GM 1927-04 APQP Manual

Materials/DCS File Logs ? Supplier has verified that all SOR and GD&T requirements are reflected in the design record ? All stakeholders completely understand materials requirements and callouts in the design record ? Supplier should plan to validate the maximum regrind amount per the material spec for PPAP

approval

? Supplier has contracted all materials and identified GM-approved sources where required ? Supplier has resources to PPAP material suppliers ? Escalation Drop Downs

o G – Material requirements are called out in the design record(s) and understood

o Y – Material callouts are present in the design record, but approved source not identified yet o R – Material callouts are required, but not present in the design record yet o R – GM-approved source does not yet exist for required material Design Appearance Quality ? Supplier has received and clearly understands the latest level Design Appearance Requirements

(DAR) document for grain and material specifications

? Supplier has received and understands all required testing for appearance related validation, such

as APOPS, Solar testing, MatSpec, etc., and has developed a plan to complete all testing on time for PPAP

? Supplier has received and understands Grain Instruction Form / Process

? Supplier has reviewed the design to understand how the design and supplier?s process will affect

the final appearance in respects to the GM requirements listed in the DAR and has raised any

concerns (For example, a plastics parts supplier has reviewed mold flow to understand where knit lines will be and if that is acceptable to GM requirements) ? Escalation Drop Downs

o G – DAR Latest Level Received

o G – Appearance related validation testing complete

o G – Tooling Design complete proper Draft Identified for Grain

o Y – Tooling design not complete proper draft Identified; no impact to PPAP target o Y – Test identification has not been completed; no impact to PPAP target o R – DAR not received at latest level

o R – Tooling design not complete; impact to PPAP target

o R – Test identification has not been completed; impact to PPAP target

o R – Appearance Related Validation testing not complete for required full PPAP date Containerization ? Supplier has been in contact with the GM Containerization engineer and GM DRE and working on

incoming and outgoing packaging design, including footprint and dunnage where applicable, if the containers are returnables or expendables for both incoming and outgoing containers

? Supplier has been in contact with the GM Containerization engineer and has plan and timing for

when the outgoing shipping containers will be available and the amounts for each build; timing plan should include when all containers will be available, how many containers will be available at each build, how many containers will be available at R@R and if the quantity is sufficient

? Supplier shall provide production parts for all shipping trials as part of container validation, should

be included in timing & build plan

GM 1927-04 Advance Product Quality Planning Manual May 2011

Page 10 ? Supplier should have a design for expendable packs and timing for all validation testing of packs,

design should be approved by the GM DRE and Containerization Engineer

? Supplier has maintenance plan which includes storage, handling, and cleaning for containers to

ensure racks are properly maintained throughout the life of the program ? Escalation Drop Downs

o G – No Container Issues, design on track o R – Prototype Container – No design o Y – Prototype Container - Design issues o Y – Preliminary design in process

o R – GM Container Engineer not identified o R – Containers not in process Tiered Supplybase

? The supplier has confirmed lead time for all Tiered supplier requirements; Plans are adequate to

support program timing

? The supplier has adequate Supplier Quality procedures and resources in place, in accordance with

their commodity requirements

? The supplier has cascaded Run @ Rate planning activities to its Tiered supplybase

? Tiered supplier items that are either Directed-Buy or Approved Source List items have a clear

agreement between the supplier and GM as to APQP coverage responsibilities

? Tier 1 has verified Tiered Supplier manufacturing feasibility and received documentation stating so ? Tier 1 has reviewed and approved the Tiered Supplier?s preliminary PMFEA , assembly equipment

error proofing, and all applicable GM part specific audits

? KCDS/Pass Thru Characteristics must be reviewed by GM DRE/SQE to verify control method at

tiered suppliers and incoming inspection at Tier1 ? Escalation Drop Downs

o G – Tiered Supplier?s plans are in place and adequate

o Y – Tiered Supplier?s plans are not adequate, but recovery plans that support program timing

are in place

o R – Tiered Supplier?s plans are not adequate, and recovery plans that support program timing

are not in place PPAP ? PPAP plans have been discussed by the supplier and the individual SQE responsible for approving

the PPAP. Both parties have an understanding and a documented agreement of expectations for both content and timing.

? The plans should target Full PPAP Approval prior to the Vehicle MVBS MRD.

? If this supplier is a Tiered Supplier (such as in Directed-Buy arrangements), adequate timing is in

the plan to allow the Tier 1 supplier to complete PPAP prior to the Vehicle MVBS MRD.

? Open issues affecting the completion of PPAP on time are documented and have an action plan. ? Issues that do not have a clear plan for success of on-time PPAP have already been escalated for

management assistance. ? Escalation Drop Downs

o G – Plans in place for on time PPAP

o Y – Plans in place, but need close monitoring to ensure on time PPAP o R – No plans for PPAP in place

o R – Plans in place, but PPAP timing at serious risk

GM 1927-04 Advance Product Quality Planning Manual May 2011

Page 11 ? Supplier clearly understands expectations regarding the purpose of the 1411 in the PPAP process ? Supplier clearly understands all program deliverables for PPAP (validation, dimensional, etc.) and

is aware that all issues must be documented on the 1411 at the time of the first PPAP submission ? Supplier has access to AIAG manual and forms for PPAP ? Escalation Drop Downs

o G – Supplier understands requirements and has successfully completed 1411 in the past o Y – Supplier has not completed 1411 forms before, but understands requirement o Y – Supplier does not have access to AIAG documents, but has plan

o R – Supplier has no understanding of 1411 requirements & requires training R@R ? GM Purchasing has provided Contracted Daily Capacity (LCR) demand data to the supplier for

each awarded part

? GM Purchasing and the supplier have agreed on daily operating hours that will be used to meet

Contracted Daily Capacity requirements

? The supplier has prepared capacity planning files showing expected process cycle times, number of

tooling sets, and machine capacity loads, and any shared capacity with other program regardless of OEM

? The capacity planning data shows adequate coverage of Contracted Daily Capacity requirements ? If multiple tool sets or machines will be phased in over time for staged increases in capacity, the

plans and timing requirements are documented

? The supplier and the individual SQE responsible for approving PPAP have documented the agreed

upon expectations for the Run @ Rate event, per GP-9 requirements ? Escalation Drop Downs

o G – Contracted Daily Capacity, operating hours, and capacity plans are documented and show

adequate coverage

o Y – Contracted Daily Capacity requirements are not adequately covered, but a recovery plan is

in place to ensure coverage

o Y – Run @ Rate event plans are not documented

o R – Contracted Daily Capacity requirements are not documented

o R – Contracted Daily Capacity requirements are not covered by current plans, and an adequate

recovery plan is not in place

o R – The supplier has not performed capacity planning for these parts GP-12 ? The supplier is knowledgeable about GP-12 activities and requirements.

? The supplier has identified whether these GP-12 activities are to be developed off similar products

that have been previously launched, or whether new GP-12 activities need to be developed. ? Appropriate timelines have been established. ? Escalation Drop Downs

o G – Supplier knowledgeable about GP-12

o Y – Supplier needs training on GP-12 – plan in place o R – Supplier not committed to GP-12 QSB ? If Supplier is QSB compliant and GM has verified then no further action required ? If supplier is not compliant, then

o Supplier should have QSB materials and completely understands GM requirements

GM 1927-04 Advance Product Quality Planning Manual May 2011

Page 12 o Supplier should complete a QSB self-assessment using the GM QSB Audit located on

SupplyPower, formulate a gap analysis to the requirements, and an action plan to address and discrepancies, GM SQE to review and approve self assessment audit and action plan

o Supplier has prioritized timing plan for implementation of each QSB Section, SQE to approve o Supplier timing should include the minimum implementation requirements for Valve B and full

QSB implementation should be complete by end of supplier launch

? Escalation Drop Downs

o G – Supplier has completed 1st QSB self-assessment o G – Supplier is QSB compliant and GM has verified

o G – Supplier is Yellow to QSB requirements with plan for compliance prior to SOP o Y – Supplier is Yellow to QSB with no plan for compliance prior to SOP o R – Supplier has not completed 1st QSB self-assessment

GM 1927-04 Advance Product Quality Planning Manual May 2011

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