GM APQP 手册Word文档格式.docx
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ProcessControlPlan8
DimensionalPlan9
Materials/DCSFileLogs10
DesignAppearanceQuality10
Containerization10
TieredSupplybase11
PPAP11
R@R12
GP-1212
QSB12
ValveB14
GeneralRequirements14
DesignReview14
CommercialIssues15
PlantLayoutandProcessFlow15
DFMEA15
LessonsLearnedandWarranty16
GageandToolingEquipmentReview16
R16
PFMEAandErrorProofing17
ProcessControlPlan17
DimensionalPlan17
Materials/DCSFileLogs17
DesignAppearanceRequirements18
Containerization18
TieredSupply-Base18
PPAP19
R@R19
GP-1219
QSB19
PPAP21
GeneralRequirements21
Commercial/OpenIssues21
PFMEA&
ErrorProofing21
DesignAppearanceRequirements21
TieredSupply-Base22
R@R22
GP-1222
R@R23
GeneralRequirements23
DesignReviews,Math,andGD&
T23
ErrorProofing23
TieredSupply-Base23
GP-1223
Appendices24
AppendixA-APQPGeneralTiming25
AppendixB–AssessmentRasic26
AppendixC–GlobalAPQPRASIC27
AppendixD–RequiredDocuments,References,&
Resources28
DesignReview28
CommercialIssues28
PlantLayoutandProcessFlow28
DFMEA28
GMSQE28
LessonLearnedandWarranty28
GageandToolingEquipmentReview28
ValidationandADVP&
R28
PFMEAandErrorProofing28
ProcessControlPlan28
DimensionalPlan28
Material&
DCSLogs29
GMDE&
MaterialsEng.29
Appearance/Grain/Cloth29
Containerization29
TieredSupplybase29
PPAP29
R@R29
GP1229
QSB29
AppendixE–Glossary30
GMAdvanceProductQualityPlanning
GM’svisionistoDesign,Build,andSelltheWorld’sBestVehicles,inordertodothatwemusthavearobustplan.Thatplanmustincludegreatdesigns,greatmanufacturingprocessesandgreatqualitysystems.Wehavelearnedthatthecriticalcomponentstoasuccessfulqualitysystemarecommunicationandstandardizedwork.ThepurposeofthismanualistocommunicateGM’sexpectationsandprovidestandardizedworkduringtheproductdevelopmentcycle.
ThismanualisintendedasasupplementtotheAIAGAdvanceProductQualityManual,whichprovidestheframeworkanddetailforgoodadvancequalityplanning.ThemanualisdesignedtohelpGMpersonnelandsuppliersunderstandtheexpectationsspecificallyrelatedtoGMlaunches.
InordertohelpsupportGM’svision,theplanningprocesshasbeensplitintofourreviews,ValveA,ValveB,PPAPandR@R.Inthefollowingsectionstherearefourproceduresdefining‘who,what,andwhen’foreachofthereview.Eachprocedureincludesstandardizedworkshowingtherequirements,escalationoptions,referencedocuments,andmethodologybehindeachtask.
WorkInstructions
ThefollowingaretheworkinstructionsforthetaskrequiringastatusofRed,Yellow,orGreen.TheyareintendedtoshowtheSQEandSupplierwhatthe‘ideal’stateforeachtaskis.Theultimategoalistoreachthe‘ideal’stateforeachtaskinordertosupportprogramtimingfordeliveringaqualitypartbytherequiredPPAPdate.Deviationsfromthe‘ideal’statearelistedintheworkinstructions.TheappropriatecategoryshallbeselectedandloadedintoGQTSbythesupplierregardlessifthepart(s)arestatusedasSupplierorCustomerMonitored.Iftheparts(s)arestatusedasCustomer-Monitored,theSQEwillapprovethesupplier’ssubmission.Aworksheet(GM1927-34)hasbeenprovidedfortheSQEandsuppliertouseasasummarysheet.Also,includedintheworkinstructionsareResourcesandReferences,regionaldocumentationrequirements,andsuggestedmethodologiestohelptheteamachievetherequiredcontent.
ValveA
GeneralRequirements
Timing:
∙ValveAistargetedtobecompletedthree(3)weekspriortoToolKick-Off(TKO).TKOiscommodityspecificandisbasedontheofficialprogramtimingtemplategeneratedthroughtheProgramTimingOffice.
∙TheindividualtasksshallbecadencedappropriatelyfromsourcingtotheValveAevent.SeeAppendixAforrecommendedcadenceofevents.
Ownership:
∙Allevents(ValveA,ValveB,PPAPandR@R)shallbecoordinatedbythesupplierwithinputfromSQE.
∙ValveAshallbeattendedataminimumby:
oSupplier:
ProgramManagement,Quality,Manufacturing,andEngineering
oGM:
SQE,DesignReleaseEngineer,andPurchasing
oOptionalattendees:
DimensionalEngineering,GD&
Tgroup,andAppearanceEngineer
Deliverables:
∙Asupplierkick-offmeetingshallbeconductedatawardofthebusiness.TheGM1927-14shouldbeusedasreferenceandbestpracticeforthemeetingagendaandcontentdiscussion.GMSQEshallcommunicateprogramtimingdeliverablesatthattime.Thesuppliershallmaintainacontactlistforeachprogramoverthelifeoftheprogram.Thelistshallincludeataminimum:
Name,Position,CellPhone,email,24-hourcontact,andescalationpriority(i.e.whoshouldbecalled1st,2nd,etc)forallnecessarysupplierpersonnel.
∙Eachprogramshallhaveoneopenissueslistthatincludesallprogramissues;
thiswouldinclude,butisnotlimitedto,allcommercial,design,engineering,qualityandmanufacturingissues.
∙APQPspecifictimingitemsshallbemaintainedononeoverallprogrammanagementtimelinewithadditionalprogramcriticalinformationsuchastimingfortooling,testingetc.
∙Red,Yellow,orGreenstatusshallbeidentifiedforeachitemlistedperAppendixAanddocumentedaccordingtoGM1927-34intheAPQPmodule.
DesignReview
∙Engineeringhasconfirmedthatmathdataisreleasedandisaccessibletosupplier.
∙Mathdataandrelatedfilesincludeallappropriatenotesonothernecessaryitemssuchasmaterials,testspecifications,softwarerequirements,etc.
∙ReleasedengineeringdatahasbeencomparedtotheSOR/SSTSandCTS;
alldiscrepancieshaveanadequateactionplanforresolution.
∙Suppliertoconfirmavailabilityofthemathdataandnotesandhasconfirmedfeasibilityforproduction.
∙KeyCharacteristicDesignationSystem(KCDS)meetingisscheduledorhasbeencompleted
∙SuppliertoreviewGD&
Tdocumentationforthefollowing:
oThedatumschemesareconsistentwithbothproductuseandprocessintent.
oPlansforgagedevelopmentareconsistentwiththedatumscheme.
oTolerancesareunderstoodandverifiedachievablebythesupplier.
oIncasesofnewtechnologyortightertolerancesthanhistoricallyachieved,anactionplanisneededtomonitortheprogressofcapabilityperformancethroughouttheprocessdevelopmentphase.
∙EscalationDropDowns
oG–AdequatemathdataandGD&
Treleased–Supplierhasconfirmedfeasibility
oY–Adequatedesigndatanotavailable–recoveryplaninplace
oY–Datumsortolerancesnotagreedto–recoveryplaninplace
oY–Feasibilitynotconfirmed–recoveryplaninplace
oY–KCDSnotcompletedbutscheduled
oR–Adequatedesigndatanotavailable–recoveryplannotinplace
oR–Datumsortolerancesnotagreedto–recoveryplannotinplace
oR–Feasibilitynotconfirmed–recoveryplannotinplace
CommercialIssues
∙SupplierreceivedpiecepriceandtoolingcontracttothelatestavailablelevelofMathData
∙SupplierhasreceivedtoolingPO
∙SQEtoverifythatsupplierhasnoadditionalcommercialissues,i.e.issueswithdirected-buysupplierspricing,etc.
oR–NotoolingPO
oR–Additionalcommercialissues
oY–Contractsneedtobeupdated
oG–Nocommercialissues
PlantLayoutandProcessFlow
∙PlantLayout
oSuppliertoprovidecurrentplantlayoutfortheentirefacilityincludingplannedareawherenewprogramwillbehoused,theshipping,receiving,inventory,suspect/scrapmaterialholdareas,etc.
oSuppliertoprovidedetailedviewofareawhereprogramwillbehoused,ifapplicableshouldincludecellconfiguration,in-process&
finishedgoodsinventoryarea,scraparea,etc.
oGMSQEshouldreviewlayouttomakesuretherearenoconcerns,i.e.overlappingreworkandfinishedgoodsstorage,ifthereareissuessupplierneedstoprovideaplantoaddress/control
∙ProcessFlow
oSuppliertoprovideadiagramforproductionandpre-productionprocessbothshouldincludeshipping,receiving,andrework,andshouldcoordinatewiththePFMEAandControlPlan;
preliminarydiagramshouldincludeGP-12
oProcessflowshouldincludeeveryoperationwithintheprocessofmakingthispartinaccordancewiththeAIAGAPQPandControlPlanManual
∙EscalationDropDown
oR–Supplierdoesnothaveaplan/spacetohousethenewprogram
oY–Supplierhastomoveexistingprogramstohousenewprogram
oG–Supplierhasnoissueswithhousingnewprogram
DFMEA
∙GeneralRequirements
oSupplierhasdoneallnecessarydesignanalysisforpartandtoolmanufacturability,i.e.moldflowanalysis,toolmaterialhardness,etc,fortheparticularcommodity
oSupplierhasappliedtheDFMEAtoallrelevantareas
oSupplier&
GMhavereviewedallwarrantyissuesandincorporatedallcorrectiveactionsintotheDFMEA
oSupplierhasevaluatedthedesigntodetermineifpotentialfailureswillbeaddressedviaprocesscontrolortheassemblyequipment
∙GM–DesignResponsible
oSupplierhasworkedwithGMDREtobuildDFMEA
oSupplierhasreviewedtheDFMEAcorrespondingtothecurrentdesignfromtheGMDRE
∙Supplier–DesignResponsible
oSupplierhasreviewedtheSOR/SSTSandCTSforalldesign,governmental,reliability,appearance,serviceability,and