart Header information added, required elements grouped with
sub-headings
GM 1927-3 Supplier Quality Statement of
Requirements (SOR) Sections clarified, redundant listings of procedures and requirements removed. Section 3 identifies GM procedures and reference documents
GM 1927-4 Required Quality Information Reordered requirements and grouped under sub headings GM 1927-5 Open Issues Three type categories added
GM 1927-6 Commodity Sourcing Strategy
Meeting Checklist
Minor revisions
GM 1927-7 WWP APQP Assessment Name revised plus minor wording revisions
GM 1927-8 Timing and Feasibility Form removed
GM 1927-9 Serial Tooling/Checking
Equipment
Form removed
GM 1927-10 Lessons Learned Process
Overview Revised to incorporate the Global Lessons Learned web system
GM 1927-11 Global Lessons Learned &
Implementation Process
Form removed
GM 1927-12 Commodity Criteria Checklist Form removed
GM 1927-13 Technical Review Checklist
Guidelines
Minor revisions
GM 1927-14 APQP Kick-Off Checklist Minor revisions, TS 16949 direction added
GM 1927-15 APQP Kick-Off Meeting
Presentation
Revised to correlate to the APQP web overview
VIII
October 2002 GM 1927
9
October 2002 Suffixed Documents continued
GM 1927-16 Process Control Plan Audit
Worksheet Checklist revised to correlate with the GP-9 Run @ Rate procedure June 2001 form GM 1962-B.
GM 1927-17 GM and Supplier Program
Contacts
Functional positions added
GM 1927-18 Typical Agenda Commodity
Sourcing Strategy Meeting Name revised to correlate with revisions in corporate processes
GM 1927-19 Supplier Manufacturing
Assessment Letters
Model year revised on form letters GM 1927-20 Process Capability Over Time Example removed from body of form GM 1927-21 RPN Reduction Summary Chart No changes
M GM 1927-22 Program Management RASIC Form to be used as an example
M GM 1927-23 Directed Buy/Directed Source
Checklist
Required signatures revised
M GM 1927-24 Supplier Program Review Flow Removed
M GM 1927-25 Subcontractor Program Status
Matrix Name revised to correlate with direction in Appendix 2 for Suppliers of Complex Systems/Sub-assemblies
M GM 1927-26 Subcontractor Detailed Status
Matrix Revised to correlate with corporate development process nomenclature for build events
GM 9727-27 Fixture Design Matrix New form
GM 1927-28 Global Powertrain PFMEA
Risk Ranking Form
New form for suppliers of Powertrain components Appendices
Appendix 1 Document Usage Guidelines by
Global Region Updated to include addition of two forms, GM 1927-27 and GM 1927-28. Removed five forms, GM 1927-8, GM 1927-9, GM 1927-11, GM 1927-12 and GM 1927-24M
Appendix 2 Complex Systems/Sub-
assemblies APQP Management
Plan Name revised. The term ―module‖ replaced with Complex System/Sub-assembly. Format revised to focus on the Tier 1 supplier responsibilities to manage the APQP process for all subcontractor suppliers. The Tier 1 supplier has the responsibility to drive adherence to the Global APQP requirements including specific requirements focused on complex systems/sub-assemblies.
Appendix 3 Glossary of Terms Terms added
IX
October 2002 GM 1927
10
Global Process
1 Task Number:1
Task Name:Commodity Sourcing Strategy Meeting
Task Owner:Buyer. SQE participates in meeting.
Task Timing:Pre-Sourcing
Task Description: The purpose of the Commodity Sourcing Strategy Meeting is to involve all GM stakeholders in the Advanced Purchasing process on a particular commodity package to develop and
understand the sourcing process, content, timing, and strategy to ensure that the RFQ-package
contains all information needed to receive comparable quotes. It is intended that these
meetings be conducted on all commodities identified for early sourcing by the platform. Key
Stakeholders meet to review key program information and timing as referenced in the
Advanced Purchasing ―Typical Agenda‖ (GM1927-18)
Deliverables: Generic functional requirements for inclusion into the Engineering SOR
?List of Critical and Non-Critical Commodities that the Supplier shall prepare and obtain
GM approval for the ADVP&R Cover Sheet if required per the SOR.
?Agreement by stakeholders on process, content, timing and strategy of the sourcing
package
?Guidelines and expectations for Supplier Workshops (technical design issues /timing,
team members, questionnaire, etc.)
?Target date for Technical Reviews
?Communication Strategy - process to be used to communicate information to Key
Stakeholders
?M Program Management RASIC GM1927-22M for specific commodity
?APQP Open Issues List (GM1927-5)
Customer for Deliverables:Purchasing*, Engineering*, Supplier Quality*, Marketing, PC&L and any
additional functional groups as appropriate
* Mandatory participation as Key Stakeholders
Necessary Inputs:Source of Input:
Technical documents (BOM, SOR, SSTS/CTS etc.) Engineer
ADV Process Tasks and Deliverables Engineer
Creativity Team Bidders List (enhanced quality metrics) Buyer
Lessons Learned on previous programs Buyer/SQE/Engineer
Program related information Key Stakeholders (ref. GM1927-18) Resources: Purchasing, Supplier Quality, Engineering
Methodology:
?The Commodity Sourcing Strategy meeting date is identified on the Sourcing Program Plan.
?Buyer sends invitation to appropriate Key Stakeholders identified for specific component/commodity/system.
?The buyer conducts the meeting (typical agenda GM1927-18).
?Key Stakeholders discuss and review program information and timing.
?Each Stakeholder discusses pertinent requirements:
-Review of Engineering requirements in technical documents
-upplier Quality Statement of Requirements
-Warranty and IPTV requirements
?Key Stakeholders Review potential bidders list to restrict Request for Quotation (RFQ) distribution to suppliers meeting GM criteria, and to identify suppliers that need to be visited for conducting Potential Supplier
Assessments (PSA) or Sourcing Team Evaluation Process (STEP) visits.
Task Number:1 continued
Task Name:Commodity Sourcing Strategy Meeting
Methodology: (continued)
?Supplier Workshops for technical design issues are planned (if applicable):
-Questions are developed for the Supplier Workshops and dates are established.
- A core group (sub-group of Stakeholders) is defined that will: Attend Supplier Workshops, summarize results and refine functional requirements based on workshop findings.
?Key Stakeholders discuss and agree on the process, content, timing and strategy of the sourcing package.
?The buyer clarifies the timing of each step in the AP Sourcing process and what is expected from each Stakeholder. Action items are also reviewed.
SQE Responsibility:
?Participate in the meeting.
?Clarify the role of the SQE in the sourcing process.
?Review the requirements stated in the SQ SOR with the other Stakeholders.
?Obtain knowledge of what is being sourced (functional aspects of part).
?Obtain knowledge of timing (sourcing and program).
?Confirm ―Make or Purchase‖ (MOP) c oding has been done for modules/integrated packages (Should accompany SOR).
?Inquire about any sequencing plans.
?Reviews suppliers on Creativity Team Bid List and corresponding performance with enhanced metrics.
?Identify suppliers that will require‖ Business Case‖ Action Plans due to performance problems.
?Provide SQ questions to be included in the Pre-Workshop questionnaire.
?Provide an overview of the GM Global Lessons Learned web site process using the GM 1927-10 and communicate Lessons Learned information obtained from the GM Global Lessons Learned web site for the specific commodity.
?M Understand the Complex System/Sub-assembly and system requirements and verify with the engineer or buyer that the Program Management RASIC for the specific commodity (similar to GM 1927-22M) will be included in the RFQ.
?Verify with the buyer that the roles and responsibilities have been clearly defined for any directed buy parts;
complete the GM 1927-23M if applicable and ensure the completed form does not contradict any Purchasing contracts.
?Utilize the Commodity Sourcing Strategy Meeting Checklist GM1927-6 as appropriate (recommended).
?Start the APQP Open Issues list (GM1927-5) with any items that need to be addressed. Consideration should be given to missing technical information, decisions on modularity, etc.
?Understand Functional / End of Line Test requirements
Additional Information:
Supplier Quality Statement of Requirements GM1927-3
Required Quality Information GM1927-4
Open Issues list GM1927-5
Commodity Sourcing Strategy Meeting Checklist GM1927-6
Lessons Learned Process Overview GM1927-10
Typical Agenda Stakeholders Meeting GM1927-18
M Program Management RASIC GM example 1927-22M
Task Number: 2
2 Task Name:Technical Review
Task Owner:Buyer, SQE participates in meeting.
Task Timing:Pre-Sourcing
Task Description:The Technical Review is a meeting attended by the supplier, buyer,
engineer, and SQE, with representation from other affected organizations. The purpose of the
meeting is to review quotations to insure that all requirements in the RFQ-package have been
understood and that the supplier has potential to produce parts meeting GM expectations (any
item related to the manufacturability of the part, including timing, design, manufacturing
capability, packaging, etc.).
Deliverables: ?Identification of suppliers that are capable and should continue in the sourcing process
?Initial WWP APQP Risk Assessment GM1927-7 for appropriate suppliers
?Updated APQP Open Issues List GM1927-5
Customer for Deliverables:Buyer, SQE, Engineer
Necessary Inputs:Source of Input:
Technical documents Engineer
Supplier’s Quality History SQE
ADVP&R Cover Sheet GM 1829 (if required by SOR) Supplier
Preliminary SFMEA / DFMEA Block Diagram Supplier
Required Quality Information GM 1927-4 Supplier
Prototype plan Supplier
M Inputs for Complex Systems/Subassemblies
Buyer
M Carryover part contact list Buyer
Resources:Purchasing, Engineering, Supplier Quality, Supplier
Methodology:
?The buyer invites potential suppliers to Technical Review Meetings.
?Supplier addresses topics related to timing, design capability (if applicable), manufacturability of the part as designed, quality processes, packaging, and transportation.
?Supplier addresses the specific quality topics listed in the Required Quality Information letter GM1927-4.
?Supplier provides Team Feasibility Commitment (QS-9000 requirement per 4.2.3.3)
?SQE reviews expectations relative to Lessons Learned. (GM 1927-10)
?At the conclusion of the Technical Review, the Buyer, SQE and Engineer complete the WWP APQP Assessment GM1927-7.
SQE Responsibility:
?Prior to the meeting review specific documents provided in the supplier’s quote and prepare questions.
?Ask questions relative to quality and any issues related to the manufacturability of the component/system.
?Ask questions pertaining to the supplier’s responses to items requested in the quality portion of the RFQ package.
?Provide a five-minute overview of the Lessons Learned process.
?Participate in the WWP APQP Assessment GM1927-7.
?Complete the Technical Review Checklist GM1927-13. (recommended)
?Ensure the supplier understands the Supplier Quality SOR (recommended).
?This is required prior to signing the Sourcing Recommendation form.
Task Number:2 continued
Task Name: Technical Review
?Update the APQP Open Issues List GM1927-5 with concerns related to the supplier’s ability to meet the quality expectations.
?Finalize plans for needed supplier visits (PSA or STEP for new suppliers)
Note: If a technical review is not held, the SQE should review the Quality information submitted as part of the supplier’s quote, prior to performing the WWP APQP Assessment. Input should be obtained from the buyer and GM engineer.
Supplier Responsibilities:
?Supplier must provide the ―Required Quality Information‖ (GM1927-4) together with their quote.
?At the technical review, the supplier is expected to review the following information:
1.Preliminary timing charts. Supplier will highlight any concerns relative to tooling / testing that may impact
providing a quality process/part on time.
2.Review of the manufacturing facility. Where is it located? How long has it been in operation? What
modifications to the facility would be required to support the RFQ volumes?
3.The time frame of the last review by a General Motors SQE (please specify type of review conducted).
4. Preliminary process flow diagrams. (Including any special assembly techniques, test methods, and
Containment procedures used)
5. Plans in place to meet the IPTV targets.
6.Capability studies on similar parts, along with plans for error proofing, data analysis, and record keeping
must be included in plan
7.AIAG APQP Appendix E-Team Feasibility Commitment
8.Manpower resource commitment to ensure successful completion of program; proper skills and training to
perform the necessary tasks.
9. Provide evidence from previous project to demonstrate experience on the new product.
Additional Information:
Supplier Quality Statement of Requirements (GM1927-3)
Required Quality Information letter (GM1927-4)
APQP Open Issues List (GM1927-5)
WWP APQP Assessment (GM1927-7)
Lessons Learned Process Overview (GM1927-10)
Global Process
3 Task Number:3
Task Name:WWP APQP Assessment & Sourcing
Task Owner:Buyer Sourcing Recommendation / SQE and Buyer WWP APQP Assessment
Task Timing:Initial WWP APQP Assessment as input to the sourcing recommendation
Second WWP APQP Assessment in the Prototype/Validation Vehicle timeframe
Task Description:The WWP APQP Assessment is a tool to assess the potential for problems early in the vehicle development process and to determine which parts and/or suppliers will require additional
focus. It is intended that the assessment be conducted on all new parts / suppliers. A supplier
is selected by a quality assured sourcing decision, approved by all Key Stakeholders.
Deliverables:
Completed WWP APQP Assessment GM1927-7 for each part including Complex
Systems/Subassemblies
?Initial assessment will be available for review at sourcing meeting
?WWP APQP Assessment indicating the level of GM involvement in the APQP process
?Supplier selected with SQ or designates signature on the sourcing recommendation form. Customer for Deliverables:Supplier Quality, Purchasing, Engineering
Necessary Inputs:Source of Input:
Technical documents Engineer
Design stability Engineer
Supplier’s technical capability Supplier/Engineer
Supplier’s manufacturing process capability on similar parts Supplier/SQE
Supplier’s past quality history and performance reports SQE/Supplier
Supplier’s manufacturing site information Supplier/Buyer
Supplier’s sub-contractor plan Supplier/Buyer
QS-9000 status Supplier/Buyer/SQE
Preliminary DFMEA, PFMEA, and Flow Diagram Supplier/SQE
Historical program management experience by supplier SQE
(Launch history, lessons learned, etc.)
M Understanding of Complex System/Sub-assembly Supplier/SQE/ Buyer/Engineer Complexity of management structure Buyer
Regional SQ support availability SQE
Capacity of system Supplier/Buyer/SQE
Customer Impact of part Engineer/SQE
Supplier Assessment (PSA, QSA, STEP, etc.) SQE/Team
Resources: Purchasing, Supplier Quality, Engineering and Supplier.
Methodology:
?The first WWP APQP assessment is conducted prior to the Sourcing decision.
If a Technical Review is held, the assessment should be conducted directly following this review. The Buyer,
SQE and Engineer evaluate the information presented throughout the sourcing process by the supplier and
evaluate that information as it applies to the questions on the assessment form.
If the buyer does not conduct a Technical Review, the SQE has the responsibility to contact the Buyer and
Engineer for their joint input in completing the risk assessment.
Global Process
Task Number: 3 continued
Task Name: WWP APQP Assessment & Sourcing
Methodology (Continued)
?The WWP APQP Assessment must be updated at least once prior to the last Gate Review #3 build event.
?The cross-functional sourcing team agrees to select the supplier with the best qualifications.
M For Complex Systems/Sub-assemblies:
◆The supplier completes an assessment of all tiered suppliers manufacturing capabilities using the WWP
APQP Assessment GM 1927-7 or equivalent.
M For sub-components not sourced, the supplier should provide a detailed sourcing plan to the SQE.
◆
M The SQE reviews the list of assessed sub components to determine if the supplier has appropriate ◆
resources assigned to support the program.
SQE Responsibility:
?Lead the initial WWP APQP Assessment process at the time of the technical review.
?Work jointly with the Sourcing Team to identify activities and actions required to eliminate or reduce risk identified on the WWP APQP Assessment document.
?Sign sourcing recommendation for selected supplier.
?Determine the appropriate level of APQP follow-up and Run @ Rate based on the WWP APQP Assessment
?>21 - (A) assessed commodities/parts will have customer-monitored APQP and Run @ Rate
?0 to 20 - (B and C) assessed commodities/parts can be either customer or supplier-monitored for APQP or Run @ Rate (discretion of SQE / Division)
?Update the WWP APQP Assessment prior to Gate Review #3
?Adjust APQP and Run @ Rate plan based on changes in the assessment level.
Supplier Responsibilities:
Provide all necessary data required prior to sourcing. (See necessary inputs)
Additional Information:
WWP APQP Assessment GM1927-7
Global Process
4 Task Number: 4
Task Name:Supplier Gate Reviews
Task Owner:SQE for Kick-off Meeting, Supplier for remaining meetings
Task Timing:Four reviews as shown on APQP Project Plan
Task Description: The purpose of the Supplier Gate Reviews is to review the progress of items according to the APQP Project Plan (GM1927-1) and track the status and progress of items listed on the APQP
Timing Chart (GM1927-2). The reviews are also intended to review the APQP Open Issues list
(GM1927-5) and identify any additional GM and supplier issues that require resolution. These
review meetings are intended as an APQP team review of the part and process development and
to capture the learnings from each build event. The first review is coordinated by the GM SQE
for all customer-monitored APQP parts. For parts that are supplier monitored APQP, the
supplier is expected to conduct gate reviews internally.
Deliverables:
?Updated APQP Timing Chart (GM1927-2)
?Updated APQP Open Issues List (GM1927-5)
?Completed APQP Kick-off Meeting Checklist (GM1927-14)
?GM & Supplier APQP Contact List completed (GM-1927-17)
?Supplier Process Capability (GM1927-20) and RPN Reduction Plan (GM1927-21) Additional Deliverables for Suppliers of Complex Systems/Sub-assemblies (reference GM 1927 Appendix 2): ?Directed Buy/Directed Sourced Checklist (GM 1927-23M) Applicable if not in RFQ
?Subcontractor Program Status Matrix (GM 1927-25M)
?Subcontractor Detailed Status Matrix (GM 1927-26M)
Customer for Deliverables: SQE, Buyer, Engineer, Readiness Coordinator, Manufacturing as appropriate.
Necessary Inputs:Source of Input:
Program timing for key events Engineer/Buyer
Detailed timing for tools, facilities, etc. Supplier
Lessons Learned Checklist (GM1927-12) SQE
APQP Open Issues List (GM1927-5) Supplier/SQE
APQP Timing Chart (GM1927-2) Supplier/SQE
Resources: Buyer, Engineer, SQE, Readiness Coordinator, Manufacturing as appropriate
Methodology:
?Supplier Gate Review #1 (APQP Kick-off Meeting)
This meeting should occur within 30 days of the supplier receiving formal notification of the business award.
The meeting contains both instructions to the supplier, and report out by the supplier. The SQE uses the
instructional portion of the meeting to rela y GM’s expectations relative to APQP and the timing of the
program. The supplier is expected to give updates on the following:
-APQP Kick-off Meeting Checklist (GM1927-14) GM 1927 Task 4
-GM & Supplier Program Contacts (GM1927-17) GM 1927 Task 4
-APQP Open Issues list (GM1927-5) GM 1927 Task 5
-APQP Timing Chart (GM1927-2) GM 1927 Task 5
-AIAG Appendix E - Team Feasibility Commitment GM 1927 Task 6
-Initial Process Flow Chart GM 1927 Task 7
-DFMEA status / AIAG APQP DFMEA checklist (A-1) GM 1927 Task 8
-Initial PFMEA / AIAG APQP PFMEA checklist (A-7) GM 1927 Task 12
Global Process
Task Number:4 continued
Task Name:Supplier Gate Reviews
Methodology Supplier Gate Review #1 (APQP Kick-off Meeting): (continued)
-Initial Control Plan / AIAG APQP Control Plan checklist (A-8) GM 1927 Task 13
-Preliminary Run @ Rate Plan GM 1927 Task 16
-Lessons Learned(GM1927-10)
-Facilities plan for Greenfield/Brownfield/Transplant manufacturing sites; plan to include any affected subcontractors facilities
-Management plan for all tiered suppliers including a Spill Management Plan
M APQP Program Management requirements for suppliers of Complex Systems/Sub-assemblies (reference GM 1927 Appendix 2):
-M WWP APQP Assessment GM 1927-7 or equivalent for all subcomponents sourced
-M Subcontractor Program Status Matrix (GM1927-25M)
-M Directed Buy/Directed Source Checklist (GM1927-23M) as applicable if not included in the RFQ
?Supplier Gate Review #2
This meeting occurs during the timeframe of GM’s Beta / Integration Vehicle Build. The meeting should occur at least 2 weeks prior to a scheduled Quality Valve or Build Readiness Review. The SQE provides feedback relative to program timing. The supplier is expected to provide updates on the following:
-APQP Open Issues List (GM1927-5) GM 1927 Task 5
-APQP Timing Chart (GM1927-2) GM 1927 Task 5
-Review identified build concerns
-Supplier Manufacturing Assessment of Design (GM1927-19 Letter #2) GM 1927 Task 6
-Process Flow Chart review including AIAG APQP Process Flow Checklist (A-6) GM 1927 Task 7
-AIAG APQP Design Information Checklist (A-2) GM 1927 Task 9
-DFMEA status plus AIAG APQP DFMEA Checklist (A-1) GM 1927 Task 8
-Gage concept review status GM 1927 Task 10
-Facilities/Equipment/Serial Tooling update including AIAG APQP New Equipment Checklist (A-3) GM 1927-10
-PFMEA review including AIAG APQP PFMEA Checklist (A-7) GM 1927 Task 12
-Establish initial RPN Reduction Plan baseline (GM1927-21) GM 1927 Task 12
-GP-11 Prototype Part Approval Status GM 1927 Task 11
-Process capability data gained from early builds (GM1927-20)
-Control Plan review including AIAG APQP Control Plan Checklist (A-8) GM 1927 Task 13
-Run @ Rate planned capacity analysis GM 1927 Task 16
-Lessons Learned GM 1927 Task 17
-Facilities plan for Greenfield/Brownfield/Transplant manufacturing sites; plan to include any affected subcontractors facilities
-Directed Buy/Directed Source Checklist changes, if applicable (GM1927-23M)
-Management plan for all tiered suppliers including a Spill Management Plan
M APQP Program Management requirements for suppliers of Complex Systems/Sub-assemblies reference GM 1927 Appendix 2):
-M WWP APQP Assessment GM 1927-7 or equivalent for any sub components sourced since the last review. GM 1927 Appendix 2
-M Updated Subcontractor Program Status Matrix (GM1927-25M) GM 1927 Appendix 2
-M Subcontractor Detailed Status Matrix (GM1927-26M) GM 1927 Appendix 2
*M SQE may request above information for specific high risk subcontractors as needed
Task Name:Supplier Gate Reviews
?Supplier Gate Review #3
This meeting occurs during the timeframe of GM’s Gamma / Validation Vehicle Build. The meeting should occur at least 2 weeks prior to a scheduled Quality Valve or Build Readiness Review. The SQE provides feedback relative to program timing and provides a risk assessment update. The supplier is expected to give updates on the following:
-APQP Open Issues List (GM1927-5) GM 1927 Task 5
-APQP Timing Chart (GM1927-2) GM 1927 Task 5
-Review identified build concerns GM 1927 Task 5
-Supplier Manufacturing Assessment of Prototype (GM1927-19 Letter #3) GM 1927 Task 6
-Capability concerns based on historical data and proposed design
-Design review status GM 1927 Task 9
-Progress of Facility/Equipment/Tooling/Fixtures/Gages GM 1927 Task 10
-Tooling update including AIAG APQP New Equipment Checklist (A-3) GM 1927 Task 10
-GP-11 GM 1927 Task 11
-Directed Buy checklist changes, if applicable (GM1927-23M)
-Management plan for all tiered suppliers including a Spill Management Plan
-Facilities plan for Greenfield/Brownfield/Transplant manufacturing sites; plan to include any affected subcontractors facilities
-PFMEA review including AIAG APQP PFMEA Checklist (A-7) GM 1927 Task 12
-RPN Reduction Plans and progress from baseline (GM1927-21) GM 1927 Task 12
-Control Plan review including AIAG APQP Control Plan Checklist (A-8) GM 1927 Task 13
-Process Control Plan Audit Worksheet review (GM1927-16) GM 1927 Task 13
-Run @ Rate capacity status GM 1927 Task 16
-Lessons Learned GM 1927 Task 17
-GP-12 Plan GM 1927 Task 14
M APQP Program Management requirements for suppliers of Complex Systems/Sub-assemblies (reference GM 1927 Appendix 2):
-M WWP APQP Assessment GM 1927-7 or equivalent for any sub components sourced since the last review. GM 1927 Appendix 2
-M Subcontractor Program Status Matrix (GM1927-25M)
-M Subcontractor Detailed Status Matrix (GM1927-26M)
-M Directed Buy/Directed Sourced Check list (GM1927-23M) (not to conflict with the Purchasing
-M All functional build issues related to Complex Systems/Sub-assemblies and sub-components identified during prototype builds must be reviewed and documented
*M SQE may request the above information for specific high risk subcontractors as needed
?Supplier Gate Review #4
This meeting should be conducted a minimum of 2 weeks prior to GM’s Production / Plant Vehicle Quality Valve Review. The SQE provides feedback relative to program timing. The supplier is expected to give updates on the following:
-APQP Open Issues List (GM 1927-5) GM 1927 Task 5
-APQP Timing Chart updates (GM 1927-2) GM 1927 Task 5
-Review identified build concerns GM 1927 Task 5
-Supplier Manufacturing Assessment of Manufacturing Process Capability and Production Readiness (GM1927-19 Letter #4) GM 1927 Task 6
-AIAG APQP Design Information Checklist (A-2) GM 1927 Task 9
-Process Flow Chart review including AIAG APQP Process Flow Checklist (A-6) GM 1927 Task 7
?Supplier Gate Review #4 (continued)
-DFMEA status including AIAG APQP DFMEA Checklist (A-1) GM 1927 Task 8
-Tooling status including AIAG APQP New Equipment Checklist (A-3) GM 1927 Task 10
-Gage and Fixture status, Gage Approval and Gage R&R GM 1927 Task 10 & 16
-PFMEA status including AIAG APQP PFMEA Checklist (A-7) GM 1927 Task 12
-Supplier’s Process Capability with respect to the design tolerances
-RPN Reduction Plans (GM1927-21) GM 1927 Task 12
-Control Plan review including AIAG APQP Control Plan Checklist (A-8) GM 1927 Task 13
-GP-12 Plan GM 1927 Task 14
-PPAP status update GM 1927 Task 15
-Run @ Rate status update GM 1927 Task 16
-Lessons Learned GM 1927 Task 17
-Management plan for all tiered suppliers including a Spill Management Plan
-Facilities plan for Greenfield/Brownfield/Transplant manufacturing sites; plan to include any affected subcontractors facilities
M APQP Program Management requirements for suppliers of Complex Systems/Sub-assemblies (reference GM 1927 Appendix 2):
-M WWP APQP Assessment GM 1927-7 or equivalent for any sub components sourced since the last review. GM 1927 Appendix 2
-M Subcontractor Program Status Matrix (GM1927-25M)
-M Subcontractor Detailed Status Matrix (GM1927-26M)
*M SQE may request the above information for specific high risk subcontractors as needed
SQE Responsibility:
?Use APQP Kick-off Meeting Presentation (GM1927-15) to provide overview of Global APQP.
?Prepare the GM & Supplier APQP Contact Checklist (GM1927-17) with names of GM contacts; forward to the supplier to obtain names for their team.
?Provide program timing information at all reviews.
?Review APQP Kick-off Meeting Checklist (GM1927-14) (if applicable by SQ region).
?Review Lessons Learned experience at the APQP Kick-off Meeting to re-emphasize discussion from the Technical Review reference GM1927-10
?Throughout the program, ensure Lessons Learned are being documented by the supplier in the appropriate FMEA (design, process, system) and in the APQP Open Issues List (GM 1927-5)
?Confirm that the supplier’s process capability and RPN reduction plans will satisfy design and zero PPM requirements.
?Drive supplier developed action plans whenever the Manufacturing Assessment Letters (GM1927-19) indicate problems.
?Identify and communicate key timing and program issues to GM management.
?M Supplier Quality Engineers, if assigned to a specific sub-component, should participate in all four Supplier Program Reviews.