GM Global APQP for Suppliers

Phone on Vibrate
Ground Rules

This is your class, feel free to ask questions at any time!

Manuel Yamada Tel Aviv, Israel

April 12th, 2010

AGENDA
Introductions APQP Process and Expectations Project Plan Customer vs Supplier Monitored APQP APQP management in GQTS APQP Requirements GM Requirements Q&A

Global APQP Vision

Become more proactive, by moving right side activities to the left QSB for suppliers upfront after sourcing Schedule early cross functional blitz audits on high risk suppliers

Streamline the APQP Process to be more effective Identify key deliverables for each quality gate during the APQP process Track and report the results of the agreed deliverables, not just PPAP and R@R

Supplier Responsibility

The goal of a successful program launch and mass production is to provide:

Quality @ Rate On Time

Background

Linkages of the ISO/TS 16949:2002, AIAG APQP and Global Supplier Quality Manual
GM Global APQP AIAG APQP

ISO/TS 16949 7.1 Planning of Product Realization

Background

GM APQP Global Process

Global APQP Team Goals & Results Identify Quality Indicators Develop Quality Tasks (17 total) Develop Global Supplier Quality Manual, GM-1927

Reason: Global Sourcing and World Vehicles

Global APQP
GM-1927 Global Supplier Quality Manual is
the General Motors Common Global APQP Manual
GMs common direction for the development and implementation of an APQP plan Download from GMSupplyPower
GM
General Motors Corporation

Advanced Product Quality Planning

Worldwide Purchasing

November 2000

GM 1927 Documents and Forms

Ordering:

Ordering information for all documents and manuals listed or referenced throughout this manual (GM 1927) is contained on page II
Electronic Copies:

This manual and all documents that are part of this manual (this includes any document with a GM 1927 number) can be found through the internet at the GMSupplyPower website
The address is www.gmsupplypower.com, then follow these steps: Log in Select Quality Power Select Library Select Supplier Quality Select APQP Manual & Documents

Global APQP
Summary Points
Global APQP driven by ISO TS 16949 and AIAG APQP

Common Global APQP Process for GM Worldwide

- All GM Divisions and Regions will use the Same Process - Common Requirements for Suppliers - Common Forms and Charts

Common Direction and One Voice from all GM Supplier

Quality Engineers Supports Global SQ Communication Structure

- Supplier Program Status is shared between Regions - All Information Available on GMSupplyPower website at www.gmsupplypower.com

Global APQP
Customer Monitored APQP Supplier Monitored APQP
Customer Monitored SQE work closely with supplier Supplier work closely with GM SQE Supplier Monitored SQE paper/electronic review of supplier Supplier keep GM aware

GM Global APQP Monitoring

SQE is the responsible for invite and conduct Gate #1 (Kick-Off Meeting) for all parts on both Customer or Supplier Monitored APQP

Customer Monitored SQE Responsibilities

Drive the suppliers progress in the development Raise issues that might jeopardize a quality part
within the program timing either to suppliers or GMs upper management, as appropriate

Assure quality @ rate on time

Execute the content and provide updates per the Invite and conduct all remaining Gate Reviews Work closely with GM SQE
Supplier Monitored Supplier Responsibilities

Customer Monitored Supplier Responsibilities

of all quality related documents listed on APQP Project Plan

Implement an advanced product quality planning process with all sub-tier suppliers

APQP Project Plan

Participate in the remaining Supplier Gate

Review meetings
when in the manufacturing facility

Adhere to supplier manufacturing site protocol Attend PDT and associated program meetings Drive/Enforce the process of suppliers quality
system development

Execute the content of the APQP Project Plan Implement an advanced product quality
Responsible for meeting quality, timing and
planning process with all sub-tier suppliers

Apply APQP Workbook Audits and upload all Key

Supplier Monitored SQE Responsibilities Monitor the suppliers adherence to program
timing and track open issues addressing Deliverables to GQTS

Workbook internally in a management review and submit the results to GM

Provide parts for all GM build events Present tasks and deliverables of APQP
affect program timing

capacity requirements

Notify SQE when quality issues arise that might

Global APQP
Customer Monitored APQP vs

Supplier Monitored APQP

There is an inverse relationship Customer monitoring means more responsibility for the SQE Supplier monitoring means more responsibility for the Supplier

Global APQP Tasks changed as following:

01-Commodity Sourcing Strategy Mtg 02-Technical Reviews 03-Risk Assessment / Sourcing 04-Supplier Gate Reviews 05-Timing Charts / Open Issues 01-Commodity Key Stakeholders Mtg 02-Technical Reviews 03-Supplier Eligibility

04-Gate Reviews
05-Timing Charts / Open Issues 06-QSB 07-Flow Chart

06-Feasibility / Assessment Letters

07-Flow Chart 08-DFMEA 09-Design Reviews

08-DFMEA
09-Design Reviews 10-Tooling & Equipment Reviews 11-Gage Development & Approval

10-Gage, Tooling and Equipment Reviews

11-GP-11 12-PFMEA 13-Control Plan

12-PFMEA
13-Control Plan 14-GP-12 15-PPAP

14-GP-12
15-PPAP 16-Run @ Rate 17-Lessons Learned

16-Run @ Rate
17-Lessons Learned

 Corporate Planning sets time frames

Combination of the Best Processes

GPSC SUPPLIER QUALITY IMPROVEMENT PROCESS
GLOBAL SOURCING IMPROVEMENT MEETING QUALITY WORKSHOP LEVEL II CONTROLLED SHIPPING

LEVEL I CONTROLLED SHIPPING

SUPPLIER QUALITY PROCESSES & MEASURES (GP-5) PERFORMANCE MONITORING

TIME LINE
EARLY PRODUCTION CONTAINMENT (GP-12) RUN @ RATE (GP-9) PRODUCTION PART APPROVAL (PPAP) PROTOTYPE SAMPLE APPROVAL (GP-11) PRE-PRODUCTION MEETING ADVANCED PRODUCT QUALITY PLANNING (APQP) SOURCING DECISION POTENTIAL SUPPLIER ASSESSMENT

CONTINUOUS IMPROVEMENT (GP-8)

LIFE OF PART

GM Global APQP

START OF PRODUCTION

1. Commodity Sourcing Strategy Meetings

APQP Project Plan
Prototype Planning AIAG APQP Product Design and Development Process Design and Development Product and Process Validation Feedback, Assessment and Corrective Action
Structure Vehicle Integration Vehicle Validation Vehicle MVBns MVBs SOP

Pilot / Pre-Launch

Launch / Production

GM GVDP APQP Task Commodity Sourcing 1 Strategy Mtg 2 Technical Reviews Risk Assessment / 3 Sourcing Supplier Gate 4 Reviews Timing Charts / 5 Open Issues Feasibility / 6 Assessment Letters 7 Flow Chart 8 DFMEA 9 Design Reviews Gage, Tooling and 10 Equipment Reviews Gate Reviews GR-1 GR-1 GR-1,3 Sourcing Activities o------o o------o TR

GR-1

GR-2

GR-3

o o
Update Risk

Initial-TR

GR-1,2,3,4
Initial-TR

o o
Initial -TR

o
Letter 2

o
Letter 3

o
Letter 4

GR-4
o

GR-1,2,3,4 GR-1,2,4 GR-1,2,4 GR-2,3

o
Prototype

o
Production

o o
RPN Reduction DFMEA o o

o
DFMEA

o o
KCDS Workshop

o
Update

o o
GD&T

o o

o o
Prod Concept-TR

o o
Gage Concept Approval

o
Gage Design Approval Gage Approval/R&R, Tool Completion

Execute Execute The Commodity Sourcing Strategy Meeting is the responsibility of the Buyer 11 GP-11 GR-2,3 o o o o RPN Reduction Prototype / RPN Baseline Internal GM people only Initial-TR Production / RPN Reduction 12 PFMEA GR-1,2,3,4 o o o o o o o o The first time the SQE becomes officially involved Prototype GP-12 & Production in the APQP process Initial-TR 13 Control Plan GR-1,2,3,4 o o o o o o o Commodity Sourcing Strategy Meeting is the first task that by the Initial-TR Execute is tracked Plan Exit (Platform Discretion) 14 GP-12 GR-3,4 o o o o APQP Project Plan

GR-1,2,3,4

15 PPAP 16 Run @ Rate (GP-9) 17 Lessons Learned

GR-4
Plan Capacity Analysis Capacity Analysis

o o o o o o o o o o

o
Conduct Run@Rate

GR-1,2,3,4 GR-1,2,3,4

o o

o o

1. Commodity Key Stakeholders Meeting (CKSM)

Key points
Introduce and establish Key Stakeholder ownership, identify program-specific strategies in the Engineering & Advance Purchasing Sourcing Process (E&APSP) and ensure that the RFQpackage contains all information needed to receive comparable quotes. Review potential bidders list proposed by Buyer to restrict Request for Quotation (RFQ) distribution to suppliers that meet GM criteria. Identify suppliers that will require Quality Business Case action plans and start planning any required audits. Review the requirements stated in the SQ SOR GM1927-3, and the Part-Specific Quality & Process SOR (if applicable) to ensure that they are be included in the Request For Quotation package (suppliers must be capable to meet those specific requirements if available).

1. Commodity Key Stakeholders Meeting (CKSM)

Available Data for Supplier Performance

- CT Bid List - PSA/PCPA audit report - GMSupplyPower (Six Panel Chart and Box Chart)

Supplier Commitment Letter is required for any suppliers to be sourced with not Green status

Supplier Quality SOR

Supplier Quality Statement of Requirements

Supplier Quality has a Global Statement of Requirements that applies to all suppliers. SOR Included in the GM RFQ. Supplier Quotations to GM must include a signed copy of the SOR, indicating compliance to these requirements.

Please sign, date and return page 5 of this document with your bid package as record of your understanding of these requirements. Powertrain suppliers please sign, date and return page 6 also.

1. All suppliers are expected to supply parts to General Motors with zero defects. Funding is to
be identified in the initial quote and subsequent quotes to reflect error occurrence detection (poka yoke, error proofing devices, etc) and defect outflow prevention to customers. Controls implemented at a later date are the financial responsibility of the supplier.

2. ISO/TS 16949 or QS-9000 - Quality System Requirements

All suppliers to General Motors must be certified to one of these standards and have a current certificate available demonstrating compliance to GM supplements. These standards require an extensive, formal, audited evaluation of suppliers quality and manufacturing methods. The evaluation is conducted by a third party certified registrar. Suppliers not certified to ISO/TS 16949 or QS-9000, or those suppliers constructing or purchasing facilities to manufacture the parts being quoted, must include an outline of their certification attainment plan with their quote for further consideration.

3. General Motors Procedures and Reference Documents

Suppliers are to adhere to the requirements contained in the following documents: Advanced Product Quality Planning & Control Plan Reference Manual (AIAG) Potential Failure Mode and Effects Analysis (FMEA) Reference Manual (AIAG) Fundamental Statistical Process Control (SPC) Reference Manual (AIAG) Measurement Systems Analysis (MSA) Reference Manual (AIAG) Production Part Approval Process (PPAP) Manual (AIAG) Key Characteristics Designation System (KCDS) GM-1805QN GP-5 Supplier Quality Processes and Measurements Procedure. GM-1746 GP-7 Component Verification and Traceability Procedure. GM-1730 GP-8 Continuous Improvement Procedure. GM-1747 GP-9 Run @ Rate. GM-1960 GP-10 Evaluation and Accreditation of Supplier Test Facilities. GM-1796 GP-11 General Procedure for Pre-Prototype and Prototype Material. GM-1820 GP-12 Early Production Containment. GM-1920 GM-Supplier Technical Information GM-1825 Traceability Identifier Requirement TIR-15-300. GM-1731 Supplier Quality Weld Support Manual Shipping Parts Identification Label Standard. GM-1724 Fixture Standards Requirement GM-1925 Operating Guide for Suppliers of Prototype Material NAO-0065

Signature of Supplier Representative

2. Technical Reviews
Review manufacturability, timing, design, manufacturing capability, packaging, etc., issues related to a commodity. NOTE: There may be situations where a TR is not held. SQE must take responsibility for a review of the Quality info. This should be done prior to performing the GPSC APQP Assessment. Attendees: Buyer, Engineer, SQE, Supplier, Manufacturing Engineer, Other pertinent organizations Outcome: - Identifying suppliers that should not continue in the sourcing process - Initial GQSC APQP Assessment signed by the buyer, DRE and SQE (this is required prior to signing the Sourcing Recommendation form). - Initial APQP Open issues list

Technical Review Checklist

Risk Assessment
Risk Assessment

Customer Monitored APQP

or
Supplier Monitored APQP

3. Sourcing Eligibility
For a supplier location to be eligible to receive a new business award from GM the manufacturing location to be sourced must either be: Green on the GM Creativity Team Bid List (CTBL) for Quality for the specific commodity, OR

Have a supporting Quality Business Case (QBC) QUAD report approved according to the criteria outlined in this task.
Supplier is requested to provide necessary information as required and support audit requests at short notice. - Identifying suppliers that should not continue in the sourcing process - Initial GQSC APQP Assessment signed by the buyer, DRE and SQE (this is required prior to signing the Sourcing Recommendation form). - Initial APQP Open issues list

4. Gate Reviews
The purpose of the Gate Reviews is to review the progress of all APQP Tasks as stated on the APQP Project Plan GM1927-1 and track the status and progress of items listed on the APQP Timing Chart GM1927-2. These review meetings are intended as an APQP team review of the part and process development and to capture the lessons learned from each build event. The Gate Review #1 (Kick-Off Meeting) is coordinated by the GM SQE for all APQP parts. Used to review the progress of items according to the APQP Project Plan (GM1927-1) and track the status and progress of items listed on the APQP Timing Chart (GM1927-2)

109 Part J

4. Gate Reviews Key points

Intended as a Readiness Review of the suppliers ability to support specific GM build events and achieve both Full PPAP and R@R according to the program requirements
Coordinated by the SQE Conducted by the SQE on all parts tracked as customer-monitored APQP Conducted internally by the Supplier if the parts are supplier monitored APQP Aligned with GM build events

4. Gate Review

4. Gate Reviews Key Deliverables

The Key Deliverable documents (see chart) are to be uploaded into GQTS. All other APQP documents and forms (referenced in the GM Global APQP Supplier Status Summary Workbook GM1927-34) are to be retained 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.

4. Gate Reviews Key Deliverables

Gate Deadline (Time from SORP in weeks) GVDP 5.0 timing reference Review Key Deliverables GM Global APQP Supplier Status Summary Workbook QSB Audit (Gap Analysis) or Greenfield Checklist (Action Plan) Timing Plan Kick-Off Check list PFMEA Check list RPN Reduction Summary Subcontractor Status Supplier ADV Plan (ADVP&R) showing execution status QSB Audit (Compliance) or Greenfield Checklist (Complete) Run @ Rate Capacity Workbook Dimensional Report PPAP Worksheet (if not fully approved) GP12 Audit PPAP Approval Run @ Rate Execution PCPA R@R Module GM1927-16 Form/ Document

ALL Within 30 days of business nomination advice / contract -78 Initiated after CVER and completed 5 weeks after IVER Completed 10 weeks prior Matching 1 GA

GM1927-34 GM1927-30 GM1927-31 GM1927-2 GM1927-14 GM1927-37 GM1927-21 GM1927-25 GM1829 GM1927-30 GM1927-31 GM1927-35 GM1927-32 GM1411 GM1927-33

Gate 1

Gate 2

-52

Gate 3

-35 -15 -8

Completed 3 weeks prior PPV MRD Completed 1 week prior MVBs MRD

Gate 4 PPAP Run @ Rate

Gate Review # 1 - APQP Kick Off Meeting

Delivery
Kick off checklist (GM 1927-14) Program team contact list (GM 1927-17) APQP Timing chart APQP open issue list

Initial PFD/PFMEA/PCP
Lessons learned QSB Audit (Gap Analysis) or Greenfield Checklist (Action Plan)

Major disruption prevention plan

APQP Kick Off Meeting

GM AND SUPPLIER PROGRAM CONTACTS

Who to Contact?
GM1927-17 List the Key Positions needed to Manage New Programs

Part name: GM Program: Supplier Name: Manufacturing Location Address: Supplier Mfg. Plant Manager: GM Phone (fax,mobile)

Part number: Model Year: DUNS #: Phone: SUPPLIER Phone (fax,mobile)

Position Advance SQE Buyer Design Engineer VLE PPM Proto PE Manuf. Engineer GM Plant Rep GD&T Readiness Coord. Containerization Reliab. Engineer Paint Engineer Current SQE

Name

E-mail

Position Project Manager Sales Mgr Design Engineer Quality Manager Laboratory Supv.

Name

E-mail

Packaging Engineer 1st Shift Contact nd 2 Shift Contact rd 3 Shift Contact SubContractor

APQP Contact List.doc

GM1927-17

Gate Review # 2

Updated timing plans

Updated Open Issues PFMEA checklist

RPN reduction summary

Subcontractor planning Lessons Learned and best practice review Major disruption prevention plan

Gate Review # 3
On-tracking timing chart, PFD/PFMEA/PCP, Quality improvement activities, tier supplier improvement status etc Open issue review Identify high risk open issues QSB Audit (Compliance) or Greenfield Checklist (Complete) Run @ Rate Capacity Workbook

Supplier ADV Plan (ADVP&R) showing execution status

PPAP plan and requirements

Gate Review # 4
Updated timing plans, PFD/PFMEA/PCP, Open Issues, Quality improvement activities, tier supplier improvement status etc

Dimensional Report
PPAP Worksheet (if not fully approved) GP12 Audit Conduct Supplier Launch Day assessment

Gate Reviews 2,3,4

Meeting Subjects Include:
APQP Major/Open Issues List APQP Timing Chart Updates Progress of Tooling/Fixtures/Gages Lessons Learned Design Issues RPN Reduction 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 Plan Identify build issues/concerns

Gate Review Delivery

Global APQP for SQEs

Gate Review Delivery

5. Timing Charts / Open Issues

Key points
Supplier timing chart match GM master timing requirement / MRD requirement Supplier shall understand the logic consequence for each activity and milestone

Supplier timing shall have high confidence of timing achievability

Supplier shall identify potential risk by this report card, and usage of escalation process Use updated Open issue list as meeting minutes and program management tool

APQP Timing Chart

APQP Timing Chart

Proactive Conformance to AIAG APQP Requirements and GM Global APQP Tasks
Develop Detail Plans for Each Part / System
- Robust Part Designs - Robust Processes with Error-proofing ZERO DEFECTS Maintain Program Timing - Design Completion - Prototype Part Delivery - Accurate Sample Submissions and Part Delivery

APQP Timing Chart

Key Elements:
- Data/Sample comparison - ADVP&R - Engineering approval - Material substitution/approval - Tier supplier plan - New facility, M&E - Tooling building - Gage/fixture building - FOS - A-B-C Comparison (GS) - ETO - PPAP SPR & Submission - PTR - GP12 GP9 - Acceleration and pipeline/inventory build up plan

APQP Timing Chart

APQP Timing Chart breakdown Tooling list and timing chart M&E timing chart Sub-contractor timing chart People Hiring and Training planning Green/Brown field building planning ADVP&R

Open Issue List

6. QSB (Quality Systems Basics)

Supplier is requested to work in QSB implementation from the beginning of the program development (Gate Review # 1) Action plan for implementation to be updated on a regular basis according to the actions taken based on the plan dates
APQP QSB Task must be compliant by Gate Review # 4

7. Flow Chart
Provide a Logical Pictorial Representation of the Process Flow that can Purpose: be used as the Foundation for PFMEAs. Control Plans, Work Station Layouts, etc.

Review Process Flow Charts 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 SQE Responsibility: Ensure that the Flow Chart Includes Inspection and Rework

Supplier Responsibility:
Create Preliminary Process Flow Chart using a Similar 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 SQE

7. Flow Chart
Inspection

Rework
Scrap

Packaging
Shipping KCC

Example: Initial process flow chart

Nonconforming part shall be reintroduced into the process stream at or prior to the point of removal

9. Design Review
Key points Purpose: Ensure that the Design has been adequately Defined to Build Tools
and Gauges Ensure engineering data is the latest version

Ensure supplier get SOR and engineering spec. Ensure supplier understand the engineering data/spec and testing method Review KPC/PQC list and control method ADVP should be approved by GM BOM Material substitution and approval

Minimum validation requirement for salable PPAP

Example: KPC/PQC and corresponding control method

N O

KPC

Value

KCC

Control Method

VE:30607.5mm 1
Length

WM:31187.5mm

Extrusion: Cutting Aging: Temperature; time Finishing: End cutting

Extrusion: Automatic cutting Aging: PLC Finishing: 100% DIM check & SPC Mixing: Bar code Extrusion: PLC Aging: PLC control SPC

Compr ession Load

VE/WM: 10.75mm 8~14N

Mixing: Ingredient quantity Extrusion: Temperature; Line speed Aging: Temperature; time

Example: Supplier DV/PV plan and result

Verify suppliers lab (GP10 Process) and closely follow up the parts bench tests conducted by the supplier

Example: BOM

10. Tooling & Equipment Reviews

Purpose:
To conduct reviews of a Tooling and/or Equipment to ensure that the manufacturing process is: designed to the latest drawing change level built

certified
so as to produce: quality parts at rate according to GM program requirements

11. Gage Development and Approval

Purpose:
To design, build and certify gages according to latest GD&T release and per GM requirements. SQE approve gage per GM 1925 Fixture Standards, including:

Ensure that any part changes are incorporated into gages.

Evaluate Coordinate Measuring Machine (CMM) report to ensure gage accuracy.

Ensure gage instructions (ODS) are available at the manufacturing operation.

Verify integrity of gage for fit and function and GR&R (reference MSA AIAG). Verify that it is properly identified as GM property.

11. Gage Development and Approval

Supplier Responsibility:
Design, build, certify gage dimensionally (including a third party certification), perform complete AIAG MSA (GR&R and Bias study) and meet all requirements established by GM1925. A lean gage (pull ahead CMM holding fixture) should be available for first IVER build.

12. PFMEA
TOP 5 RPN Reduction Plan (Correct RPN value) !

ITS A LIVING DOCUMENT!

Top RPN Reduction Plan

13. Control Plan

Define the Method being used to Control all KPCs, PQC and KCCs for Parts being Manufactured for Vehicle Builds.

Prototype Control Plan

Pre-Launch (GP-12) Control Plan

Implementing from the first production part ship to GM assembly line

Production CP: shall be verified by Pre-launch PCP

Control Plan
Key points
SQE shall define PCPA schedule and frequency based on the risk priority of part and process (Based on risk assessment) Supplier and SQE shall verify final inspection to ensure a robust inspection method

Its a living document to address any change in product/process and reflect updated control for quality issue

14. GP-12
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
Prototype Pre-Launch (GP-12)

Production: shall be validated by Pre-launch PCP

GP-12
GP12 Audit/Verification and take corrective action Layered Audits by supervisor/Manager Proactive Controlled Shipping Strategy and Execution A. Failure to execute GP-12 will result in Controlled Shipping Level 2 and other possible consequences. B. Shipment of non-conforming material will result in Controlled Shipping Level 2.

Duration of GP-12

GP-12 must be implemented for a period of time or quantity of parts as specified by the customer or until the Production Control Plan has been validated, whichever is longer. If time or quantity is not specified, GP-12 will remain in effect through acceleration or a minimum of 2 weeks, whichever is longer.

15. PPAP
Production Part Approval Process
Defines generic requirements for production and bulk materials

Indicates the suppliers understanding of the engineering design record and specifications requirements
Indicates the process can consistently meet the requirements at production rate

PPAP
Applicability

Applies to all internal and external supplier sites of production and service parts unless otherwise specified by the authorized customer representative

PPAP
Key points
Supplier Production Trial Run PPAP pre-production PPAP SPR PPAP is not one day job

Supplier Production Trial Run

- Supplier has to proof their process stability before PPAP production

- Walk through the manufacturing process to verify the PFD/PFMEA/Control Plan and error proofing
- Make sure KPC and KCC are clearly identified and communicated at the shop floor - Make sure operators are properly trained - Review error proofing application in the process - Verify the results of the production trial run to determine any actions required before going to next step - Verify GM engineering approval status and possible design change status

Significant Production Run For production parts, product for PPAP shall be taken

from a significant production run:

From 1 to 8 hours of production

To total a minimum of 300 consecutive parts

Produced at the production site, at the production rate, using production tooling, gages, operators, etc.

Each unique manufacturing process shall be represented

Bulk material samples shall be taken from steady state operation

Customer Notification The organization shall notify the authorized customer representative SQE of any planned changes to design, process, or site Upon notification and approval, and after change implementation, submission is required unless otherwise specified

PPAP Submission levels Level 1 - Warrant only Level 2 - Warrant with product samples Level 3 - Warrant, product samples and data (considered the default level)

Level 4 - Warrant and customer requirements

Level 5 - Warrant, product samples and data for review at suppliers location All required information shall be available or included in the submission (levels 2-4) regardless of submission level!

16. Run @ Rate GP9

Verifies capability Must meet: QTC on contract Five working days per week Required for all new parts 1 Day production at supplier site = 1 Day usage in GM

Run @ Rate GP9

Key points
Begin from program Kick-Off (Initial GP-9) Need to verify from time to time
- Tooling/M&E review
- FOS - PPAP SPR - After Salable PPAP (According to Hours per day)

No later than 8 weeks prior to SORP

Run @ Rate Approval Decisions

Pass (FULL PPAP) Pending PPAP Fail

17. Lessons Learned

Key points
SQE shall review Lessons learned from the every beginning of a program SQE shall ensure countermeasure in place to prevent repeating same problem (Error-proofing, 100% inspection, SPC) SQE shall share Lessons Learned of similar part/process with supplier

SQE shall drive supplier to implement Lessons Learned as a systematic tool for continuous improvement

Example: Design Lessons learned and best practice to achieve robust design

Driving GM to be the BEST!!!

Thank You

Global APQP for SQEs