GMAPQPProgram

1、1Supplier Program Review Meeting #1GM1927-15APQP Kick-off Meeting Advanced Product Quality Planning2Supplier Program Review Meeting #1Purpose: Communicate the process that will be used to provide program updates for APQP Deliverables. Confirm APQP communication Channels between Supplier and GM. Ensu

2、re that GM requirements are understood. Understand current program status to ensure conformance to GM Timing. Provide a formal process to raise open issues for resolution. Form joint focus on future steps.3 Background - APQP - Global APQP Development APQP Project Plan Overview APQP Kick-off Meeting-

3、 SQ Requirements- Program Timing- Review Checklists- Identify Open Issues SummaryAgendaAdvanced Product Quality PlanningWorldwide PurchasingNovember 2000General Motors CorporationGM4Background Definition:Advanced Product Quality Planning - APQPStructured method defines and establishes steps necessar

4、y to ensure product meets customer requirementsRequired for all new partsResponsibility of the supplierPurpose & Structure:Communicates the requirements necessary to develop a product quality planTop Management support by the supplier is key to the success of the any APQP processRequires an envi

5、ronment of trust and cooperation between all parties APQP5QS- 9000 APQP DirectionEstablishment of an Advanced Product Quality PlanQS-9000 section requires the establishment of an advanced product quality planAIAG APQP Manual is referenced as the document that should be used Detail of specifi

6、c deliverables was not clearly defined Separate “unique” Regional & Divisional requirements developedBackground 6GM Global APQP GM-1927 is the General Motors Common Global APQP Manual GMs common directionfor the development andimplementation of an APQP planGlobal APQP Development Advanced Produc

7、t Quality PlanningWorldwide PurchasingNovember 2000General Motors CorporationGM7Common Global APQP Process for GM WorldwideGM-1927 replaces all regional and divisional APQP reference manualsGM-1927 harmonized and standardized the multiple regional and divisional APQP manuals Aligns with the 5 phases

8、 within the AIAG APQP manual and provides the detail required to implement an APQP plan Aligns with GMs 4 Phase Program Timing and DeliverablesGlobal APQP Development 8Global APQP Development 9START OF PRODUCTION RUN RATE (GP-9)PRODUCTION PARTAPPROVAL (PPAP)PROTOTYPE SAMPLEAPPROVAL (GP-11) PRE-PRODU

9、CTION MEETINGADVANCED PRODUCT QUALITY PLANNING (APQP)SOURCING DECISION POTENTIAL SUPPLIERASSESSMENTADVANCE PLANNING & PREVENTIONWWP SUPPLIER QUALITY IMPROVEMENT PROCESSLIFE OF PARTTIME LINE EARLY PRODUCTION CONTAINMENT (GP-12)GLOBAL SOURCING IMPROVEMENT MEETING QUALITY WORKSHOP LEVEL II CONTROLL

10、ED SHIPPINGLEVEL I CONTROLLED SHIPPING SUPPLIER QUALITY PROCESSES & MEASURES (GP-5) PERFORMANCE MONITORING CONTINUOUS IMPROVEMENT (GP-8)PROBLEM RESOLUTIONGM Global APQPA P Q P P ro ject P lan4 P has eP has e 0P has e 1P has e 2P has e 3G M P re -so u rcin gP la n a n d D e fin eP ro d u ct D e s

11、ig n a n d D e ve lo p m e n tA IA GP ro ce ss D e sig n a n d D e ve lo p m e n tP ro d u ct a n d P ro ce ss V a lid a tio nF e e d b a ck, A sse ssm e n t a n d C o rre ctive A ctio nV D PP re-s ourc ing-96-92-88-84-80 -76-72-68-64-60-56 -52-48-44-40-36-32-28-24-20-16-12-8-404812162024G e n e ric

12、 A lp h aB e taP ro toF E1 F E2 F E3P P A PP ilo tS S FA P Q P T a skP ro g ram R e view sPR-1PR-2 PR-3 PR-4 1 K ey S tak eholders M tgP R -1o -o2 Tec hnic al R eview sP R -1o -o3 R is k A s s es s m entP R -1, 2, 3T R o-o4 S upplier P rogram R eview soooo5 Tim ing C harts /O pen Is s uesP R -1,2,3,

13、4oooooooooo6 F eas ibility LettersP R -1,2,3,4ooo7 F low C hart P R -1,2,4oo -oo -o8 D F M E AP R -1,2,4ooo9 D es ign R eviewP R -2,3oo10 G age R eviewP R -2,3,4o - -o11 G P -11 P R -2,3o - -o12 P F M E A S trategyP R -1,2,3,4oo -ooo -oo13 C ontrol P lanP R -1,2,3,4oo -oo -oo14 G P -12 P R -4o -o15

14、P P A P P R -4 o -o16 R un R ate (G P -9)P R -1,4oo o -o17 Les s ons LearnedP R -1,2,3,4ooooooPlac omplete/s tac onc ept des ign gage approv al, KCDS f inal Plain itia l -in itia l-in itia l-GD&T prototy pe f inal prototy pe f inal prototy pe Complete (Platf orm in itia l -TRK ick-o ff in itia l

15、-planUpdate Ris kSQ Global APQPCombination of the Best Processes Experience10Manual ContentsPrefaceTable of Contents RASIC Explanation of PMIs (Process Model Integration)PMIs for 17 Tasks / Deliverables Appendices Glossary Global APQP The 17 Tasks are the Key for Success!Advanced Product Quality Pla

16、nningWorldwide PurchasingNovember 2000General Motors CorporationGM11APQP “At a Glance”Shows the linkage of the 17 deliverables to: GMs 4 phase timing GMs Sourcing Process AIAG APQP 5 phases within the APQP planning process The focus of the APQP Project Plan is on timing of each deliverable Levels of

17、 completeness for specific deliverables is clearly identified The required completion of items is tied to the specific GM build eventAPQP Project PlanAPQP Project Plan4 PhasePhase 0Phase 1Phase 2Phase 3GM Pre-sourcingPlan and DefineProduct Design and DevelopmentAIAGProcess Design and DevelopmentProd

18、uct and Process ValidationFeedback, Assessment and Corrective ActionVDPPre-sourcing-96-92-88-84-80 -76 -72-68-64-60-56 -52-48-44-40-36-32-28-24-20-16-12-8-404812162024Generic AlphaBetaProtoFE1 FE2 FE3PPAPPilotSSFAPQP TaskProgram ReviewsPR-1PR-2 PR-3 PR-4 1 Key Stakeholders MtgPR-1o-o2 Technical Revi

19、ewsPR-1o-o3 Risk AssessmentPR-1, 2, 3TR o-o4 Supplier Program Reviewsoooo5 Timing Charts/Open IssuesPR-1,2,3,4oooooooooo6 Feasibility LettersPR-1,2,3,4ooo7 Flow Chart PR-1,2,4oo-oo-o8 DFMEAPR-1,2,4ooo9 Design ReviewPR-2,3oo10 Gage ReviewPR-2,3,4o- -o11 GP-11 PR-2,3o-o12 PFMEA StrategyPR-1,2,3,4oo-oo

20、o-oo13 Control PlanPR-1,2,3,4oo-oo-oo14 GP-12 PR-4o-o15 PPAP PR-4 o-o16 Run Rate (GP-9)PR-1,4oo o-o17 Lessons LearnedPR-1,2,3,4ooooooPlacomplete/staconcept design gage approval, KCDS final Plainitial -initial-initial-GD&T prototype final prototype final prototype Complete (Platform initial -TRKi

21、ck-off initial-planUpdate Risk Global APQP12APQP Project PlanAPQP Project PlanGM GVDP GenericAPQP Task Gate ReviewsSourcingActivitiesGR-1GR-2 GR-3 GR-4 1Commodity Sourcing Strategy MtgGR-1o-oo2 Technical ReviewsGR-1o-oo3Risk Assessment / SourcingGR-1,3TRooo4Supplier Gate Reviews5Timing Charts / Open

22、 IssuesGR-1,2,3,4ooooooooooooooooooooooooooo6Feasibility / Assessment LettersGR-1,2,3,4oooo7 Flow Chart GR-1,2,4oooooo8 DFMEAGR-1,2,4ooooooo9 Design ReviewsGR-2,3oooo10Gage, Tooling and Equipment ReviewsGR-1,2,3,4ooooo11 GP-11 GR-2,3oooo12 PFMEAGR-1,2,3,4ooooooo13 Control PlanGR-1,2,3,4oooooo14 GP-1

23、2 GR-3,4ooo15 PPAP GR-4oo16 Run Rate (GP-9)GR-1,2,3,4ooooooo17 Lessons LearnedGR-1,2,3,4oooooAIAG APQPPilot / Pre-LaunchPrototypeLaunch /Feedback, Assessment and Corrective ActionProductionProduct Design and DevelopmentPlanningProcess Design and DevelopmentProduct and Process ValidationGage Concept

24、ApprovalGage Design ApprovalGage Approval/R&R, Tool CompletionKCDS WorkshopProductionPlanInitial-TRInitial -TRInitial-TR Initial-TRGD&T GP-12 & ProductionExit (Platform Discretion)Initial-TRInitial-TRPlanUpdate RiskProd Concept-TR Conduct RunRateStructureVehicleIntegrationVehicleValidati

25、on VehicleMVBsSOPMVBnsAlphaBetaGamma / ProtoPre-Pilot / Pilot 1Pilot / Pilot 2FE1FE2FE3SSFCapacity AnalysisLetter 2Letter 3Letter 4Update DFMEARPN Reduction ExecuteExecutePrototype / RPN BaselinePrototypeProduction / RPN ReductionRPN ReductionPrototypeExecuteCapacity Analysis13APQP Project Plan4 Pha

26、sePhase 0Phase 1Phase 2Phase 3GM Pre-sourcingPlan and DefineProduct Design and DevelopmentAIAGProcess Design and DevelopmentProduct and Process ValidationFeedback, Assessment and Corrective ActionVDPPre-sourcing-96-92-88 -84-80 -76 -72-68-64-60-56 -52-48-44-40-36-32-28-24-20-16-12-8-404812162024Gene

27、ric AlphaBetaProtoFE1 FE2 FE3PPAPPilotSSFAPQP TaskProgram ReviewsPR-1PR-2 PR-3 PR-4 1 Key Stakeholders MtgPR-1o-o2 Technical ReviewsPR-1o-o3 Risk AssessmentPR-1, 2, 3TR o-o4 Supplier Program Reviewsoooo5 Timing Charts/Open IssuesPR-1,2,3,4oooooooooo6 Feasibility LettersPR-1,2,3,4ooo7 Flow Chart PR-1

28、,2,4oo-oo-o8 DFMEAPR-1,2,4ooo9 Design ReviewPR-2,3oo10 Gage ReviewPR-2,3,4o- -o11 GP-11 PR-2,3o-o12 PFMEA StrategyPR-1,2,3,4oo-ooo-oo13 Control PlanPR-1,2,3,4oo-oo-oo14 GP-12 PR-4o-o15 PPAP PR-4 o-o16 Run Rate (GP-9)PR-1,4oo o-o17 Lessons LearnedPR-1,2,3,4ooooooPlacomplete/staconcept design gage app

29、roval, KCDS final Plainitial -initial-initial-GD&T prototype final prototype final prototype Complete (Platform initial -TRKick-off initial-planUpdate RiskStartHereTask 4APQP Project PlanSupplier ActivitiesSupplier Program Reviews14Task 4) Supplier Program ReviewsFour Major Program Reviews: Purp

30、ose: Ensure Suppliers Quality Plan is Progressing to Meet GM Program Timing Provide a Formal Process to Raise Issues for Resolution Pre-Production Meeting (APQP Kickoff) Beta Prototype Build Review Gamma Prototype Build Review Pilot (Final PPAP Submission) ReviewMeeting Responsibility: Pre-Productio

31、n Meeting is Scheduled by SQE Meetings 2, 3, 4 are Scheduled by SupplierTODAYOverview154) Supplier Program Reviews APQP Major/Open Issues List APQP Timing Chart Updates Progress of Tooling/Fixtures/Gages Supplier Manufacturing Assessment Letters (3 letters) Lessons Learned Design Issues RPN Reductio

32、n Plans AIAG New Equipment Checklist (A-3) AIAG Process Flow Checklist (A-6) AIAG PFMEA Checklist (A-7) AIAG Control Plan Checklist (A-8) GP-12 PlanSQEs will Review Documents at MeetingsMeeting Subjects Include:Suppliers need to be prepared for each meeting with supporting documentsSupplier Program

33、Reviews 2,3,4Task 6165) Timing Charts / Open IssuesSQE Responsibility: Purpose: Ensure Program Deliverables are Executed on Schedule Review the APQP Timing Chart and APQP Issues List Identify and Communicate Key Timing and Program Issues with GM ManagementSupplier Responsibility: Create and maintain

34、 an APQP Timing Chart and Open Issues List Maintain Detail behind Each High Level APQP Chart Review Timing Chart and Issues List at All Program Reviews Identify and Communicate Any Changes to SQE Identify and Communicate Key Timing and Program Issues with SQE176) Manufacturing Assessment LettersManu

35、facturing Assessments:Design - can the Design be Manufactured to Conform to all GM Performance Requirements?Prototype - using the Intended Production Process, will all Parts Conform to GM Requirements?Process Capability - will the Production Process Provide Parts that Conform to GM Requirements?Supp

36、lier Responsibility: Evaluate Feasibility during 3 stages of program development Submit Letters Signed by the Manufacturing Plant ManagerPurpose: Supplier Evaluates Manufacturability of the Part 18ABC Company123 Part LaneAnywhere, Michigan 48000(313)777-7777July 12, 1997GM Supplier Quality EngineerG

37、M Release EngineerGeneral Motors CorporationSUPPLIER MANUFACTURING ASSESSMENT OF DESIGNAs required by General Motors, ABC Company held a manufacturing review of the Model Year design on date. The review has led us to the following position:(Select one) Manufacturing is confident the design is manufa

38、cturable to GM requiredquality levels, within PPAP design specifications, and within PPAPcapability requirements. Manufacturing is making a commitment toachieve zero defects as specified in the GM Supplier Quality Statement ofRequirements. There are no concerns to report. Manufacturing has minor con

39、cerns about the design which have beenreported to the design community and are described below. We areconfident that the design will be modified to accommodate our issues andbe manufacturable to GM required quality levels, within PPAP designspecifications, and within PPAP capability requirements. Ma

40、nufacturingis making a commitment to achieve zero defects as specified in the GM SupplierQuality Statement of Requirements. Manufacturing has major concerns about the design and we are not confident that we canproduce this part at required quality levels. These concerns are described below.Design Is

41、 Manufacturable to GM Required Quality LevelsManufacturing is making a commitment to achieve zerodefects.Minor concerns about the design . Confident that designwill be modified.manufacturableto Required Quality Levelscommitment to achieve zerodefects.Major concerns about design, not confident part c

42、an be produced at GM Required Quality Levels6) Manufacturing Assessment Letters197) Flow ChartSQE Responsibility: Purpose: Provide a Logical Pictorial Representation of the Process Flow that can be used as the Foundation for PFMEAs. Control Plans, Work Station Layouts, etc. Review Process Flow Chart

43、s at Sourcing (if available), at Prototype, at Production Part Approval and Regular Production Ensure that the Production Version is linked to the PFMEA and Control Plan Ensure that the Flow Chart Includes Inspection and ReworkSupplier Responsibility: Create Preliminary Process Flow Chart using a Si

44、milar Process Create and Maintain the Flow Chart through Prototype and into Production Ensure the Flow Chart is Linked to the PFMEA and Control Plan Communicate any Changes to the SQE208) Design Failure Mode and Effects AnalysisPurpose:Support the Design Process in Reducing the Risk of FailureSQE Re

45、sponsibility: Confirm that a DFMEA has been Completed Ensure that Supplier has a DFMEA for input to PFMEA Lessons Learned Checklist to Design OwnerSupplier Responsibility: GM Design Responsible Suppliers must participate in DFMEA Reviews with Product Engineer Share Knowledge and Experience on Simila

46、r Designs Recommend Action Plans for Severity, Occurrence, Detection Targets Supplier Design Responsible Lead Cross-functional Team to Develop and Improve FMEA Schedule Review Meetings with GM Product Engineer Develop Action Plans for Severity, Occurrence, Detection Targets Maintain DFMEA for PPAP S

47、ubmission219) Design ReviewsPurpose:Ensure that the Design has been adequately Defined to Build Tools and GaugesSQE Responsibility: Participate in KCDS Workshop and GD& T Reviews Participate in Design Reviews addressing changes in Manufacturing Process/ Quality/Timing/ RiskSupplier Responsibilit

48、y: Participate in KCDS Workshop and GD& T & Design Reviews Participate in Defining Measurable KPCs Participate in Defining Appearance Specifications Satisfy all Performance and Material Testing Requirements Ensure that the Manufacturing Process can achieve Tolerances on a Continuing BasisQua

49、lity of the Design Directly Impacts Process Design and Process Quality2210) Gage, Tooling & Equipment ReviewsPurpose: Ensure that the Manufacturing process is being designed, built and certified to produce parts with quality at rate according to GM program requirementsSQE Responsibility: Confirm

50、 that Gage, Tooling and Equipment Timing is on Schedule to Support Program Requirements Confirm that the Gauge Agrees with the Functional Part Usage, Complies with GD&T, Includes Measurement of KPCs and is at the Correct Change Level Ensure Gage is Used as Indicated in Process Flow Chart and Con

51、trol Plan Supplier Responsibility: Design, Build and Obtain Certification of Gages Participate in Reviews with General Motors Relative to Design, Build and Certification of the Gage23Purpose: Ensure Part Problems are Identified and Corrected in order to Minimize the Impact of Part Variation upon Des

52、ign Evaluation, Manufacturing, and Assembly. Supplier Responsibility: Adhere to Requirements Specified in GP-11. Ship Parts and Documentation as Specified in GP-11 and the Prototype Purchase Order. Respond to and Resolve Issues Identified in Prototype Build. Revise the Flow Chart, PFMEA, and Control

53、 Plan as Problems are Identified throughout GP-11 and the Prototype Build. Update the APQP Open Issues List and APQP Timing Chart as Problems and Changes Occur.Prototype will act as a Mirror for Problems that will Appear at Pilot = Address Issues Early in Program!11) GP 11 Prototype2412) PFMEA Strat

54、egyPurpose:Assure Potential Failure Modes of the Process have been Considered and AddressedSQE Responsibility: Attend initial PFMEA Development Team Meeting Monitor Progress and Review PFMEA with Supplier Supplier Responsibility: Initiate PFMEA prior to Sourcing as part of the Quotation to GM Drive

55、Error Prevention and Detection throughout the Process Prepare PFMEA - Multi-disciplinary team Insure that PFMEA results have been incorporated into Control Plan Revise PFMEA if Process / Material / Manufacturing Location Changes Develop and Implement RPN Reduction Plans2513) Control PlansPurpose: De

56、fine the Method being used to Control all KPCs and KCCs for Parts being Manufactured for Vehicle Builds. SQE Responsibility: Verify use of PFMEA & Statistical Data to determine Necessary Controls Verify Update of Control Plan with Solutions from PFMEA Verify Pre-Launch Issues have been Incorpora

57、ted into Production PlanSupplier Responsibility: Develop Pre-sourcing Control Plan Ensure Control Plan Flows from PFMEA & Process Flow Chart Use Pre-Launch Control Plan to Validate Production Control Plan Update Control PlanProcess Control Plan Audits will be Conducted at Run Rate2614) GP 12 Ear

58、ly Production ContainmentPurpose: Establish a Containment Plan during Start-up and Acceleration that will Quickly Identify Quality Issues at the Suppliers Facility; i.e., a Pre-Launch Control Plan. SQE Responsibility: Provide GP-12 Timing to the Supplier Review the Suppliers Process and Pre-Launch C

59、ontrol Plan Verify that any PR&R, Prototype or Pilot Issues are in Control Verify that the Supplier used PFMEA & Statistical Data to Set Controls Supplier Responsibility: Develop the Pre-Launch Control Plan Based on Experience from Prior Issues Implement the Pre-Launch Control Plan Monitor G

60、P 12 Data and Modify Internal Process to Eliminate Issues Monitor Customer Issues and PR&Rs, Update Control Plans 2715) Production Part Approval ProcessPurpose: Determine if All Customer Engineering Design Records & Specifications Requirements are properly understood by the Supplier and that the Process has the Potential to Produce Product Meeting these Requirement