GM-1927-APQP.doc

General Motors CorporationGM GlobalAPQP Advanced Product Quality PlanningWorldwide PurchasingOctober 2002Revision 2PrefaceThis 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 GMs 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. WolfM. MorettiWorldwide Purchasing Latin American OperationsSupplier QualitySupplier QualityT.NejmanM. AldeaPowertrainAsian Pacific OperationsSupplier QualitySupplier QualityW. KraatzM. SchenleberNorth American Vehicle OperationsEuropean OperationsSupplier QualitySupplier QualityITable of ContentsPreface.ITable of Contents .IIManual Content Explanation .IVCustomer Monitored/Supplier Monitored Matrix .VAPQP Process Model Flow .VIRevision History.VIIAPQP Task DefinitionsTask 1: Commodity Sourcing Strategy Meeting .1Task 2: Technical Reviews .3Task 3: Risk Assessment & Sourcing.5Task 4: Supplier Program Reviews .7Task 5: Timing Charts/Open Issues .12Task 6: Feasibility & Manufacturing Assessment Letters .13Task 7: Flow Chart .15Task 8: DFMEA .16Task 9: Design Reviews .18Task 10: Gage, Tool & Equipment Reviews .20Task 11: GP-11 Pre-prototype & Prototype Material.23Task 12: PFMEA Development.25Task 13: Control Plan .27Task 14: GP-12 Early Production Containment .29Task 15: PPAP .31Task 16: Run Rate (GP-9) .33Task 17: Lessons Learned .36AppendicesAppendix 1Document Usage Guidelines by Global Region.38GM 1927-1APQP Project Plan GM 1927-2APQP Timing Chart GM 1927-3Supplier Quality Statement of Requirements (SOR)GM 1927-4Required Quality Information Letter GM 1927-5APQP Open Issues Form GM 1927-6Commodity Sourcing Strategy Meeting ChecklistGM 1927-7WWP APQP Assessment GM 1927-10Lessons Learned Process OverviewGM 1927-12Lessons Learned Criteria Checklist GM 1927-13Technical Review Checklist IIAppendix 1GM 1927 Documents (continued)GM 1927-14APQP Kick-Off Meeting Checklist GM 1927-15APQP Kick-Off Meeting Presentation GM 1927-16Process Control Plan Audit Worksheet GM 1927-17GM & Supplier Program Contact List GM 1927-18Typical Stakeholders Meeting Agenda GM 1927-19Manufacturing Feasibility Letters GM 1927-20Process Capability Over Time GM 1927-21RPN Reduction Summary ChartMGM 1927-22MProgram Management RASICMGM 1927-23MDirected Buy ChecklistMGM 1927-24MSupplier Program ReviewsMGM 1927-25MSubcontractor Program Status MatrixMGM 1927-26MSubcontractor Detailed Status MatrixGM 1927-27Fixture Design MatrixGM 1927-28Global Powertrain PFMEA Risk Ranking FormNote: M indicates documents specific to suppliers of Complex Systems/Sub-assembliesAppendix 2MComplex Systems/Sub-assembly APQP Management.40 PlanAppendix 3Glossary of Terms.44IIIManual Content ExplanationEach 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 Resourcesthis includes people of organizations involved in completing the task Methodologybrief description of the task and purpose SQE Responsibilitiesbrief description of actions required Supplier Responsibilitiesbrief description of actions required References and additional information.AppendicesThe 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 ProcurementGM Global APQPAll 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 GMs SupplyPower at .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 DocumentsAll AIAG specific documents referenced can be obtained by contacting AIAG at 01-248-358-3003. Documents can also be ordered by accessing the web at www.AIAG.org. In Europe contact Carwin Ltd at 44-1708-861333. Note to Suppliers:This manual is intended to be comprehensive and “all-encompassing”; however, certain circumstances will prompt questions. If you have any questions regarding any part of this manual you are encouraged to contact your respective Supplier Quality Engineer.IVCustomer vs. Supplier Monitored APQPThe 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 MonitoredSupplier MonitoredAPQPAPQPAPQP ActivitySupplierGMSupplierGM1Key StakeholdersCommodity Sourcing Strategy Meeting.N/AR N/AR2Technical ReviewsSRSR3WWP APQP Assessment & SourcingN/ARN/AR4Supplier Gate ReviewsRARI5Timing Charts/Open IssuesRARA 6Feasibility & Manufacturing Assessment LettersRARI7Flow Chart RARI*8DFMEA (1 Supplier Design Responsible, 2 GM Design Responsible)R (1)S (2)ARI*9Design Review (1 Supplier Design Responsible, 2 GM Design Responsible)R (1)S (2)S (1)R (2)SRI10Gage, Tool and Equipment ReviewSRRASRI11GP-11 RARA12PFMEA DevelopmentRARI*13Control PlanRARI*14GP-12 RARI*15PPAP RARA16Run Rate (GP-9)RARA17Lessons LearnedRIRIR Responsible (GM or Supplier)A Approve - GM approves deliverablesS Support completion of deliverables (GM or Supplier)I Inform GM reviews deliverables at discretion of SQEC ConsultN/A Not Applicable May be reviewed by GM as part of PPAP (Depending on submission level)STEP I:Pre-sourcing ActivityA. Buyer conducts Commodity Sorucing Strategy Meeting1B. Purchasing sends out RFQC. 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 commitment6STEP V:Product and Process ValidationA. SQE conducts advanced PPAP15 and tool shop reviews10B. SQE reviews and statuses PPAP package15C. RunRate16 (GP-9) is performedD. Gate Review #44 is conducted PPAP15 and RunRate16 Status Feasibility Letter #36 Updated Timing chart5 and Open Issues list5STEP II:Plan and Define ProgramA. SQE schedules APQP kick-off meeting4B. SQE hosts APQP kick-off meeting4C. 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 Learned17STEP VI: Feedback, Assessment and Corrective ActionA. Supplier performs GP-8 and updates control plan13B. GP-12 is completed14C. Lessons learned captured and DFMEA/PFMEA are updated17D. APQP is concluded Updated control plan13 DFMEA8/PFMEA12 updated with lessons learnedVIxnumber = Indication of corresponding APQP Task NumberSTEP IV:Process Design and DevelopmentA. 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 plans12E. GP-11 parts, modules and systems approved11F. 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 Assessment3STEP III:Product Design and DevelopmentA. SQE attends design reviews and conducts scheduled workshops9B. SQE reviews gage, tool & equipment concept10C. SQE reviews prototype draft of process flow chart7, PFMEA12 and Control Plan13D. GP-11 plan approved by appropriate GM department11E. 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 list5Advanced Product Quality Planning (APQP)Top Flow DownRevision HistoryOctober 2002Tasks 1-17Task 1Commodity Sourcing Strategy Meetingname 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 2Technical 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 3WWP APQP Assessment & SourcingName revised from Risk Assessment to WWP APQP Assessment. Clarifications made for suppliers of Complex Systems/Sub-assemblies.Task 4Supplier Gate Reviewsname revised from Supplier Program Reviews to Supplier Gate Reviews to correlate with the terms used in the P APQP tracking system. Referenced made pertaining to Directed Buys. Task numbers referenced next to requirements due at each of the 4 Gate Reviews.Task 5Timing Chart and APQP Open Issues Listminor name revision and other minor clerical revision.Task 6Feasibility and Manufacturing Assessment Letters“Deliverables” section, clarified AIAG APQP and Control Plan Manual Appendix E as source for the Team Feasibility Commitment Task 7Process Flow Chartsrevised name from Develop, review and update Process Flow Charts to Process Flow Charts. Task 8DFMEATask 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 9Design Reviewsrevised 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 10Gage, Tooling and Equipment Reviewsrevised 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 11GP-11 Pre-Prototype and PrototypeClarified task write-up and included GP-11 GM 1820 document form numbers in the Additional Information section.Task 12PFMEArevised 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 1927-28Task 13Control PlansNecessary Inputs section added Special Characteristics and Lessons Learned. SQE Responsibilities section, revised requirements.Task 14Early Production Containment (GP-12)minor revisionsVIIRevision HistoryOctober 2002Tasks 1-17 continuedTask 15Production 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-E364Task 16GP-9 Run Raterevised 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 17Lessons Learnedrevised name from Lessons Learned Communication & Update to Lessons Learned. Included the required use of the GM Lessons Learned website.Suffixed DocumentsGM 1927-1APQP Project PlanRevised to correlate with program development termsGM 1927-2APQP Timing ChartHeader information added, required elements grouped with sub-headingsGM 1927-3Supplier Quality Statement of Requirements (SOR)Sections clarified, redundant listings of procedures and requirements removed. Section 3 identifies GM procedures and reference documentsGM 1927-4Required Quality InformationReordered requirements and grouped under sub headingsGM 1927-5Open Issues Three type categories addedGM 1927-6Commodity Sourcing Strategy Meeting ChecklistMinor revisionsGM 1927-7WWP APQP AssessmentName revised plus minor wording revisionsGM 1927-8Timing and FeasibilityForm removedGM 1927-9Serial Tooling/Checking EquipmentForm removedGM 1927-10Lessons Learned Process OverviewRevised to incorporate the Global Lessons Learned web systemGM 1927-11Global Lessons Learned & Implementation ProcessForm removedGM 1927-12Commodity Criteria ChecklistForm removedGM 1927-13Technical Review Checklist GuidelinesMinor revisionsGM 1927-14APQP Kick-Off ChecklistMinor revisions, TS 16949 direction addedGM 1927-15APQP Kick-Off Meeting PresentationRevised to correlate to the APQP web overviewVIIIRevision HistoryOctober 2002Suffixed Documents continuedGM 1927-16Process Control Plan Audit WorksheetChecklist revised to correlate with the GP-9 Run Rate procedure June 2001 form GM 1962-B.GM 1927-17GM and Supplier Program ContactsFunctional positions addedGM 1927-18Typical Agenda Commodity Sourcing Strategy MeetingName revised to correlate with revisions in corporate processesGM 1927-19Supplier Manufacturing Assessment LettersModel year revised on form lettersGM 1927-20Process Capability Over TimeExample removed from body of formGM 1927-21RPN Reduction Summary ChartNo changesMGM 1927-22Program Management RASICForm to be used as an exampleMGM 1927-23Directed Buy/Directed Source ChecklistRequired signatures revisedMGM 1927-24Supplier Program Review FlowRemovedMGM 1927-25Subcontractor Program Status MatrixName revised to correlate with direction in Appendix 2 for Suppliers of Complex Systems/Sub-assembliesMGM 1927-26Subcontractor Detailed Status MatrixRevised to correlate with corporate development process nomenclature for build eventsGM 9727-27Fixture Design MatrixNew formGM 1927-28Global Powertrain PFMEA Risk Ranking FormNew form for suppliers of Powertrain componentsAppendicesAppendix 1Document 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 1927-24MAppendix 2Complex Systems/Sub-assemblies APQP Management PlanName 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.Appen