GM 1927 Supplier Quality Manual_Sept2009

7/24/2019 GM 1927 Supplier Quality Manual_Sept2009

1/107

General Motors Corporation

Worldwide Purchasing

Global Purchasing and Supply Chain

September 21, 2009 I GM1927

GlobalGlobal

Supplier QualitySupplier Quality

ManualManual


2/107

Preface

This Reference Manual represents the collaborative efforts of multiple GM worlwie teams en!a!e

to evelop a GM "ommon process manual that inclues #$%$, &aunch, an "urrent %ualit'( $rior to

this, multiple ocuments e)iste to efine a Supplier %ualit' process from #$%$ throu!h "urrent%ualit'(

APQP

The #$%$ portion of this manual efines GM*s common !lobal prouct +ualit' plannin! re+uirements

that are necessar' to evelop an implement an #$%$ process for a prouct or service( It is intene

as a stanar to provie the Supplier %ualit' n!ineer, an the supplier, a common format from whichto procee with all steps of #$%$(

Launch

The &aunch portion of this manual efines stanari-e processes that support specific supplier launch

reainess activities an #$%$ eliverables( These !loball' approve activities are esi!ne to assist in

the assessment of launch reainess of all suppliers an ensure e)ecution of flawless launches(

Current

The "urrent portion of this manual efines the stanari-e wor. aroun common processes use

!loball' to protect our manufacturin!/assembl' plants an to rive s'stemic improvement to thesuppl' base(

#pprove b'

Global Supplier %ualit' irectors

September 21, 2009 II GM1927


3/107

Table of Contents

$reface(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((II

Table of "ontents(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((III

Manual "ontent )planation((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((

Section 1 Global APQP

"ustomer Monitore/Supplier Monitore Matri)((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((2

Global #$%$ R#SI"(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((3

ocument 4sa!e Guielines(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((5

APQP Task Definitions

Tas. 1 "ommoit' 6e' Sta.eholers Meetin!(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((

Tas. 2 Technical Reviews((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((7

Tas. 3 Sourcin! li!ibilit' (((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((8

Tas. Supplier Gate Reviews(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((10

Tas. 5 Timin! "harts/:pen Issues((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((12

Tas. %ualit' S'stems ;asics((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((13

Tas. 7 12 arl' $rouction "ontainment((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((2Tas. 15 $$#$(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((25

Tas. 1 Run ? Rate((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((27

Tas. 17 &essons &earne(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((29

September 21, 2009 III GM1927


4/107

Section 2 Global Launch

ocument 4sa!e Guielines(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((31

Supplier %ualit' &aunch $ro@ect $lan(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((31

Launch Task Definitions

Tas. 1 &aunch Mana!ement Team((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((32

Tas. 2 Global &aunch Reportin!(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((3Tas. 3 Supplier &aunch Ris. #nal'sis((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((35

Tas. &aunch Issue scalation(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((3

Tas. 5 Supplier "ommunication "onferences(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((37

Tas. Supplier &a'ere #uits(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((38

Tas. 7 #$%$ Team Reviews(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((39

Tas. 8 6e' Supplier Reviews((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((0

Tas. 9 Supplier &aunch #uit ASB $rocess(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((2

Tas. 10 ;uil Issue Trac.in!((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((3

Tas. 11 $lant ail' ;uil Summar' Report((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((

Tas. 12 3r$art' "ontainment AS$B > optional(((((((((((((((((((((((((((((((((((((((((((((((((((((((((5Tas. 13 ;ounar' Samples > optional(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((

Section Global Current

ocument 4sa!e Guielines b' Global Re!ion((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((8

Supplier Trainin!(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((9

#pprove 3r$art' $roviers(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((9

Current Task Definitions

Tas. 1 "ontinuous Improvement(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((50Tas. 2 %ualit' S'stems ;asics((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((52

Tas. 3 Shutown/Start 4p #ctivit'(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((5

Tas. $rocess "ontrol $lan #uit((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((58

Tas. 5 "reativit' Team Support((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((0

Tas. Global mer!in! Issue/#lert $rocess((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((3

Tas. 7 Ma@or isruption $revention #ctivit'((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((5

Tas. 8 "ontrolle Shippin! 1((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((8

Tas. 9 "ontrolle Shippin! 2((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((71

Tas. 10 Supplier $erformance Review Meetin!s((((((((((((((((((((((((((((((((((((((((((((((((((((((((((75Tas. 11 3r$art' $rovier $rocess(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((77

Tas. 12 Top


5/107

Manual Content %&planation

This manual contains three A3B sections( ach section has tas.s that are reference b' a

tas. number an inclues the followin!

Tas. name

Tas. :wnerAsB

Tas. Timin! Aappro)imateB

Tas. escription

6e' eliverables upon completion of the specific tas.

"ustomerAsB for the eliverables

Cecessar' Inputs to complete the specific tas. incluin! source for each input

&istin! of ResourcesEthis inclues people of or!ani-ations involve in completin! the tas.

Methoolo!'Ebrief escription of actions in table format arran!e b' action owner

References an aitional information

Docu$ent Procure$ent

'or$s

GM forms an ocuments reference in this manual GM 1927 can be obtaine throu!h GM

Suppl'$ower at www(!msuppl'power(coman be copie for use(

GM General Proce(ures )GPs*

General $roceures AG$sB reference can be obtaine throu!h GM Suppl'$ower atwww(!msuppl'power(coman be copie for use(

Labels + Ta,s

&abels an ta!s reference in the #$%$ process can be obtaine as followsGM#$ an GM F contact the S%

GM#M F &abels an ta!s can be obtaine from an' supplier as lon! as it meets stanarsientifie in the General $roceures

GMC# F "ontact "MS $rint Solutions 1>73>953>32, e)tension 211, 73>953>325

A-AG Docu$ents

#ll #I#G specific ocuments reference can be obtaine b' contactin! #I#G at 01>28>358>3003(

ocuments can also be orere b' accessin! the web at www(#I#G(or!( In urope contact Carwin

Ltdat >1708>81333(

.ote to Suppliers/

This manual is intene to be comprehensive an all>encompassin!H however, certain circumstances

will prompt +uestions( If 'ou have an' +uestions re!arin! an' part of this manual 'ou are encoura!eto contact 'our respective Supplier %ualit' n!ineer

September 21, 2009 GM1927
http://www.gmsupplypower.com/http://www.gmsupplypower.com/http://www.gmsupplypower.com/http://www.gmsupplypower.com/


6/107

Global #$%$ $rocess

Section 1

Global APQP

September 21, 2009 1 GM1927


7/107

Global #$%$ $rocess

Custo$er "s0 Supplier Monitore( APQP

The followin! matri) escribes the responsibilit' ifferences between "ustomer>MonitoreH

an Supplier>MonitoreH #$%$( Suppliers are responsible for carr'in! out all the RH activities

shown in the supplier column of the matri), whether or not their parts are esi!nate as customer

or supplier>monitore #$%$( If a part is esi!nate as customer>monitore #$%$, a GMrepresentative will monitor an approve the #$%$ activities(

APQP Acti"ity

Custo$er Monitore(

APQP

Supplier GM

Supplier Monitore(

APQP

Supplier GM

1 "ommoit' 6e' Sta.eholersMeetin!( C/# R C/# R

2 Technical Reviews S R S R

3 Sourcin! li!ibilit' C/# R C/# R

Gate Review J1 A6ic.>:ff Meetin!BRemainin! Gate Reviews

SR

R#

SR

RI

5 Timin! "harts/:pen Issues R # R I

%S; R # R #

7 12 R I R I

15 $$#$ R # R #

1 Run ? Rate AG$>9B R # R I

17 &essons &earne R I R I

! Responsible> Tas. :wner AGM or SupplierB

A Approve> #pprove eliverables AGMB

S SupportF Support "ompletion of eliverables AGM or SupplierB

- Inform> Review eliverables at iscretion of S% AGMB

.A Cot #pplicable

Global #$%$ R#SI"September 21, 2009 2 GM1927


8/107

Global #$%$ $rocess

Global #$%$ R#SI" A"ont(BSeptember 21, 2009 3 GM1927


9/107

Global #$%$ $rocess

Docu$ent sa,e Gui(elinesSeptember 21, 2009 GM1927


10/107

Global #$%$ $rocess

' 3 !eference 4nly )infor$ation only5 nothin, to fill out*

MD 3 Man(atory Docu$ent )specific for$at re6uire(*

M- 3 Man(atory -nfor$ation )for$at $ay "ary5 content $an(atory*

!D 3 !eco$$en(e( Docu$ent )not $an(ate(5 at a $ini$u$ content shoul( be re"ie7e(*

Docu$ent .u$ber

Man(atory

)ploa( toGQTS*

Man(atory !eco$$en(e(

#$%$ $ro@ect $lan GM1927>01 13 R

#$%$ 6ic.>:ff Meetin! "hec.list GM1927>1 M

$rocess "ontrol $lan #uit Kor.sheet GM1927>1 M

GM an Supplier $ro!ram "ontacts GM1927>17 MI

$rocess "apabilit' :ver Time GM1927>20 R

R$C Reuction Summar' "hart GM1927>21 M

irecte ;u'/irecte Source

"hec.list

GM1927>23 M

Subcontractor $ro!ram Status Matri) GM1927>25 M

Subcontractor etaile Status Matri) GM1927>2 MI

Global Ga!e Re+uest GM1927>29 M%S; #uit GM1927>30 M

Greenfiel = ;rownfiel evelopment

#ssessment $rocess

GM1927>31 M

imensional Results GM1927>32 M

G$12 #uit GM1927>33 M

#$%$ Supplier Status Kor.boo. GM1927>3 M

Run ? Rate "apacit' Kor.boo. GM1927>35 M

%S; Kor.shop $resentation GM1927>3 5

"ommoit' 6e' Sta.eholersMeetin! "hec.list GM1927>

=#$S$ "ommoit' 6e' Sta.eholers Invitees / 6e' Sta.eholers "hec.list / S:R "hec.list

Task .u$ber/ 2



12/107

Global #$%$ $rocess

Task .a$e/ Technical !e"ie7

Task 47ner/ ;u'er

Task Ti$in,/ $re>Sourcin!

Task Description/ Review the supplier technical proposal to ensure that all re+uirements in the Rpac.a!e

have been unerstoo an supplier has a plan to prouce parts meetin! GM e)pectations(

8ey Deli"erables/

Ientification of suppliers that are capable

"omplete #$%$ Supplier #ssessment GM1927>7

Custo$er for Deli"erables/;u'er, S%, n!ineer, Manufacturin! n!ineer

.ecessary -nputs/ Source of -nput/

Technical ocuments n!ineer

Supplier*s %ualit' Distor' S%

&ist of irecte ;u's ;u'er

"arr'over part contact list ;u'er

Re+uire %ualit' Information as per GM1927>3 item J12 Supplier

!esources/$urchasin!, n!ineerin!, Supplier %ualit', Manufacturin! n!ineer, Supplier

!esponsible Metho(olo,y /

;u'er Invite potential suppliers to Technical Review Meetin!s(

;u'er 4pate the :pen Issues &ist with concerns relate to the supplier*s abilit' to meet the re+uirements(

R Ientif' specific a!ena items for Suppliers to cover in Technical Review(

R #ssess Supplier technical capabilit' for continuation in the sourcin! process(

S% #t the conclusion of the Technical Review, the ;u'er, S% an n!ineer complete the #$%$ Supplier

#ssessment GM1927>7 Athis is re+uire prior to si!nin! the Sourcin! Recommenation formB(

S% $rior to the meetin!, review specific ocuments provie in the supplier*s +uote pac.a!e as per S% S:R

GM1927>3 an prepare +uestions relate to +ualit' an manufacturabilit' in orer to assess supplier

capabilit' an to support S% recommenation about supplier continuation in the sourcin! process(

S% nsure Supplier unerstans the S% S:R GM1927>3, an $art>Specific %ualit' = $rocess S:R AifapplicableB an returns them properl' si!ne(

S% $rovie a brief overview of the &essons &earne process(

S% "omplete the Technical Review "hec.list GM1927>13 ArecommeneB(

Supplier Review information as re+ueste b' Re+uire %ualit' InformationH item in the S% S:R GM1927>3

$reliminar' timin! charts

Di!hli!ht concerns relative to toolin!, !a!es or testin! that ma' impact $$#$

Revisions to manufacturin! facilit', incluin! Greenfiel or ;rownfiel plans

Manpower resource commitment to ensure successful completion of pro!ram proper s.ills

an trainin! to perform the necessar' tas.s(Preliminary process flow diagrams, PFMEA and Control Plan:

Di!hli!ht an' special assembl' techni+ues, test methos or containment proceures use(

"apabilit' stuies on similar parts

"onfirm error proofin!, ata anal'sis, an recor .eepin! is inclue an review plan to meet

an' GM warrant' tar!ets Areview e)istin! open $RR an warrant' sufficienc'/action plans,ata on similar proucts an plans for future reuctionsB(

Tiere supplier mana!ement

$resent process an resource plan for evaluation an mana!ement of tiere suppliers(

Supplier $rovie evience of prior prouct e)perience or technical e)pertise relevant to new prouct(

!eference Docu$ents/

Supplier %ualit' Statement of Re+uirements GM1927>3 / $art>Specific %ualit' = $rocess S:R / #$%$ :pen

Issues &ist GM1927>5 / #$%$ Supplier #ssessment GM1927>7 / Tech Review "hec.list GM1927>13

=#$S$ Tech Review )ample #!ena / Tech Review "hec.list


2


13/107

Global #$%$ $rocessTask .u$ber/

Task .a$e/ Sourcin, %li,ibility

Task 47ner/ S%

Task Ti$in,/ $re>sourcin!

Task Description/


14/107

Global #$%$ $rocess

Task .u$ber/ continue

Task .a$e/ Sourcin, %li,ibility

Sourcin, Appro"al Matri&/

Supplier Location

Type

CT:L

Quality!atin,

TS1;

!e6uire( Au(it Co$$ents

Greenfiel ACew

"onstructionB :R;rownfiel A)istin!

;uilin!B

C/# Co, but

Sister


15/107

Global #$%$ $rocessTas. Cumber

Task .a$e/ Gate !e"ie7s

Task 47ner/ S% for 6ic.>off Meetin!, Supplier for remainin! meetin!s

Task Ti$in,/ Asshown on #$%$ $ro@ect $lan

Task Description/ The purpose of the Gate Reviews is to review the pro!ress of all #$%$ Tas.s as state on the

#$%$ $ro@ect $lan GM1927>1 an trac. the status an pro!ress of items liste on the #$%$Timin! "hart GM1927>2( These review meetin!s are intene as an #$%$ team review of the

part an process evelopment an to capture the lessons learne from each buil event( TheGate Review J1 A6ic.>:ff Meetin!B is coorinate b' the GM S% for all #$%$ parts(

Key Deliverables:

The 6e' eliverable ocuments Asee chartB are to be uploae into G%TS( #ll other #$%$ ocuments an forms

Areference in the GM Global APQP Supplier Status Summary Workbook GM1927-34) are to be retaine 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.

GateDea(line

)Ti$e fro$

S4!P in

7eeks*

G9DP ?0@ ti$in,

reference!e"ie7

8ey

Deli"erables

'or$

Docu$ent

#&&GM Global #$%$ Supplier Status Summar'

Kor.boo.GM1927>3

Kithin 30 a's ofbusiness nomination

avice / contract

Gate 1

%S; #uit AGap #nal'sisB or Greenfiel "hec.list

A#ction $lanB

GM1927>30

GM1927>31

Timin! $lan GM1927>2

6ic.>:ff "hec. list GM1927>1

>78

Initiate after "R

an complete 5

wee.s after IR

Gate 2

$33

>15"omplete 1 wee.

prior M;s MR$$#$ $$#$ #pproval

>8Run ?

Rate

Run ? Rate )ecution R?R Moule

$"$# GM1927>1

Custo$er for Deli"erables/ S%, ;u'er, n!ineer, Reainess "oorinator, Manufacturin! as appropriate(


$ro!ram timin! for .e' events n!ineer/;u'er

etaile pro!ram timin! Supplier

#$%$ :pen Issues &ist GM1927>5 Supplier/S%

#$%$ Timin! "hart GM1927>2 Supplier/S%

!esources/ ;u'er, R, S, S%, Reainess "oorinator, Manufacturin! n!ineer

September 21, 2009 10 GM1927

44


16/107

Global #$%$ $rocess

Task .u$ber/ = continue

Task .a$e/ Gate !e"ie7s

!esponsible Metho(olo,y/

S% Two 6ic.>:ff meetin!s coul potentiall' occur( :ne for $urchasin! scheule b' the ;u'er AIt isoptional in the #$ processB an one for Supplier %ualit' scheule b' the S%( It is esirable that the

two meetin!s be combine into one( If the ;u'er conucts a 6ic.>:ff meetin!, the S% must ensure thatthe content of Global #$%$ Gate Review J1 is inclue or a separate #$%$ Gate J1 must be conucte(

S% #uit tas.s = eliverables ientifie in the GM Global #$%$ Supplier Status Summar' Kor.boo. Gate

1 A6ic.>:ff Meetin!B / Gate 2 / 3 / / $$#$ an Run = Rate for all customer monitore #$%$ parts(

S% #t the #$%$ 6ic.>off Meetin!, review &essons &earne, S% S:R GM1927>3 an the $art>Specific%ualit' = $rocess S:R Aif applicableB to re>emphasi-e iscussion from the Technical Review(

S% Throu!hout the pro!ram, ensure &essons &earne are ocumente b' the supplier in the appropriate35 Run at Rate Kor.boo., is

sufficient to meet contractual re+uirements an pass the Run at Rate(

S% &ea Greenfiel/;rownfiel evelopment assessment process GM1927>31 Aif applicableB( It is

encoura!e that the ;u'er an the $rouct n!ineer ta.e part in the auits(S% n!a!e the irecte ;u' sub>component assi!ne GM S% in the S'stem/#ssembl' Gate Reviews, in

case GM1927>23 Aapprove b' S% irectorB has state that irecte ;u' sub>components $$#$ or

Run?Rate must be approve b' GM an once the component S% is other than S'stem/#ssembl' S%(

S% Ientif' an communicate .e' timin! an pro!ram issues to GM mana!ement(

Supplier :ff meetin!(

:ff meetin! internall' an report the result to GM(

Supplier


17/107

Global #$%$ $rocess

Task .u$ber/ ?

Task .a$e/ Ti$in, Chart an( APQP 4pen -ssues List

Task 47ner/ Supplier

Task Ti$in,/ Reviewe at Gate Reviews an throu!hout the pro!ram

Task Description/ # etaile review of all timin! charts an concerns is conucte perioicall' to ensure thatpro!ram eliverables are e)ecute on scheule( These reviews are conucte on GM

monitore parts trac.e usin! the #$%$ process( to>ate #$%$ Timin! "hart GM1927>2 or e+uivalent format containin! all re+uire information Ato be

uploae to G%TS at Gate Review J1B

#$%$ :pen Issues list GM1927>5

Custo$er for Deli"erables/Supplier %ualit' n!ineer


:pen issues S%/Supplier/n!ineer/;u'er

etaile timin! for toolin!, facilities, !a!es, etc( Supplier

!esources/Supplier, S%, n!ineer, Manufacturin! n!ineer, an other members of the pro!ram team as appropriate


S% Review the #$%$ Timin! "hart an #$%$ :pen Issues &ist, minimum monthl'(

S% rive supplier to evelop recover' plans on issues impactin! timin!, +ualit' or capacit'(

S% Ientif' an communicate .e' timin! an pro!ram issues to GM mana!ement(

Supplier "reate an #$%$ Timin! "hart GM1927>2 or e+uivalent an trac. tas.s to completion in line with chart(

"reate an #$%$ :pen Issues &ist GM1927>5 an present upates to S% at all Gate Reviews minimum(

Supplier Sub>component milestones shall be pulle ahea of Tier 1 assembl' milestones b' wee.s to protect

GM pro!ram timin!(

Supplier 4pate timin! chart as timin! chan!es occur an communicate an' chan!es, concerns an issues to S%on an on!oin!>basis Amaintain aitional etail behin each hi!h level #$%$ Timin! "hart item,

aitional etail must be tie to hi!h level chart to ensure timin! is upate automaticall'B(

Supplier evelop recover' plans for issues impactin! timin! an rive the plan to maintain pro!ram timin!(

Supplier 4tili-e #$%$ :pen Issues list to capture all issues re+uirin! action(


#$%$ Timin! "hart GM1927>2

#$%$ :pen Issues list GM1927>5

September 21, 2009 12 GM1927

5


18/107

Global #$%$ $rocessTask .u$ber/ ;

Task .a$e/ QS: Quality Syste$s :asics


Task Ti$in,/ Gate 1 AGap #nal'sisB an Gate 3 A"omplianceB

Task Description/ %S; is a set of the 10 basic strate!ies in orer to assure +ualit'(

1( "onformin! $rouct 7( &a'ere $rocess #uits3( erification Station 80 R$CRis. Reuction AReverse $30( %S;

to be assesse a!ainst the manufacturin! plant %ualit' S'stems inepenent of prouct or specificmanufacturin! process(

Rules for the application of the %S; #uits

"ustomer Monitore #$%$ F Manator'

Supplier Monitore #$%$ F #t S% iscretion Arecommene, if not passe within last 3 'ears

#uit must be performe b' GM S% or a Thir $art' where a!ree

S% / ;u'er

/ R

off the #ction $lan final implementation GM1927>30( In face

of lac. of full implementation, the open issues will be aresse b' Master ot Aattache to the auit formBan the $ro!ram Mana!ement $RR rules will be applie(

S% off the #ction $lan final implementation of the Greenfiel = ;rownfiel

evelopment #ssessment $rocess GM1927>31(

Supplier #t the %S; Gap #nal'sis auit, or at the Greenfiel = ;rownfiel evelopment #ssessment $rocess auit,

provie action plans with appropriate etail, timin!, ownership, etc(

Supplier Implement an verif' effectiveness of all the action plan items before Supplier Gate Review J3(

Supplier 6eep the customer upate re!arin! implementation status an an' issues or concerns with implementation


%S; $resentation GM1927>3

%S; #uit 30

Greenfiel/;rownfiel chec.list GM1927>31

September 21, 2009 13 GM1927

6APQP QS: Task $ust be co$pliant on or before PPAP

Gate ):e,innin, 7ith Mo(el ear 2@1@ pro,ra$s*


19/107

Global #$%$ $rocess

Task .u$ber/ B

Task .a$e/ Process 'lo7 Charts


Task Ti$in,/ Initial chartFprior to sourcin!, reviewe at Gate 2 an Gate 3, approve at Gate

Task Description/ basis to S%(


#I#G #vance $rouct %ualit' $lannin! an "ontrol $lan manual $rocess


20/107

Global #$%$ $rocessTask .u$ber/

Task .a$e/ D'M%A

Task 47ner/ esi!n :wner AGM n!ineer or SupplierB

Task Ti$in,/ Initiate before or at esi!n concept

Task Description/ The ups anrevise esi!n

!uielines an atabases accorin!l'

Revise with new&essons &earne from

valiation anprotot'pe buils


21/107

Global #$%$ $rocess

Task .u$ber/ continue

Task .a$e/ D'M%A


S% "onfirm that the Supplier Aif not esi!n responsibleB is wor.in! with the GM n!ineer on evelopmentof the


22/107

Global #$%$ $rocessTask .u$ber/ !oin! basis

Task Description/ Reviews to ensure the esi!n has been ae+uatel' efine to enable construction of tools an!a!es(

8ey Deli"erables/

efine an measurable 6"S esi!nators

G=T

#ppearance, performance an material testin! specifications

Custo$er for Deli"erables/Supplier


S:R / SSTS / "TS n!ineer

#ppearance specifications n!ineer

$erformance an material specifications n!ineer

$rouction #ssembl' ocuments if available n!ineer

;ill of Material A;:MB n!ineer

!esources/n!ineer, Supplier %ualit' n!ineer, Supplier, Subcontractors


esi!n

:wner

Scheule an conuct 6"S wor.shop( S%, GM n!ineer an supplier participate in wor.shop( The

purpose of the wor.shop is to efine critical prouct characteristics, an critical process control

characteristics(

esi!n

:wner

Scheule an conuct G=T review( The S%, GM n!ineer an supplier participate in the review(

The purpose of the review is to efine esi!n imensionin! an tolerance on the rawin! as these items

relate to the actual function of the part(

esi!n

:wner


23/107

Global #$%$ $rocessTask .u$ber/ 1@

Task .a$e/ Toolin, an( %6uip$ent !e"ie7s


Task Ti$in,/ :ff with final e+uipment at final prouction location previousl' to $$#$ run

"onuct toolin! reviews = auits throu!hout buil process(

S% /

S%T

#t the toolin! bu'>off or $$#$ approval, verif' the e)istence of GM owne toolin! an that it is properl'

ientifie as GM propert'(

Supplier Review all timin! an inform GM S% about an' chan!es from ori!inal pro@ect timin!(

Supplier esi!n, buil an obtain certification of an valiation of toolin! an e+uipment as per latest math ata(

Supplier $articipate in esi!n reviews with GM an ensure G=T, 6$", $%" an #%" re+uirements are inclue

in the toolin!, e+uipment an functional test esi!n( #lso ensure toolin! an e+uipment will prouce partsto process capabilit' re+uirements(

Supplier Inform GM about an' esi!n an process chan!es re!arin! an' new or moifie tools, rearran!ement ofe)istin! toolin! or e+uipment, an' prouct or process chan!es impactin! fit, form, function, performance

an urabilit' of saleable prouct, an' test/inspection methos an an' new facilities(

Supplier $rior to tools bein! !raine, imensional verification is re+uire b' GM an #pproval to Grain formsi!ne Averif' with S% on re!ional re+uirementsB(

Supplier nsure $3B(


September 21, 2009 18 GM1927

10


24/107

Global #$%$ $rocess #I#G "hec.list #>3

September 21, 2009 19 GM1927


25/107

Global #$%$ $rocessTask .u$ber/ 11

Task .a$e/ Ga,e De"elop$ent + Appro"al


Task Ti$in,/ Startin! A"onceptB at $3 release an complete b' $$#$ #pproval

Task Description/ To esi!n, builan certif' !a!es accorin! to latest G=T release an per GM re+uirements(

8ey Deli"erables/

GM1927>29 full' approve b' S% or GM Ga!e n!ineer 8 wee.s prior to $$#$ ate(

Custo$er for Deli"erables/GM Ga!e n!ineer, GM Supplier %ualit' n!ineer, Manufacturin! &ocation


$art Math ata A$2B an G=T A$3N$2 O wee.sB imensional n!ineer an esi!n n!ineer

6"S esi!nators esi!n Release n!ineer

Ga!e esi!n an ;uil #pproval GM Ga!e n!ineer

Timin! re+uirements ;u'er / S% / Supplier

!esources/ Supplier, GM Ga!e Group, S%, GM esi!n Release n!ineer, imensional n!ineerin!


S% Startin! at Gate Review J1, ensure supplier is aware of GM1927>29 Ga!e Re+uest an GM 1925

components(

S% / S%G Review complete !a!e esi!nAsB base on !a!e concepts approve b' GM Ga!e n!ineer(S% / S%G Review construction to ensure that !a!e meets latest G=T, a!rees with functional part usa!e / atum

strate!' an inclues measurement of 6"S esi!nators(

S% / S%G #pprove !a!e per GM 1925


26/107

Global #$%$ $rocess Ga!e Re+uest "ertification GM1927>29

Task .u$ber/ 12

Task .a$e/ P'M%A


Task Ti$in,/ Startin! at 6ic.>:ff Meetin! an complete b' $$#$

Task Description/ nsure that potential failure moes of the process have been consiere an aresse toreuce ris. of efects throu!h R$C reuction strate!'(

8ey Deli"erables/

$buils,customer

complaints, aninternal ata for the

life of the part


27/107

Global #$%$ $rocessTask .u$ber/ 12 continue

Task .a$e/ P'M%A

!esponsible Metho(olo,y/continueS% #tten initial $Specific %ualit' = $rocess S:R Aif applicableB is applie to support $21, an monitorpro!ress at each Gate review an ensure that action plans have been ae+uatel' efine for hi!h R$Cs an

hi!h severit' failure moes as re+uire.

S% nsure supplier has complete $21

Global $


28/107


Task .a$e/ Control Plans


Task Ti$in,/ Initial raft prior to Sourcin!, upates parallel $launch issues have been incorporate into the prouction $"$(

S% Kal. the prouction floor an verif' that the controls liste on the plan are in place an bein! use(

"omplete the $rocess "ontrol $lan #uit "hec.list GM1927>1 as part of the auit of the prouctionprocess(

Supplier evelop a preliminar' $"$ usin! an e)istin! $"$ on a similar part( This first version of the control planis then submitte with the +ualit' portion of the supplier*s bi pac.a!e(

Supplier evelop a pre>launch $"$ for use on the first prouction parts shippe to assembl' plants AG$>12B an

prouction $"$ usin! the preliminar' $"$ as a founation( The $launch $"$ oes not nee to be separate from

the prouction $"$( $re>launch controls can be ocumente on the prouction $"$ as lon! as the' are

clearl' ientifie as such( 4se the pre>launch $"$ to valiate the effectiveness of the prouction $"$(

#ppl' #I#G chec.list #>8

Supplier Manufacturin! site shall ocument, maintain, an retain $"$*s an iniviual $rocess "ontrol "harts for

all characteristics ientifie as 6$", $%" = R( :n!oin! process control shall be emonstrate

AocumenteB throu!h the continuous use of inustr' stanar statistical methos an techni+ues anprocess control charts( $rocess control charts for 6$", $%", an R characteristics shall be retaine in a

September 21, 2009 23 GM1927

13


29/107

Global #$%$ $rocessrecoverable format for a minimum of 3 'ears(

Task .u$ber/ 1 continue

Task .a$e/ Control Plans

!esponsible/ Metho(olo,y continue

Supplier Manufacturin! site shall applies 100Q inspection fre+uenc' to all characteristics ientifie as #%" an

control all 8



30/107


Task .a$e/ %arly Pro(uction Contain$ent )GP12*


Task Ti$in,/ G$>12 start at $$#$ non>saleable to meet $$ containment until achieve a!ree e)it criteria

Task Description/ stablish a containment plan urin! start>up an acceleration, so that an' +ualit' issues are+uic.l' ientifie at the supplier*s facilit' an not at the GM customer*s facilit'( This

proceure applies to all new an chan!e parts that re+uire $$#$ for start>up or acceleration(

8ey Deli"erables/

arl' $rouction "ontainment $lan G$12 #uit GM1927>33 Ato be uploae to G%TS at Gate Review JB

Custo$er for Deli"erables/GM Manufacturin! or #ssembl' 12 area(

$rocess in place to prevent shipment of material that has not !one throu!h G$>12(

Recor of results(

S% Review supplier*s initial G$>12 ata to assess compliance to process intent(

Supplier evelop an earl' prouction containment plan as specifie in G$>12, incluin!, but not limite to

# separate inspection area whenever possible Ama' re+uire chec.s within the process for

components that are not available for chec. after assembl'B(

$rocess to ensure that all non>conformances are containe within the facilit' an prompt

containment an irreversible corrective actions are applie if non>conformances are iscovere(

Ientification of the person responsible for the containment process(

100Q chec. of specific features for pre>pilot an pilot material, as re+uire(

4se of !reen ots Asi!ne b' a esi!nate senior mana!ement representativeB on shippin! labels to

esi!nate compliance(

4se of the arl' $rouction "ontainment $lan until the a!ree e)it criteria is met(

Supplier Root "ause an' non>conformances foun b' GM manufacturin! locations an implement aitional

chec.in! provisions to the pre>launch chec.list( Ientif' an communicate an' chan!es to S%(

Supplier Re+uire compliance to G$>12 from all subcontractors, as well as monitor an maintain their recors( This

will re+uire that subcontractors pull ahea their G$>12 to allow the Tier 1 G$12 timin! compliance(


#I#G #vance $rouct %ualit' $lannin! an "ontrol $lan manual = $rouction $art #pproval $rocess Manual

September 21, 2009 25 GM1927

14


31/107

Global #$%$ $rocess G$ 12 = G$>12 #uit GM1927>33

Task .u$ber/ 15

Task .a$e/ Pro(uction Part Appro"al )PPAP*


Task Ti$in,/ $rior to $$#$ Submit ate

Task Description/ etermine if all customer en!ineerin! esi!n recor an specification re+uirements are

properl' unerstoo b' the supplier an that the process has the potential to prouce prouct

meetin! these re+uirements urin! an actual prouction run at the +uote prouction rate(

8ey Deli"erables/

Minimum 100Q imensional :6 $$#$ Con>Saleable before $$ with imensional Report GM1927>32

an GM Kor.sheet GM>111, if re+uire Aboth ocuments to be uploae to G%TS at Gate Review JB

&aunch "ontrol $lan G$>12, plus $rouction "ontrol $lanB Supplier

Measurement S'stems #nal'sis Stuies Supplier

imensional Results Supplier

Material, $erformance Test Results Supplier

Initial $rocess Stu' Supplier

%ualifie &aborator' ocumentation Supplier

#ppearance #pproval Report A##RB, if applicable Supplier

Sample $rouct Supplier

Master Sample Supplier

"hec.in! #is Supplier

Recors of "ompliance to customer specifics Supplier

$art Submission Karrant Supplier

;ul. Material Re+uirements "hec.list Afor bul. material onl'B Supplier

!esources/ $urchasin!, Supplier %ualit', $rouct n!ineerin!, Material n!ineerin!, aliation n!ineerin!,

imensional Mana!ement, $art #pproval &aborator', #ppearance &aborator', $aint n!ineerin!

!esponsible/ Metho(olo,y;u'er "ontract part, establish initial $$#$ submission ate an enter ate into G$S(

S% etermine submission level an +uantit' of samples(

S% "onfirm $$#$ submission ate with the supplier an ensure supplier upates G%TS as re+uire(

S% Review the submission an etermine the $$#$ status in accorance with the #I#G $$#$ manual( Input

the $$#$ approval status into the G%TS s'stem(#ttach to the $$#$ recor in G%TS the followin! ocuments

$SK

imensional Report

Material an $erformance Test Report

##R Aif applicableB


15


32/107

Global #$%$ $rocess GM111 Aif applicableB

GM30 Aif applicableB

S% Cotif' supplier of part $$#$ status(

September 21, 2009 27 GM1927


33/107

Global #$%$ $rocessTask .u$ber/ 15continue

Task .a$e/ Pro(uction Part Appro"al )PPAP*


S% #ppl' the #$%$ Supplier Status Kor.boo. > $$#$ #pproval Gate ecision GM1927> 3(

S% rive aherence to $$#$ submission ate, as scheule on GM 1927>2 #$%$ Timin! "hart(

S% Review $$#$ submissions as appropriate an confirm the $$#$ status as per the #I#G $$#$ manual an

GM specifics(S% nsure ae+uate recover' plans GM111 are provie for $$#$ without full approval(

S% specific S:R( $rovie ocumentation of compliance with the $$#$submission A$$#$ full approval re+uires compliance to S:RB(

Supplier $rovie GM111 for S% si!nature for an' part submitte that re+uires action plan to achieve full

approval( $rovie an' other appropriate si!nature epenent on issue as re+uire on the GM111(

Supplier $rovie the samples applie to Matchin! verification with imensional inspection results as per Global

$art Submission $roceure for Matchin! GM1007 an imensional Report GM1927>32(

Supplier The supplier shall ocument containment plans until the S% is satisfie process capabilit' has been

achieve(

Supplier Shipment of parts for Saleable proucts is onl' allowe if the $$#$ Status AG%TS $$#$ Shippin! StatusB

is #pprove or Saleable with a vali e)piration ate( GM ma' choose to allow parts with a Con>Saleable

Status to ship for a Saleable buil but these parts nee to be retrofitte before the prouct is elivere to

the customer(

Supplier Cotif' S% before the $$#$ re>submission if an' process chan!e occurs relative to the previous $$#$

review(

Supplier Guarantee the accomplishment of the #$%$ Supplier Status Kor.boo. F $$#$ #pproval Gate ecision(


#I#G $rouction $art #pproval $rocess manual

#I#G Statistical $rocess "ontrol manual

#I#G Measurement S'stems #nal'sis AMS#B manual

#I#G #vance $rouct %ualit' $lannin! an "ontrol $lan manual

#I#G $otential 111

General Motors "ommoit' si!n>off GM30

Generic Supplier # $rocess Tas.s = eliverables AGMK300B

Global $art Submission $roceure for Matchin! GM1007

GM "ustomer Specifics F IS:/TS199

$art>Specific %ualit' = $rocess S:R Aif applicableB

September 21, 2009 28 GM1927


34/107

Global #$%$ $rocessTask .u$ber/ 1;

Task .a$e/ !un E !ate )!E!*


Task Ti$in,/ Gate 1, Gate 3, an at Run at Rate

Task Description/ erif' that the supplier*s actual manufacturin! process, while operatin! uner normaloperatin! conitions an uner total customer re+uirement, is capable of proucin!

components that simultaneousl' meet %ualit' an ail' "ontracte "apacit'8ey Deli"erables/

"omplete R?R "apacit' Kor.boo. an R?R for each part

erification Supplier can meet ail' "ontract "apacit' in one a'

Custo$er for Deli"erables/Supplier %ualit' an $urchasin!


$$#$ ocumentation Supplier

GM*s ail' re+uirement A&"RB ;u'er

Supplier*s "ontracte Tool "apacit' Supplier = ;u'er AcontractB

$lanne = unplanne owntime recor Supplier

Kritten confirmation of +ualit', capacit' an eliver' Supplier

for all sub>components

!esources/S%, ;u'er, n!ineer, an Supplier

!esponsible/ Metho(olo,y Arefer to R?R ia!ram at en of the tas.B

S% nsure the supplier is plannin! to install the proper capacit' to meet the ail' "ontracte "apacit'

throu!h the use of the "apacit' Kor.boo. GM1927>35 at Gate 1 an Gate 3(

S% Review an status the actual Run at Rate A"ustomer or Supplier MonitoreB ata submitte b' thesupplier to ensure ae+uate actual installe capacit' meets contract re+uirements(

S% "onuct the Gate 1 #$%$ 6ic.>off meetin! an evaluate the supplier*s R?R plan(

S% "onfirm that the ail' contracte capacit' is accurate an is !reater than or e+ual to GM*s ail're+uirement A&"RB( If there is a iscrepanc' or contract capacit' information is missin!, contact the

bu'er(

S% "omplete the scalation $rocess for Gate 1 if an' contract information missin! an forwar to S%

Mana!er(

S% "onuct the Gate 3 #$%$ Review an etermine R?R $#SSH metrics an avise supplier(

S% "omplete the scalation $rocess for Gate 3 if supplier i not complete all re+uire information anforwar to S% Mana!er(

S% #tten R?Rs esi!nate as customer monitore( nsure supplier uses the R?R Dourl' "ount Sheet(

Review ocumentation, subcontractor re+uirements, constraint operations an manufacturin! process(

S% Khen supplier submits "apacit' Kor.boo., status the R?R( If subcontractor letter is missin! status must

be a


35/107

Global #$%$ $rocess

Task .u$ber/ 1;continue

Task .a$e/ !un E !ateA!E!*


Supplier "onuct R?Rs on all parts re+uirin! a R?R(

Supplier "ompletel' fill out the R?R Dourl' "ount Sheet urin! the R?R for both the final operation an theconstraint operation(

Supplier "omplete the "apacit' Kor.boo. for all R?Rs an forwar to the S% within 2 hours(


GM1927>35

September 21, 2009 30 GM1927

END

SQE conductsKick-off meeting(Gate 1) andEscalates if

missing anycontract

information

CustomerOr

Supplieronitored

Supplier conductspractice !"! durin

##$# %uild and&orsimulations.

Supplier conducts!"! using t'e !"

ourly S'eet it'SQE present.

*s!"!

Status +#ass,

Supplier updates$#Q# open issueslist it' !"! issues

and SQE follosEscalation process

SQE conducts$#Q# meeting(Gate ) andEscalates ifmissing any

supplierinformation

Supplier completesanufacturing /lo

0iagramS'ared Capacity S'eetsanufacturing Capacity

Estimate andsu%mits to SQE

Supplier completesCapacity 2ork%ookand sends to SQE

SQE statuses!"!

*s!"!

!e3uired

SQE 'as SupplierQuality and#urc'asing

0irector appro4ee5emption

SQE statuses!"! as e5empt

Supplier conducts!"! using t'e !"!

ourly S'eet it'SQE present.

Supplier completesCapacity 2ork%ookand sends to SQE

SQE statuses!"!

Yes

NoCustomer

Supplier

No

Yes

!E! Metho(olo,y


36/107

Global #$%$ $rocess

Task .u$ber/ 17

Task .a$e/ Lessons Learne(


Task Ti$in,/ "ommoit' 6e' Sta.eholers Meetin! throu!h &aunch

Task Description/ Ma)imi-e the .nowle!e !aine from previous pro!rams an not revisit the same +ualit' or

esi!n issues(

8ey Deli"erables/

Specific %ualit' = $rocess S:R upate with &essons &earne throu!hout the #$%$ process

Custo$er for Deli"erables/S%, n!ineerin!, $T A$rouct evelopment TeamB, Supplier


)istin! &essons &earne for same commoit' S%/&essons &earne website n!ineerin! 6nowle!e for commoities n!ineer

$rocess .nowle!e for same commoit' S% / Re!ional atabases

!esources/S%, n!ineerin!, &essons &earne website

!esponsible/ Metho(olo,y/

S% Lessons Learne( p(ate /

)Co$$o(ity 8ey Stakehol(ers Meetin,*/

nsure $art>Specific %ualit' = $rocess S:R Aif applicableB is inclue in the R


37/107

Global #$%$ $rocess


GM Suppl' $ower F $art>Specific %ualit' = $rocess S:R

September 21, 2009 32 GM1927


38/107

Global &aunch $rocess

Section 2

Global Launch

September 21, 2009 33 GM1927


39/107


Docu$ent sa,e Gui(elines

' 3 !eference 4nly )infor$ation only5 nothin, to fill out*

MD 3 Man(atory Docu$ent )specific for$at re6uire(*

M- 3 Man(atory -nfor$ation )for$at $ay "ary5 content $an(atory*

!D 3 !eco$$en(e( Docu$ent )not $an(ate(5 at a $ini$u$ content shoul( be re"ie7e(*

Docu$ent .u$ber Man(atory !eco$$en(e(

Global &aunch Report Template GM1927>0 M

Supplier "onference ;rea.>:ut

%uestionnaire

GM1927>1 R

6e' Supplier Review Template GM1927>2 R

Supplier &aunch #uit form GM1927>3 M

Supplier $erformance ReviewInvitation &etter

GM1927> R

Supplier $erformance Review

$resentation Template

GM1927>5 R

4bsolete Docu$ents/ .A

.4T%/The tas.s in the followin! section of the Manual are written consierin! the re+uirements of Cew, Ma@or,

erivative, M"3 or "6 pro!ram launches( &ower content pro!rams AM"2, M"1 an #nnualsB shoulconsier tas.s an resource re+uirements relative to pro!ram ris. an appl' onl' as re+uire(


40/107


Task .u$ber/ 1

Task .a$e/ Launch Mana,e$ent Tea$ )e&clu(in, PT*

Task 47ner/ S% &aunch Group Mana!er an/or Global S% &aunch Mana!er A$latform "oorinatorB

Task Ti$in,/ >75w.s S% &aunch Mana!er assi!ne

>52w.s #ssistant S% &aunch Mana!er assi!ne>52w.s &aunch S%s assi!ne Awhere availableB

Task Description/ Staffin! of an S% &aunch Mana!ement Team to support new vehicle launch an team

responsibilities list(

8ey Deli"erables/

eicate &aunch Team 75w.s to S:R$(

S% &aunch

Mana!er

Identify source for template resources (Assistant SQ Launch Manager and Launch SQEs) based on

availability and program complexity and make a plan to engage them by -52wks to SORP.

S% &aunch

Mana!er

Conduct Kick-Off with $lant Mana!er, &aunch Mana!er, S% irector an affecte Staff

S% &aunch

Mana!er

Move S% &aunch Mana!ement Team resources on>site ahea of $$ Aappro)imatel' >0w.s prior to

S:R$B(

Scope of work for SQ Launch Management Team includes (for detail refer Tasks in this Manual):

Maintain suppl' base ris. ran.in! b' 4Cs throu!hout launch to rive miti!ation measures an resource

allocation A&aunch Manual Tas. 3B(

Support all shifts Aivie responsibilities between S% &aunch Mana!ement TeamB(

monthl' preparation of Global &aunch Report A&aunch Manual Tas. 2B(

Kee.l' or bi>monthl' presentation of Global &aunch Report to $ro!ram Team Reviews, $lant an

Manufacturin! &aunch Reviews an G$S" an Supplier %ualit' leaership reviews(

"onuct wee.l' or bi>monthl' anal'sis of $$#$, R?R, an R ata containe in Global &aunch Report(

Support $IT an IRT wee.l' for "hassis, ;o', lectrical, Trim, ;SR Aivie between S% &aunch

Mana!ement TeamB(

#tten ail' G"#, launch activit' wrap up, an throu!hput meetin!s(

September 21, 2009 35 GM1927

1


41/107

Global &aunch $rocess Represent G$S" at ma@or reviews an problem solvin! meetin!s such as $%RRs, MRRMs, $%$, &$IT,

"ore IRT*s, etc( Aas per $ro!ram &aunch team e)pectationsB(

:versee structure &aunch Issue scalation process A&aunch Manual Tas. B(

Task .u$ber/ 1 continue

Task .a$e/ Launch Mana,e$ent Tea$ )e&clu(in, PT*

Mana!e communication of &aunch e)pectations to the Suppl' base A&aunch Manual Tas. 5B(

$articipate in #$%$ Team Reviews Aterme eep ives in GMC# F &aunch Manual Tas. 7B(

rive/$articipate in problem resolution communication an follow>up !loball' A&aunch Manual Tas. 10B(

$articipate in Suppl' "hain material trac.in! calls for trouble suppliers / suppliers behin scheule

Ashorta!e callsB(

#ssist Suppl' "hain in unerstanin! an overcomin! roabloc.s to !ettin! parts to plant for MRs where

there are supplier issues(

Support "#; / K: / TK: / IT meetin!s, in consultation with $$M team A$$M team inclues

$urchasin! &aunch "oorinator roleB(

rive 6e' Supplier Review meetin!s A&aunch Manual Tas. 8B(

rive Supplier $erformance Review meetin!s as re+uire A&aunch Manual Tas. 8B(

Trac./support Darmon' Reviews, Grain bu'>off an ##R approvals, as well as ;ounar' Sample

evelopment if re+uire A&aunch Manual Tas. 13 > optionalB(

$articipate in an rive &a'ere #uits with critical suppliers A&aunch Manual Tas. B( Support plant with G$5/G$12 activities Acontainment strate!' F S$ as per &aunch Manual Tas. 12,

optional an/or "S1 an "S2B(

rive eep ive en!a!ement at Top Ris. an poor &aunch performance suppliers ASupplier &aunch #uit

> &aunch Manual Tas. 9B(


The Global &aunch $rocess :wner*s Manual



42/107


Task .u$ber/ 2

Task .a$e/ Global Launch !eport

Task 47ner/ Supplier %ualit' &aunch Mana!er

Task Ti$in,/ Start >2w.s

Task Description/ Stanar report upate minimum semi>monthl' Aever' 2 wee.sB from >2w.s coverin! suppl'

base $$#$, Run?Rate an &aunch #lert summar' specific to a $ro!ram &aunch

8ey Deli"erables/

Meet the pro!ram $$#$ an Run?Rate !lie path metrics

Custo$er for Deli"erables/$ro!ram &aunch Mana!er, Manufacturin!, $urchasin!, n!ineerin!, Supplier %ualit'


$ro!ram milestone ates $ro!ram &aunch Mana!er

&aunch #lerts Manufacturin! S% $$#$ an Run?Rate promise ates #$%$ Teams / G%TS

!esources/ Supplier %ualit'


S% &aunch

Mana!er

"reate report in line with !lobal template prior to >2w.s to S:R$ an issue minimum semi>monthl' to

relevant pro!ram an S% mana!ement an post on GM Suppl'power %ualit' librar' in&aunch/Reainess foler uner appropriate re!ional sub>foler(

C:T some re!ions an pro!rams reportin! re+uirements ma' ictate wee.l' upate post>$$(

S% &aunchMana!er

"reate cover pa!e usin! official pro!ram launch timin! an information, incluin! vehicle ima!e ifrelease Aotherwise use carr'over vehicle ima!eB(

S% &aunch

Mana!er

If pro!ram is pre>$$ ownloa Tool "onstruction Reainess slie from GSTS an inclue in

presentation, if pro!ram is post>$$ use placeholer slie in place of Tool "onstruction Reainess(S% &aunch

Mana!er

If S:R$ is 23w.s, evelop Run?Rate !lie path usin! commitment ates in G%TS an inclue in

presentation, else if S:R$ is still 23w.s use placeholer slie in place of Run?Rate !lie path(

S% &aunch

Mana!er

"apture all pro!ram Re &aunch #lerts on a Re &aunch #lert summar' slie, cross chec.in! criteria to

ensure all alerts are appropriatel' ientifie(

S% &aunch

Mana!er

"apture newH part $$#$ statistics in the main bo' of the presentation Aincluin! all part numbers first>

use for the pro!ramB an new an carr'>overH part $$#$ statistics incluin! all pro!ram parts in the

presentation bac.>up slies(

S% nsure suppliers maintain up>to>ate $$#$ an Run?Rate promise ates in G%TS from #$%$ Gate 3

onwars for all part numbers( scalate immeiatel' an' $rouction Toolin! ela's, 15w.s for G$ 5(0 33/20B an issues preventin! Run?Rate

pass b' SS0

Global &aunch #lert criteria

September 21, 2009 37 GM1927

2


43/107


Task .u$ber/

Task .a$e/ Supplier Launch !isk Analysis


Task Ti$in,/ >75 w.s to >52 w.s

Task Description/ #stanari-e process use to ran. supplier ris. relative to pro!ram launch(

8ey Deli"erables/

evelop list of Di!h Ris. suppliers



$lan 3

#$%$ #ssessment, GM1927>7#$%$ Timin! "hart, GM1927>2

#$%$ :pen Issues &ist, GM1927>5

September 21, 2009 38 GM1927

3


44/107


Task .u$ber/ =

Task .a$e/ Launch -ssue %scalationTask 47ner/ Supplier %ualit' &aunch Mana!er

Task Ti$in,/ >75w.s throu!h S:R$

Task Description/ Stanar process to communicate an escalate all &evel 1 or 2 :pen Issues an Re &aunch

#lerts

8ey Deli"erables/

arl' ientification of all &aunch Ris. issues to enable +uic. response an appropriate ris. miti!ation

implementation

Custo$er for Deli"erables/$ro!ram &aunch Mana!er, Supplier %ualit', $$M, $urchasin! Mana!er an $rouct

n!ineerin! Mana!ers



&aunch #lerts ARe, Lellow, GreenB S%

&evel 1 or 2 :pen Issues or #$%$ Gate Review elin+uencies S%

$$#$ an Run?Rate promise ates #$%$ Teams / G%TS

&aunch "#; approve chan!es an TIs $&" A$$MB



S% &aunch

Mana!er

efine stanar e)pectations to communicate an escalate items consiere as potential Re &aunches

Aminimum re+uirement is entr' in G%TSB(S% &aunch

Mana!er

"reate a lo! to follow all Re &aunch alerts for the pro!ram(

S% &aunch

Mana!er

If pro!ram is within the reportin! phase all Re &aunch #lerts must be summari-e an reporte bi>

monthl' or wee.l' as part of the Global &aunch Report(

S% Monitor all :pen Issue level 1 or 2 an escalate all potential Re #lerts to the S% &aunch Mana!er for

inclusion in the Re &aunch "ommunication an escalation process(

#$%$

Mana!er

Mana!e an Trac. S%s to ensure all potential Re &aunches are capture an communicate(

#$%$Mana!er

0#$%$ :pen Issues list, GM1927>5

September 21, 2009 39 GM1927

4


45/107


Task .u$ber/ ?

Task .a$e/ Supplier Co$$unication Conferences

Task 47ner/ $ost Sourcin! "onference > G$S" $$M

$re &aunch "onference > S% &aunch Mana!er

Task Ti$in,/ $ost Sourcin! "onference no later than > w.s

$re &aunch "onference no later than >22 w.s

20 hi!h ris.

suppliers for brea.>out sessions( Issue supplementar' invitation to ientifie suppliers an S%s for

brea.>out sessions an provie cop' of the +uestionnaire for preparation A1>2 months prior to

conferenceB(

S% ;oo. meetin! room an invite cross>functional GM attenees for brea.>out sessions A2> wee.s priorB(

"onference

:wner

up functions for complete presentation material an collate an format into Master $resentation

A1>3wee.s prior to conferenceB(

"onference:wner

#rran!e nameta!s, refreshments an securit' access as re+uire base on the final list of conferenceattenees A1>3 wee.s prior to conferenceB(

"onference

:wner

efine support staff to mana!e in!ress/e!ress of attenees, conference re!istration for attenees an

other support as re+uire Ai(e( translators, 1>3 wee.s prior to conferenceB(

S% &aunch

Mana!er

"ollate results from the brea.>out sessions, trac. an follow>up closure of critical items with responsible

S%s an #$%$ Mana!ers(


5


46/107



Supplier "onference ;rea.>:ut %uestionnaire, GM1927>1

The Global &aunch $rocess :wner*s Manual



47/107


Task .u$ber/ ;

Task .a$e/ Supplier Layere( Au(its



Task Description/ Stanari-e scheule of Supplier &a'ere #uits b' S% Team &eaers an Senior &evelMana!ers at #$%$ Gate 3 an for Di!h &aunch Ris. Suppliers(

8ey Deli"erables/

Measure effectiveness of #$%$ e)ecution an ensure appropriate ris. miti!ation ahea of enterin!

Manufacturin! ;uil phase




Supplier Ris. #nal'sis / Ran.in! Supplier %ualit' &aunch Mana!er

S% auit an $$#$ result Supplier %ualit' n!ineer



S% &aunch

Mana!er

Review ris. anal'sis results AS% &aunch Tas. 3B an !roup suppliers b' SMT( Ran. Di!h Ris.

suppliers within each SMT, then evelop &a'ere #uit supplier list( Review list before each roun

of &a'ere #uits to assess chan!es in relative ris. levels between rouns(

S% &aunch

Mana!er

$rovie list to S% Team &eaers an Senior &evel mana!ers minimum wee.s ahea of re+ueste

auit completion ate an follow>up for visit scheule AS% &aunch Mana!er ma' participate in visit

scheule as auitorB(

S% &aunch

Mana!er

Recor auit results an trac. follow>up for an' R an L&&:K items until closure( mphasi-e

rapi closure of issues ahea of manufacturin! buil phase(

GM &a'ere

#uitor

Select auit base on relevance to #$%$ Gate Aunless a specific auit is manate b' S% &aunch

Mana!erB, ensurin! focus on #$%$ Gate Review .e' eliverables AGate 3 F %S;,Greenfiel/;rownfiel, "apacit' $lan, # $lan Gate F :ff>Tool imensional Status, G$>12

implementationB(

#$%$ or S%

Team Mana!er

up R an L&&:K items until closure an report results bac. to S% &aunch Mana!er(

Measure effectiveness of #$%$ e)ecution ahea of enterin! manufacturin! buils(

S% "omplete initial auit ahea of &a'ere #uit an rive closure of all R an L&&:K items

ahea of &a'ere #uit(

S% Recor all R an L&&:K items on :pen Issues list an follow>up until closure(


#$%$ Supplier Status Kor.boo. GM1927>3

%S; auit GM1927>30

Greenfiel / ;rownfiel evelopment #ssessment GM1927>31

G$>12 auit GM1927>33


6


48/107


Task .u$ber/ B

Task .a$e/ APQP Tea$ !e"ie7s )GM.A Deep Di"e !e"ie7s*



Task Description/ Kee.l' eep ive reviews with #$%$ teams, trac.in! #$%$ Gate 3, #$%$ Gate , $$#$ Con>

Saleable, $$#$ Gate an Run?Rate "omplete Milestones an Re &aunch #lerts

8ey Deli"erables/

#herence to the GM $$#$ an Run?Rate metrics an flawless launch re+uirement


G%TS Reports #$%$ Mana!er

&aunch "#; approve chan!es an TIs $&" A$$MB

!esources/Supplier %ualit'


S% &aunch

Mana!er

Scheule re!ular reviews startin! ahea of #$%$ Gate 3 ealine( #!ree on scheule an fre+uenc'

of reviews with #$%$ Team Mana!ers(

S% &aunch

Mana!er

evelop stanar reportin! template in a!reement with #$%$ Mana!ers, incluin! #$%$ Gate Status

Aup until #$%$ Gate B, $$#$ !liepath, Run?Rate !liepath, G"# issues, %#$ issues, Re &aunch

#lerts, :pen $RRs, "ontrolle Shippin! an #ssistance Re+uire(

S% &aunch

Mana!er

nsure consistent fre+uenc' of review for all pro!ram part numbers, incluin! strate!' for reviewin!

importe parts uner the responsibilit' of overseas #$%$ teams Ama' rive rotatin! scheule to

balance number of teams presentin! a!ainst uration of reviews F consier ris. factorsB(

#$%$ Mana!er #tten review as scheule an present latest status on the a!ree template(


49/107


Task .u$ber/

Task .a$e/ 8ey Supplier !e"ie7s


Task Ti$in,/ $hase 1 >50w.s to >22w.s ASupplier monthl' presentations at GM siteB$hase 2 >18w.s to >1w.s AGM )ecutive visit to Supplier siteB$hase 3 >10w.s to :# ASupplier $erformance Reviews at GM $lantB

Task Description/ Supplier &eaership presentation of pro!ram status for Di!h &aunch Ris. commoities to cross

functional GM mana!ement team

8ey Deli"erables/

&aunch ris. miti!ation throu!h

o irect en!a!ement of supplier leaership an

o GM mana!ement monitorin! of Di!h &aunch Ris. commoities an suppliers

Custo$er for Deli"erables/$ro!ram &aunch Mana!er, Manufacturin!, n!ineerin!, $urchasin!

.ecessary -nputs/ Source of -nput/Di!h Ris. Supplier list S% &aunch Mana!er



Phase 1 Monthly Supplier Presentation at GM site

S% &aunch

Mana!er

;ase on Ris. #nal'sis from Tas. 3, ientif' the ma@or hi!h ris. suppliers b' SMT for monthl'

6e' Supplier Review presentation at GM location(

S% &aunch

Mana!er

Get enorsement of the list from responsible #$%$ Team Mana!ers an efine the 6e' Supplier

Review owners b' supplier Ausuall' the Manufacturin! S%B( The 6e' Supplier Review list can

chan!e at an' time with a!reement of the S% &aunch Mana!er an #$%$ Mana!er if it is

perceive that a specific supplier ris. has been miti!ate ahea of launch, or if new ris.s emer!e(

S% &aunchMana!er

n!a!e the 6e' Supplier Review owners to evelop a monthl' 6e' Supplier Review scheule,maintainin! consistent a' an time per month b' supplier to ma)imi-e attenance an ensurin! no

clashes / overlaps Ama' involve !roupin! multiple reviews b' SMT into consecutive timeslots toma)imi-e resource efficienc'B(

#$%$ or S%

Team Mana!er

efine invitation list for 6e' Supplier Review b' supplier Asu!!este cross functional invitees

inclue n!ineer, n!ineerin! SMT Mana!er or irector, ;u'er, $urchasin! SMT Mana!er orirector, $urchasin! $ro!ram Mana!er, SMT ehicle S'stem n!ineer, Sub>S'stem aliation

n!ineer, Manufacturin! n!ineer, ehicle &ine irector, ehicle &ine )ecutive, $ro!ram

Mana!er, $lant &aunch Mana!er, Suppl' "hainB(

#$%$ or S%

Team Mana!er

Follow-up Key Supplier Review owners to ensure consistency of scheduling and communication as

well as issue closure.

S% Scheule 6e' Supplier Review an issue invitation monthl' to stanar istribution minimum 1

wee. ahea of 6e' Supplier Review(

S% nsure supplier reainess an attenance at review F assess presentation prior to review withsupplier where possible to ensure completeness an effectiveness of cross functional meetin!(

S% "hair review an arran!e conference call etails for remote participants as re+uire(

S% up issues presente an ientifie throu!h the 6e' Supplier Reviews to ensure the' are

ae+uatel' capture an assi!ne on the :pen Issues list an subse+uentl' close out in a timel'

manner in line with commitments an pro!ram re+uirements(

Supplier $repare presentation material on the 6SR template AGM1927>2B in avance an review with GM

Mf! S% prior to first review to confirm completeness(

Supplier "apture, assi!n an follow>up open issues ientifie throu!h reviews(


8


50/107


Task .u$ber/ "ontinue

Task .a$e/ 8ey Supplier !e"ie7s


Phase 2 PreM9:s GPSC %&ecuti"e le( "isit to Supplier PlantS% &aunchMana!er

;ase on the Ris. #nal'sis from Tas. 3 an relative confience !aine throu!h $hase 1 above,ientif' Di!h Ris. suppliers for G$S" )ecutive le reviews prior to M;s Aat supplier plantB(

S% &aunch

Mana!er

efine list of participatin! G$S" )ecutives an assi!n b' supplier prior to >20w.s( Inform

)ecutives an Mf! S%s of assi!nments an e)pectations(

G$S" )ecutive Ma.e an avance call to Supplier )ecutive, ientifie b' the Mf! S% as host for the review, to

set e)pectations for the review(

G$S" )ecutive Ma.e an avance call to the ;u'er to unerstan an' commercial issues or isputes, parts missin!

contract, commercial launch ris.s an to confirm contract capacit' is !reater than &"R(

G$S" )ecutive Meet with the Mf! S% to review the >panel chart an unerstan e)istin! buil issues or launch

ris. issues(

G$S" )ecutive $rovie irection in review for issue resolution an act as roa>bloc.H buster as re+uire(

S% Scheule review ate an time with supplier in consultation with G$S" )ecutive, invite same

cross functional attenees as $hase 1 for supplier site review(Phase Supplier Perfor$ance !e"ie7s at GM Plant

S% &aunchMana!er

Cominate suppliers with multiple or ma@or +ualit' issues throu!h $$, M;ns an M;s builphases for on>site review at GM $lant(

S% &aunchMana!er

Review supplier list with $lant Mana!ement to etermine which suppliers, if an', the' wish to runSupplier $erformance Reviews AS$RB with(

&aunch S% Issue S$R invitation letter AGM1927>B to supplier an S$R stanar presentation template

AGM1927>5B(

Manufacturin!

S%

Review presentation material with supplier informall' in avance of S$R to ensure completeness(

&aunch S% Issue invitation to relevant GM $lant personnel, %ualit' personnel an n!ineer(

&aunch S% "hair S$R meetin! with supplier(

Manufacturin!

S%

"apture open issues, follow>up an report out until closure(


6SR template GM1927>2

Supplier $erformance Review Invitation &etter GM1927>Supplier $erformance Review $resentation Template GM1927>5



51/107


Task .u$ber/ up scheule F trac. all issues untilclosure(

Mf! S% Initiate $ro!ram Mana!ement $RRs an /or Re &aunch #lerts as re+uire base on auit finin!s(

Mf! S%Scheule follow>up auit after S:R$ as re+uire to review ma@or issues for closure or rive focus at

elin+uent suppliers(

Supplier"ommit to timel' closure of all open issues an re!ular an transparent internal reviews to rive

completion(

!eference Docu$ents/Supplier &aunch #uit ASB form, GM1927>3


9


52/107


Task .u$ber/ 1@

Task .a$e/ :uil( -ssue Trackin,

Task 47ner/ S% &aunch Mana!er

Task Ti$in,/


53/107


Task .u$ber/ 11

Task .a$e/ Daily :uil( Su$$ary


Task Ti$in,/ Start at $$ an issue ever' plant buil a' throu!h S:R$

Task Description/ ail' summar' of manufacturin! buil activit' issue to internal G$S" istribution

8ey Deli"erables/

"ommunicate ail' buil activit' an .e' metrics to

o hi!hli!ht issues an focus areas for S% follow>up an

o communicate status of launch to Supplier %ualit' an $urchasin! leaership

Custo$er for Deli"erables/Supplier %ualit' &eaership, $urchasin! $ro!ram &eaership, #$%$ teams


ail' manufacturin! buil summar' $lant &aunch Mana!er ail' %ualit' metrics summar' $ro!ram %ualit' Mana!er

IRT emer!in! issues &aunch S%s



S% &aunch

Mana!er

evelop stanar istribution list, incluin! #$%$ an S% Mana!ers , responsible irectors an

intereste G$S" )ecutives, an issue stanar ail' report summari-in! manufacturin! valiation

buil activit'

S% &aunch

Mana!er

"apture issues for follow>up in the Issues Trac.in! Matri) an ensure closure an feebac. to the

plant

Stan(ar( (aily report $ini$u$ te&t content )place in bo(y of e$ail*/

For (Mon/Tue/Wed/Thu/Fri)day mm/dd/yyyy

(Program Code) Acceleration at (Assembly Plant) Daily Production:

Target ActualMonday: mm/dd XXX XXX

Tuesday: mm/dd XXX XXX

Wednesday: mm/dd XXX XXX

Thursday: mm/dd XXX XXX

Friday: mm/dd XXX XXX

GCA: Daily XX.X

Bucket average XX.X (Glideath target XX.X!

AP: Daily XX.X

Bucket average XX.X (Glideath target XX.X!

P!!s: (")" #ulier $ssue Descrition.

#ssue s:%ritical &uality / %aacity / %ommercial issues and actions

Support Needed:

Supplier Readiness / Engineering Issues:


11


54/107


Task .u$ber/ 12

Task .a$e/ r(Party Contain$ent )%S%P* optional


Task Ti$in,/ Start from $$ or M;ns buil throu!h n of #cceleration

Task Description/ n!a!ement of 3rpart' to be locate on>site at GM #ssembl' plant throu!hout launch buils

in orer to e)ecute immeiate containment of an' suspect material foun on the GM #ssembl'

line with costs transferre irectl' to the responsible supplier

This optional Task is applied only at the agreement and active engagement of the GAssembly plant

8ey Deli"erables/

Immeiate 3rpart' containment of an' supplier +ualit' issue foun at the plant urin! launch with costs

transferre to supplier

Custo$er for Deli"erables/&aunch Team, GM #ssembl' $lant


$lant enorsement of S$ $lant &aunch Mana!er In>plant location for 3rpart' operation $lant &aunch Mana!er

!esources/ Supplier %ualit', 3rpart' +ualit' services provier


S% &aunch

Mana!er

iscuss containment strate!' with $lant &aunch Mana!er an etermine if S$ is an appropriate

strate!' to support manufacturin! throu!h the launch(

S% &aunch

Mana!er

Ientif' potential 3rpart' suppliers from approve "ontrolle Shippin! provier list( Invite

ientifie proviers to ma.e an S$ plan an arran!e for submission to the $lant &aunch Mana!eror ele!ate(

S% &aunch

Mana!er

Kor. with $lant &aunch Mana!er or ele!ate to !et their ecision on selecte provier, communicate

to supplier an ma.e en!a!ement plan(

S% TeamMana!er Sen out !eneral notification to all suppliers of S$ process, incluin! process introuction,stanar templates, S$ provier contact etails an GM contact etails for S$ +ueries(

3rpart'

provier

Execute ESEP as per process definition, engaging GM SQE for inspection process approval prior to

commencement of any containment actions.

S% 4pon confirmation of supplier +ualit' issue immeiatel' co>orinate with 3rpart' provier toconfirm an commence an approve inspection process an follow>up with supplier for root cause

an corrective action implementation(

S%


55/107


Task .u$ber/ 1

Task .a$e/ :oun(ary Sa$ples optional

Task 47ner/ S% &aunch Mana!er

Task Ti$in,/ M;s throu!h S:R$

Task Description/ Review ran!e of ph'sical samples representin! the anticipate manufacturin! variation in

orer to establish limits for parts with sub@ective acceptance criteria Ausuall' in relation to

appearance an colorB

This optional Task is applied only as re!uired to address cases of disputed parts with

sub"ective acceptance criteria# where re!uested by the $lant or Supplier in the absence of analternate acceptable solution

8ey Deli"erables/

#!reement on ph'sical samples representin! upper an lower bounar' conitions of acceptabilit', with parts

si!ne, ate an store in an a!ree location for +uic. access an reference

Custo$er for Deli"erables/ $lant %ualit', &aunch Team, esi!n %ualit'


&ist of sub@ective parts in ispute $lant %ualit'


56/107

Section

Global Current

September 21, 2009 51 GM1927

Global Launch Process


57/107

Docu$ent sa,e Gui(elines by Global !e,ion' 3 !eference 4nly )-nfor$ation only5 .othin, to fill out*

.A 3 .ot applicable for specifie( re,ion

MD 3 Man(atory Docu$ent )(ocu$ent type re6uire(5 specific for$at re6uire(*

M- 3 Man(atory -nfor$ation )(ocu$ent type re6uire(5 for$at $ay "ary5 $ini$u$

content $an(atory*

!D 3 !eco$$en(e( Docu$ent )(ocu$ent reco$$en(e(5 specific for$at re6uire(*

!- 3 !eco$$en(e( -nfor$ation )(ocu$ent reco$$en(e(5 for$at $ay "ary*

Document Number P GME LM N

$rocess "ontrol $lan #uit A$"$#B G 1678-19 0 0 0 0

R$C Reuction Summar' G 1678-71 0 0 0 0

%S; #uit G 1678-: 0 0 0 0

"ontrolle Shippin!#ssessment Matri) G 1678-;1 * * * *

"ontrolle Shippin! #ssessment G 1678-;7

"ontrolle Shippin! "onfirmation Repl' off Meetin! Kor.sheet G 1678-;6 0 0 0 0

"ross Re!ional Support Re+uest G 1678-91 * * * *

"T %ualit' #ction $lans G 1678-97 !* !* !* !*

Global mer!in! Issue #lert G 1678-9; * * * *

Global mer!in! Issue #lert "ommunications G 1678-9;a * * * *

I>"hart "ontrolle Shippin! G 1678-99 !* !* !* !*

Cew ;usiness Dol $rocess


58/107

Trainin, A"ailable to Suppliers throu,h r(Party Pro"i(ers

!raining "Wor#shops$ P% GME LM N

;S & >isual 2orkplace ?

$pplying S#C @ools ?

0rill 0eep A 2ide ?

Error #roofing ?

Bo% Set p OptimiDation A Error #roofing ?a%el Error #roofing ?

#/E$ ?

#ro%lem Sol4ing ?

Quality Systems Fasics ? ?

!eference 4nly Current infor$ation on trainin, an( pro"i(ers can be obtaine( in GM

Supply Po7er Quality Library r(Party Pro"i(er Mana,e$ent0

Appro"e( r(Party Pro"i(ers )Trainin,-$ple$entation*

ppro&ed Pro&iders !raining

ErrorProo'ing!raining

LabelError

Proo'ing!raining

(S )*isual

Wor#place!raining

ProblemSol&ing!raining

pplyingSPC!ools

!raining

+ob Set ,pError

Proo'ing )%ptimi-ation

!rainingCS.

/mplementati

@'e #*C Group ? ? ? ? ? ? ?

Fenc'mark@ec'nologies ? ? ? ?

uminous Group ? ? ? ? ?

>QQ *nc. ? ? ? ?

Eastern ic'iganni4ersity ?

#0C ? ? ? ?

CE* ?

E0S ?

!eference 4nly Current infor$ation on trainin, an( pro"i(ers can be obtaine( in GM

Supply Po7er Quality Library r(Party Pro"i(er Mana,e$ent0

https/7770,$supplypo7er0co$appssupplypo7er.ASAppspc(sCDS!etrie"al>

lob36uality+subna"3library+to,,lefol(er32@21

Task .u$ber/ 1

September 21, 2009 53 GM19271


59/107

Task .a$e/ Continuous -$pro"e$ent


Task Ti$in,/ Throu!hout the life c'cle of the prouct

Task Description/ efines the supplier*s responsibilit' to have an on>!oin! process for continuous improvementof the prouct an relate manufacturin! processes reference G$>8( The intent is to reuce

variationan to ensure process stabilit' an capabilit' over time( There must be a

performance attitue for -ero efects(

Criteria for Application/ #pplies to all suppliers an proucts for the life of the part(

8ey Deli"erables/

03 an or 1927>03a>nameB

rill eep Kor.sheetAGM 1927>8B

R$C Reuction Summar' AGM 1927>21B

$1a>nameB

&essons &earne Supplier

!esources/Supplier, S%, #ssembl' $lant


S% Monitor an auit the supplier*s compliance to "ontinuous Improvement re+uirements Areference G$>8B,an also continuous compliance to $art specific S:R / $"$#

S% "ommunicate specific concerns to the supplier for non>conformance, review action plans Aas re+uireB,

escalate concerns to leaership Aif re+uireB, an re+uire the supplier to implement countermeasures Aifnecessar'B(

Supplier -(entify Special Pro(uct an( Process Characteristic

Supplier shall ientif' prouct an process characteristics that re+uire 6"S approach

Inputs for this ientificationa( "ustomer rawin! Information

b( $


60/107

1( ariation control AS$"B2( "orrective action = process improvement

4pate process capabilit' / performance stuies A03, an or GM1927>03a>nameB, an have an on!oin! process to reuce variation on

characteristics ientifie as 6$"*s

Supplier ffective Root "ause #nal'sis an "orrective #ction erification A"ompliance with G$>5B

The supplier is re+uire to perform an effective anal'sis of technical root cause(

S'stemic root cause to be anal'-e throu!h the rill eep process usin! wor.sheet GM1927>

8(

erification an valiation of corrective action shoul emonstrate the abilit' to turn the

problem on an off(Supplier R$C Reuction $rocess Areference %S;, G$>8BF to have a formal an ocumente R$C reuction

process which inclues

# cross> functional team that meets re!ularl' an upates 9B an compliance to $art Specific S:R / $"$# share b' S%


G$>8

%S; A%ualit' S'stems ;asicsB GM1927>30 #uit an GM1927>3 Strate!ies

Supplier %ualit' S:R GM1927>03 an or GM1927>03a>name

G$>5

$RR

I>chart AGM1927>B rill eep Kor.sheet AGM 1927>8B

R$C Reuction Summar' AGM 1927>21B

S$" #I#G ocuments

Supplier #ction $lan 79B


61/107

Task .u$ber/ 2

Task .a$e/ QS: Quality Syste$s :asics

Task 47ner/ G$S" > "urrent Supplier %ualit' or #vance Supplier %ualit'

Task Ti$in,/ Throu!hout life of prouct

Task Description/ %S; is a wor.shop at the supplier*s plant that teaches, evelops, an facilitates

implementation of the 11 basic strate!ies of +ualit'( The intent is to share best practices an

to unerstan the !ap between the present state an the best practice( The wor.shop willinclue multi>isciplinar' emplo'ees from all levels of the supplier to evelop the founation

for each strate!' usin! ata available at the plant(

1( $anelB Suppl' $ower

Internal = )ternal ata anal'sis Supplier

Internal ocumentation Ai(e( Trainin! ocumentationB Supplier

"reativit' Team ;i &ist G%TS

A((itional -nfor$ation/

%S; Kor.shop :verview = #uit F GM Suppl' $ower website AGM Suppl'power(com %ualit' &ibrar'B

&a'ere #uit vieo A#vailable from the S%B


62/107

Task .u$ber/ 2 Task .a$e/ QS: Quality Syste$s :asics )Continue(*


S% #ppl' the %S; #uit AGap #nal'sisB at Supplier Gate Review J1 usin! %S; auit form GM1927>30(

%S; is to be assesse a!ainst the manufacturin! plant %ualit' S'stems inepenent of prouct orspecific manufacturin! process(

Rules for the application of the %S; #uits

"ustomer Monitore #$%$ F Manator'

Supplier Monitore #$%$ F #t S% iscretion Arecommene, if not passe within last 12

months

#uit must be performe b' GM S% or a Thir $art' where a!ree

S% / ;u'er

/ R

31(

Supplier #ssumes responsibilit' an ta.es ownership of all activities to implement %S;(

#vises the customer of implementation status an an' foreseen impenin! problems(

$rovies action plans with appropriate etail, timin!, ownership, etc(

Implements action plan on a timel' basis(

Supplier #t the %S; Gap #nal'sis auit, or at the Greenfiel = ;rownfiel evelopment #ssessment $rocess

auit, provie action plans with appropriate etail, timin!, ownership, etc(

Supplier Implement an verif' effectiveness of all the action plan items before Supplier Gate Review J3(

Supplier 6eep the customer upate re!arin! implementation status an an' issues or concerns withimplementation(


%S; $resentation GM1927>3

%S; #uit 30

Greenfiel / ;rownfiel chec.list GM1927>31

Supplier #ction $lan 79

Pre7ork

S% oes the followin!

- Ientif' suppliers to be traine(- $rovie overview of %S; to suppliers iniviuall' or at a supplier s'mposium Apurpose, content,

benefits, an successesB(- Inform suppliers of wh' %S; is recommene or re+uire(

- #!ree on a metho of trainin! Ai(e( supplier pa's thir part' trainer, GM provies trainin!B(

# %S; auit b' a certifie S% shall be one to etermine the necessit' for a wor.shop(

Supplier esi!nates a champion for trainin! an implementation process for each strate!'(

Supplier an Trainer ma.e arran!ements for a wor.shopAsB base on the auit results for each strate!' on the

#uit Summar' pa!e(

Strate!' N R Kor.shop Re+uire for that strate!'(

September 21, 2009 57 GM1927


63/107

Step

Metho

;* %rror proof

"erification

n!ineerin!

Mana!er

Manufacturin! = %ualit'

$lant &eaership =

n!ineers, Moel #reaSupervisor, team members

1 hour "urrent e)amples of

ocuments to compare

B* Layere( Process

au(its

$lant

Mana!er/

Manufacturin!&ea

Manufacturin! = %ualit'

$lant &eaership =

n!ineers, Moel #reaSupervisor, team members

2 hours "urrent e)amples of

ocuments to compare

8B !P. !isk!e(uction )!e"erse

P'M%A* Care)Custo$er

Acceptance An(

!e"ie7 %"aluation*

n!ineerin!Mana!er

Manufacturin! = %ualit'$lant &eaership =

n!ineers, Moel #rea

Supervisor, team members

3 hours "urrent e)amples ofocuments to compare


64/107

11* Mana,in, Chan,e n!ineerin!

Mana!er

$lant &eaership, %ualit'/

Manufacturin! n!ineers,


65/107

Task .u$ber/

Task .a$e/ Shut(o7n Startup Acti"ity

Task 47ner/ G$S" F "urrent Supplier %ualit'

Task Ti$in,/ Throu!hout the life c'cle of the prouct

Task Description/ The purpose of the Shutown/Startup #ctivit' ASDSB is to implement stanari-e wor. forboth the Supplier %ualit' Group an its suppliers, specificall' focuse aroun e)tene

shutown perios an subse+uent startups( )amples inclue "orporate AsummerHB

shutowns, "hristmas shutown, etc(, but the tas. an tools can be use b' an' supplier when

the' are face with an' e)tene shutown/startup, such as the elimination an/or restartin! of

a prouction shift or an e)tene wee.en(

The !oal of the Shutown/Startup #ctivit' is WR: ma@or isruptions cause b' a supplier*sshutown an subse+uent restart of operations(

8ey Deli"erables/

"omplete Shutown auit form

Master ot action plan for Di!h ris. suppliers

Criteria for Application/

)tene shutown perios, such as the Summer ShutownH, "hristmas ShutownH,

)traorinar' $rouction Shutown Selecte hi!h>ris. suppliers base on establishe criteria( A)amples an not limite to

are the potential hi!h r

GM 1927 Supplier Quality Manual_Sept2009

Documents

Transcript of GM 1927 Supplier Quality Manual_Sept2009