GM gp 5供方質(zhì)量過程和測量程序(英文版)剖析課件

GP-5December,2001EditionGP-5Purpose: TrainSupplierpersonnelonchangestoGP-5/GQTSProcess: ExplanationofGP-5enhancementsandscreen shotsofGQTSenhancementsProduct: UnderstandingofprocessandsystemenhancementsPurpose: TrainSupplierpersonOverviewofchangesmadetotheprocedureOverviewofPRRSystemChangesinGQTSDescriptionofGMSupplyPowerGP-5folderWhatdoesthisGP-5TrainingInclude?OverviewofchangesmadetothChangestoGP-5ControlandReworkCompanyAcompanyapprovedbyGeneralMotorstoperformcontrolledshippinglevel2inspectionsorotherworknecessarytoensureproductquality.Thiscompanyperformsdirectlyundertheresponsibilityofthesupplier.LineAccumulationsLineaccumulationsaredefinedasunavoidablediscrepanciesorsinglecasesofcommoditieswhereonlyinitialresponseisneeded.ThesePRRswillbeissuedonamonthlybasisperpartorpartgroup.DefinitionsaddedtoGP-5ChangestoGP-5ControlandRewQualityPerformanceReports

Monthly6panelchartsthatgraphicallydisplaythedatacontainedinGQTS.Chartsdisplaythefollowing:MajorDisruptions(Spills,Downtime,Stockouts)PRRsDiscrepantPartsPPMSourcingMetricsSupplierevaluationsystemthatrankseachsuppliermanufacturinglocationintermsofoverallqualityinoneofthreecategories:green,yelloworred.Therankingcriteriaarebasedonthehistoricalcommodityperformance.(Example–EnhancedMetricBidList)ChangestoGP-5DefinitionsaddedtoGP-5QualityPerformanceReportsChaChangestoGP-5PackagingPRRs(section4.2.2)PackagingPRRsarenowdefinedaspackagingissuesthatcausepart/specificationnonconformity,oreffectsalabilityofthepart.Examples:

DamagedpartormaterialthatwasinadequatelysecuredinthecontainerContainerwasinadequatelysecuredinthecarriervehicleandcausedpart/materialdamageContainerdesignand/orfabricationwasinadequateandcausedpart/materialdamageContainerthathasbeendamagedbyimproperhandlingandcausedpart/materialdamageMixedpalletsbuiltincorrectlyandcausedpart/materialdamagePartsnotpackagedtospecificationforserviceChangestoGP-5PackagingPRRsChangestoGP-5LineAccumulationPRRs(section4.3)TheLineaccumulationPRRshouldbeenteredinthesystemonlyafterthefullimpactandthemonthlyquantityisavailabletotheissuer.Whenitisappropriatefortheplant,thePRRmaybeissuedwiththefirstoccurrenceofthediscrepantpart.Regularadjustmentsofthevolumewillthenbemadeduringthemonth.Forawarenesspurposes,theissuershouldindicatethepossibilityofadjustmentswhenissuingthePRR.ChangestoGP-5LineAccumulatiChangestoGP-5ProblemLocationandDirectRunIndicator(section4.3.2)IssuermustindicateonthePRRwheretheproblemwasfound.(Phasedropdownbox)IssuermustindicateonthePRRiftheissueaffectsDirectRunRate.(DirectRunRatecheckbox)ChangestoGP-5ProblemLocatioChangestoGP-5QuantityChecked(section)The“1%or30pieces”requirementreplacedbythefollowingwording:“ThequantitycheckedMUSTbeofastatisticallysignificantsizetorepresentthepercentagedefectivewithinthebatch.”ChangestoGP-5QuantityCheckeChangestoGP-5QuantitiesforLabelIssues(section)Forpartsshippedinbulksuchasfasteners,labels,etc.(thatarereceivedinlargequantitiesatmanufacturinglocations)mislabelproblemswillbecountedusingthefollowingescalationprocess.Firstlabelingoffense(ataparticularDunslocation,inlast15months)Issuercountsonlyonequantitydiscrepantagainstthesupplier(Quantitynonconformingandestimatedquantitynonconforming=1)Secondoffense

(ataparticularDunslocation,inlast15months)Issuercountsonlyonequantitydiscrepantagainstthesupplier(Quantitynonconformingandestimatedquantitynonconforming=1)ThesupplierwillalsobeplacedonControlledShippingLevel1.Thirdoffense

(ataparticularDunslocation,inlast15months)Issuercountsallpartsagainstthesupplier.ThesupplierwillalsobeplacedonControlledShippingLevel2.

ChangestoGP-5QuantitiesforChangestoGP-5QuantitiesforLabelIssues(example-section8.4)APRRiswrittentoasupplierformislabelingapalletoftenboxesofscrews,eachboxcontaining1,000screws.Ifthisisthesupplier’sfirstlabelingoffense: QuantityChecked: 1000 QuantityNonconforming: 1 QuantitySuspect: 1000

Est.QuantityNonconforming: 1Ifthisisthesupplier’ssecondlabelingoffense: QuantityChecked: 1000 QuantityNonconforming: 1 QuantitySuspect: 1000

Est.QuantityNonconforming: 1Ifthisisthesupplier’sthirdlabelingoffense: QuantityChecked: 1000 QuantityNonconforming: 1000 QuantitySuspect: 1000

Est.QuantityNonconforming: 1000ChangestoGP-5QuantitiesforChangestoGP-5PRRClosure(section4.3.8)APRRisconsideredclosedafterthecustomerhasmovedthePRRfroman“Openor“Rejected”statustoanApprovedstatus.AnewstatusfieldisbeingaddedtoGQTS.ChangestoGP-5PRRClosure(seChangestoGP-5TimelinessofFinalResponse(section4.4.5)

Supplierswillbemeasuredonthetimelinessoftheirfinalresponse.ThefollowingtimestampswillbecapturedinthedatabaseonlyImplementeddateApproveddateGMwillusethetimestampstocalculatethefollowingmetrics:TimetoImplementation(Implementationdate-Issuedate)TimetoClosure(ApprovedDate-Issuedate)ChangestoGP-5TimelinessofFChangestoGP-5GeneralUpdatesNewBusinessHoldaddedtoprocedure(section6.0)IssuesthataffectmultipleplantscountedasonlyonemajordisruptionChangestoGP-5GeneralUpdatesPRRSystemChangesinGQTSPRRSystemChangesinGQTSPRRSystemChangesinGQTSThiswillautomaticallyclassifythePRRRecordasboth“ProblemIdentified”and“Implemented”.SecondaryNonconformanceissetas“LineAccumulation-OnlyInitialResponseRequired”SupplierhasenteredonlytheInitialresponseInStep1:InitialResponse,theConformingMaterialDatefieldissettothefirstdayofthemonthfollowingthecurrentmonth.Thisfieldissettothisdefaultvalueevenifthesupplieruserhadpreviouslyinputadatetothisfield.InStep3:ProblemIdentificationandActionPlan,thefollowingfieldswillbeset(iftheuserenteredavalueforoneofthesefields,theuserenteredvaluewillnotbechanged):· RootCausedroplistfieldtothevalueOther.· CorrectiveActionImplementationDatefieldtocurrentsystemdate.· DateChangestoFMEAwillbeCompletefieldtocurrentsystemdate.· DateChangestoProcessControlPlanwillbeCompletefieldtocurrentsystemdate.InStep4:ImplementationProcess,text“NotRequired”willbeplacedintheInstitutionalizedtextarea.LineAccumulationPRRsPRRSystemChangesinGQTSThisPRRSystemChangesinGQTSSelectacategoryPhaseboxwillnolongerdefaultto“Production”Defaultwillbe“SelectaCategory”Usermustmakeaselectionthatrepresentswheretheproblemwasfound.PRRSystemChangesinGQTSSelePRRSystemChangesinGQTSCustomerResponseaddedasStep5onSupplierResponsepage.-RadiobuttonaddedforStatus-DefaultvalueisOpen-FieldcanbeupdatedatanytimebyaGMuserIDwithPRRupdateprivileges-IfuserselectsApproved,thenthecurrentDate/TimestampwillbestoredonthedatabaseastheApprovedDate.-IfusermovesstatusfromApprovedtoOpenorRejected,thentheApprovedDate/TimestampwillberesettoNull.PRRSystemChangesinGQTSCustPRRSystemChangesinGQTSNewsearchfieldadded:PRRCustomerResponsestatus-OptionsareOpen,Rejected,Approved,All-DefaultvalueisOpen-CondensedandExpandedlogsdonotcontainthenewfield.PRRSystemChangesinGQTSNewPRRSystemChangesinGQTSCustomerResponsestatusaddedtoPrintedreport.-DatewillalsoshowifthestatusisapprovedPRRSystemChangesinGQTSCustDescriptionofGMSupplyPowerGP-5folderLatestGP-5SummaryofchangesFiat/FiasaversionofGP-5SeparateattachmentforusablecopiesofGP-5formsListofGP-5FrequentlyAskedQuestionsDescriptionofGMSupplyPowerGP-5December,2001EditionGP-5Purpose: TrainSupplierpersonnelonchangestoGP-5/GQTSProcess: ExplanationofGP-5enhancementsandscreen shotsofGQTSenhancementsProduct: UnderstandingofprocessandsystemenhancementsPurpose: TrainSupplierpersonOverviewofchangesmadetotheprocedureOverviewofPRRSystemChangesinGQTSDescriptionofGMSupplyPowerGP-5folderWhatdoesthisGP-5TrainingInclude?OverviewofchangesmadetothChangestoGP-5ControlandReworkCompanyAcompanyapprovedbyGeneralMotorstoperformcontrolledshippinglevel2inspectionsorotherworknecessarytoensureproductquality.Thiscompanyperformsdirectlyundertheresponsibilityofthesupplier.LineAccumulationsLineaccumulationsaredefinedasunavoidablediscrepanciesorsinglecasesofcommoditieswhereonlyinitialresponseisneeded.ThesePRRswillbeissuedonamonthlybasisperpartorpartgroup.DefinitionsaddedtoGP-5ChangestoGP-5ControlandRewQualityPerformanceReports

Monthly6panelchartsthatgraphicallydisplaythedatacontainedinGQTS.Chartsdisplaythefollowing:MajorDisruptions(Spills,Downtime,Stockouts)PRRsDiscrepantPartsPPMSourcingMetricsSupplierevaluationsystemthatrankseachsuppliermanufacturinglocationintermsofoverallqualityinoneofthreecategories:green,yelloworred.Therankingcriteriaarebasedonthehistoricalcommodityperformance.(Example–EnhancedMetricBidList)ChangestoGP-5DefinitionsaddedtoGP-5QualityPerformanceReportsChaChangestoGP-5PackagingPRRs(section4.2.2)PackagingPRRsarenowdefinedaspackagingissuesthatcausepart/specificationnonconformity,oreffectsalabilityofthepart.Examples:

DamagedpartormaterialthatwasinadequatelysecuredinthecontainerContainerwasinadequatelysecuredinthecarriervehicleandcausedpart/materialdamageContainerdesignand/orfabricationwasinadequateandcausedpart/materialdamageContainerthathasbeendamagedbyimproperhandlingandcausedpart/materialdamageMixedpalletsbuiltincorrectlyandcausedpart/materialdamagePartsnotpackagedtospecificationforserviceChangestoGP-5PackagingPRRsChangestoGP-5LineAccumulationPRRs(section4.3)TheLineaccumulationPRRshouldbeenteredinthesystemonlyafterthefullimpactandthemonthlyquantityisavailabletotheissuer.Whenitisappropriatefortheplant,thePRRmaybeissuedwiththefirstoccurrenceofthediscrepantpart.Regularadjustmentsofthevolumewillthenbemadeduringthemonth.Forawarenesspurposes,theissuershouldindicatethepossibilityofadjustmentswhenissuingthePRR.ChangestoGP-5LineAccumulatiChangestoGP-5ProblemLocationandDirectRunIndicator(section4.3.2)IssuermustindicateonthePRRwheretheproblemwasfound.(Phasedropdownbox)IssuermustindicateonthePRRiftheissueaffectsDirectRunRate.(DirectRunRatecheckbox)ChangestoGP-5ProblemLocatioChangestoGP-5QuantityChecked(section)The“1%or30pieces”requirementreplacedbythefollowingwording:“ThequantitycheckedMUSTbeofastatisticallysignificantsizetorepresentthepercentagedefectivewithinthebatch.”ChangestoGP-5QuantityCheckeChangestoGP-5QuantitiesforLabelIssues(section)Forpartsshippedinbulksuchasfasteners,labels,etc.(thatarereceivedinlargequantitiesatmanufacturinglocations)mislabelproblemswillbecountedusingthefollowingescalationprocess.Firstlabelingoffense(ataparticularDunslocation,inlast15months)Issuercountsonlyonequantitydiscrepantagainstthesupplier(Quantitynonconformingandestimatedquantitynonconforming=1)Secondoffense

(ataparticularDunslocation,inlast15months)Issuercountsonlyonequantitydiscrepantagainstthesupplier(Quantitynonconformingandestimatedquantitynonconforming=1)ThesupplierwillalsobeplacedonControlledShippingLevel1.Thirdoffense

(ataparticularDunslocation,inlast15months)Issuercountsallpartsagainstthesupplier.ThesupplierwillalsobeplacedonControlledShippingLevel2.

ChangestoGP-5QuantitiesforChangestoGP-5QuantitiesforLabelIssues(example-section8.4)APRRiswrittentoasupplierformislabelingapalletoftenboxesofscrews,eachboxcontaining1,000screws.Ifthisisthesupplier’sfirstlabelingoffense: QuantityChecked: 1000 QuantityNonconforming: 1 QuantitySuspect: 1000

Est.QuantityNonconforming: 1Ifthisisthesupplier’ssecondlabelingoffense: QuantityChecked: 1000 QuantityNonconforming: 1 QuantitySuspect: 1000

Est.QuantityNonconforming: 1Ifthisisthesupplier’sthirdlabelingoffense: QuantityChecked: 1000 QuantityNonconforming: 1000 QuantitySuspect: 1000

Est.QuantityNonconforming: 1000ChangestoGP-5QuantitiesforChangestoGP-5PRRClosure(section4.3.8)APRRisconsideredclosedafterthecustomerhasmovedthePRRfroman“Openor“Rejected”statustoanApprovedstatus.AnewstatusfieldisbeingaddedtoGQTS.ChangestoGP-5PRRClosure(seChangestoGP-5TimelinessofFinalResponse(section4.4.5)

Supplierswillbemeasuredonthetimelinessoftheirfinalresponse.ThefollowingtimestampswillbecapturedinthedatabaseonlyImplementeddateApproveddateGMwillusethetimestampstocalculatethefollowingmetrics:TimetoImplementation(Implementationdate-Issuedate)TimetoClosure(ApprovedDate-Issuedate)ChangestoGP-5TimelinessofFChangestoGP-5GeneralUpdatesNewBusinessHoldaddedtoprocedure(section6.0)IssuesthataffectmultipleplantscountedasonlyonemajordisruptionChangestoGP-5GeneralUpdatesPRRSystemChangesinGQTSPRRSystemChangesinGQTSPRRSystemChangesinGQTSThiswillautomaticallyclassifythePRRRecordasboth“ProblemIdentified”and“Implemented”.SecondaryNonconformanceissetas“LineAccumulation-OnlyInitialResponseRequired”SupplierhasenteredonlytheInitialresponseInStep1:InitialResponse,theConformingMaterialDatefieldissettothefirstdayofthemonthfollowingthecurrentmonth.Thisfieldissettothisdefaultvalueevenifthesupplieruserhadpreviouslyinputadatetothisfield.InStep3:ProblemIdentificationandActionPlan,thefollowingfieldswillbeset(iftheuserenteredavalueforoneofthesefields,theuserenteredvaluewillnotbechanged):· RootCausedroplistfieldtothevalueOther.· CorrectiveActionImplementationDatefieldtocurrentsystemdat