GM APQP 手册.docx

GM APQP 手册.docx

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GMAPQP手册

GMAdvanceProductQualityPlanningManual

TableofContents

GMAdvanceProductQualityPlanning1

WorkInstructions2

ValveA3

GeneralRequirements3

DesignReview3

CommercialIssues4

PlantLayoutandProcessFlow4

DFMEA4

LessonsLearnedandWarranty5

GageandToolingEquipmentReview7

ValidationandADVP&R8

PFMEAandErrorProofing8

ProcessControlPlan8

DimensionalPlan9

Materials/DCSFileLogs10

DesignAppearanceQuality10

Containerization10

TieredSupplybase11

PPAP11

R@R12

GP-1212

QSB12

ValveB14

GeneralRequirements14

DesignReview14

CommercialIssues15

PlantLayoutandProcessFlow15

DFMEA15

LessonsLearnedandWarranty16

GageandToolingEquipmentReview16

ValidationandADVP&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

PFMEA&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.

∙EscalationDropDowns

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