1 / 70

Supplier Program Review Meeting #1

Advanced Product Quality Planning. Supplier Program Review Meeting #1. APQP Kick-off Meeting (Long Version). GM1927-15. GM. General Motors Corporation. Advanced Product Quality Planning. Worldwide Purchasing November 2000. Agenda. Background - APQP

sema
Download Presentation

Supplier Program Review Meeting #1

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. Advanced Product Quality Planning Supplier Program Review Meeting #1 APQP Kick-off Meeting (Long Version) GM1927-15

  2. GM General Motors Corporation Advanced Product Quality Planning Worldwide Purchasing November 2000 Agenda • Background • - APQP • - Global APQP Development • APQP Project Plan Overview • APQP Kick-off Meeting • - SQ Requirements • - Program Timing • - Review Checklists • - Identify Open Issues • Summary

  3. GM General Motors Corporation Advanced Product Quality Planning Worldwide Purchasing November 2000 Agenda • Background • - APQP • - Global APQP Development • Requirements from Suppliers • APQP Project Plan • - Supplier Responsible • Tasks 4 -- 17 • Summary Primary

  4. Background APQP • Definition • Advanced Product Quality Planning -- APQP • Structured method defines and establishes steps • necessary to ensure product meets customer requirements • Required for all new parts • Responsibility of the supplier • Purpose & Structure • Communicates the requirements necessary to develop a product quality plan • Top Management support by the supplier is key to the success of the any APQP process • Requires an environment of trust and cooperation between all parties

  5. Background APQP • Benefits • Directs resources • Early identification of required changes • Facilitates avoidance of late changes • Enables delivery of a quality product that meets program timing at required capacity

  6. Background AIAG Linkage to QS-9000 AIAG--Automotive Industry Action Group • Standardized reference manuals, procedures, reporting formats and technical nomenclature used by Ford, Chrysler and General Motors • AIAG APQP manual one of 7 manuals developed; completed June 1994 • Provides general guidelines for development of an advanced product quality plan QS-9000 • The Harmonization of Ford, Chrysler and General Motors individual Quality System requirements • Ford--Q-101 Quality System Standards • Chrysler--Supplier Quality Assurance Manual • GM--Targets For Excellence

  7. Background • QS- 9000 APQP Direction • Establishment of an Advanced Product Quality Plan • QS-9000 section 4.2.3.1 requires the establishment of an advanced product quality plan • AIAG APQP Manual is referenced as the document that should be used • Detail of specific deliverables was not clearly defined • Separate “unique” Regional & Divisional requirements developed

  8. Background Drivers of a Global Common APQP Process • Divisions and regions “Fine Tuned” the AIAG APQP process • Result was different direction for suppliers • different reporting formats for program updates • different timing charts for program events • varying levels of detail required at different times throughout the product development cycle • Additional variation occurred when SQE’s further “Fine Tuned the requirements and developed unique forms or timing charts etc.

  9. Background Drivers of a Global Common APQP Process • Global Suppliers and Global Vehicles compounds varying levels of direction • This resulted in regional variations on the APQP process requirements • APQP • APQP • APQP • APQP

  10. Global APQP Development GM General Motors Corporation Advanced Product Quality Planning Worldwide Purchasing November 2000 General Motors Global APQP • GM-1927 is the General Motors Common Global APQP Manual • GM’s common direction for the development and implementation of an APQP plan

  11. Global APQP Development Goals of this Common Global Process • Identify the critical items • Eliminate unnecessary requirements • Support the the SQE and Supplier in performing the day-to-day APQP activities • Eliminate the divisional & regional specific direction

  12. Global APQP Development • Participation by a Global Team: • GM North America --GM Europe • GM Asia Pacific --GM Latin America • Objective: - Define the minimum product quality planning requirements necessary to develop and implement an Advanced Product Quality Plan for a product or service

  13. Global APQP Development Common Global APQP Process for GM Worldwide • GM-1927 replaces all regional and divisional APQP reference manuals • GM-1927 harmonized and standardized the multiple regional and divisional APQP manuals • Aligns with the 5 phases within the AIAG APQP manual and provides the detail required to implement an APQP plan • Aligns with GM’s 4 phase program timing and deliverables

  14. Global APQP Development Benefits • Common APQP process for GM worldwide • All GM divisions and regions will use the same process • Common requirements • Eliminates the need to keep separate files for programs due to divisional or regional “unique” requirements • Common forms and charts • Interactive computer system (GQTS APQP module) • Facilitates timely communication of requirements and data • Eliminates manual data storage • Common direction and “One Voice” from all GM Supplier Quality Engineers regardless of region or division

  15. Global APQP Development 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

  16. Global APQP Development • Summary Points • Global APQP driven byQS 9000 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 will be Shared between Regions • - All Information Available on GMSupplyPower website at www.gmsupplypower.com • - GQTS APQP Module will Accelerate Global Communication Primary

  17. Requirements from Suppliers • 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 • Identify Issues Early in Program and Drive Correction • Document on APQP Open Issues List • Maintain Communication with GM on Program Status • and Issues-- Manufacturing Assessment Letters • Expect these Same Requirements from Sub-Suppliers Primary

  18. Global APQP • The APQP Project Plan GM 1927-1, consists of 17 major deliverables/requirements • These items if completedproperlyandon timeshould result in the development of a manufacturing system that is capable of meeting the GM Quality requirements at stated capacity and ship schedules.

  19. Global APQP APQP 17 Tasks / Deliverables - Key Stakeholders Meeting - Gage / Tooling / Equipment - Technical Review Review - Risk Assessment / Sourcing - GP-11 - Supplier Program Reviews - PFMEA Strategy - Timing Charts / Open Issues - Control Plan - Feasibility / Manufacturing Letters - GP-12 - Flow Chart - PPAP - DFMEA - Run @ Rate (GP-9) - Design Review - Lessons Learned

  20. Global APQP GM General Motors Corporation Advanced Product Quality Planning Worldwide Purchasing November 2000 Manual Contents • Preface • Table of Contents • RASIC • Explanation of PMI’s (Process Model Integration) • PMI’s for 17 Tasks / Deliverables • Appendices • Glossary The 17 Tasks are the Key for Success!

  21. Combination of the Best Processes WWP SUPPLIER QUALITY IMPROVEMENT PROCESS GLOBAL SOURCING IMPROVEMENT MEETING PROBLEM RESOLUTION QUALITY WORKSHOP LEVEL II CONTROLLED SHIPPING LEVEL I CONTROLLED SHIPPING SUPPLIER QUALITY PROCESSES & MEASURES (GP-5) PERFORMANCE MONITORING TIME LINE CONTINUOUS IMPROVEMENT (GP-8) EARLY PRODUCTION CONTAINMENT (GP-12) LIFE OF PART RUN @ RATE (GP-9) GM Global APQP PRODUCTION PART APPROVAL (PPAP) PROTOTYPE SAMPLE APPROVAL (GP-11) ADVANCE PLANNING & PREVENTION Experience PRE-PRODUCTION MEETING ADVANCED PRODUCT QUALITY PLANNING (APQP) SOURCING DECISION POTENTIAL SUPPLIER ASSESSMENT START OF PRODUCTION Primary

  22. APQP Project Plan APQP “At a Glance” • Shows the linkage of the 17 deliverables to: • GM’s 4 phase timing • GM’s 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 completeness for specific deliverables is clearly identified • The required completion of items is tied to the specific GM build event

  23. APQP Project Plan Primary

  24. Supplier Program Reviews APQP Project Plan Start Here Task 4 Supplier Activities

  25. Purpose: • Ensure Supplier’s Quality Plan is Progressing to Meet • GM Program Timing • Provide a Formal Process to Raise Issues for Resolution Four Major Program Reviews: TODAY • Pre-Production Meeting (APQP Kickoff) • Beta Prototype Build • Gamma Prototype Build • Pilot (Final PPAP Submission) Meeting Responsibility: • Pre-Production Meeting is Scheduled by SQE • Meetings 2, 3, 4 are Scheduled by Supplier Overview Task 4) Supplier Program Reviews Primary

  26. Task 4) Supplier Program Reviews Supplier Program Review #1(PR#1) • Conducted after the Sourcing decision: -- GM SQE coordinates and leads this first review -- Supplier responsibilities and deliverables are reviewed • Purpose: -- Ensure the GM Global APQP requirements and responsibilities are clearly communicated and understood -- Verify Program timing and deliverables associated with program timing

  27. Task 4) Supplier Program Reviews • Supplier Program Review #1(PR#1) • Purpose: (continued) • -- Communicate process that will be used to provide program updates for APQP deliverables • Supplier Program Reviews - 4 • Timing Chart GM 1927-1 • Program Tracking Chart GM 1927-2 • Feasibility & Manufacturing Assessment Letters - 4 GM 1927-19 • -- Confirm APQP program communication channels within and between supplier and GM • APQP Project Contact List GM 1927-17

  28. 4) Supplier Program Reviews Program Review #1(PR#1) Who to Contact? GM1927-17 List the Key Positions needed to Manage New Programs

  29. 4) Supplier Program Reviews Supplier Program Review #1(PR#1) • Review of Pre-Sourcing Quality Requirements • Review items listed in the “Required Quality Information” letter GM 1927-4 contained in the RFQ • Review the “Supplier Quality Statement of Requirements” (SOR) GM 1927-3 • Review page 5 with the appropriate company representative signature • Overview of the 17 APQP deliverables and explanation of each

  30. 4) Supplier Program Reviews Required Quality Information • (GM1927-4 is Included in all GM RFQs. • Supplier submits as part of Quote to GM, includes requested documents. • Review Supplier Quality Information provided and discuss exceptions. • Update APQP Open Issues List for exceptions.

  31. Signature of Supplier Representative 4) Supplier Program Reviews Supplier Quality SOR • 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.

  32. 4) Supplier Program Reviews Program Review #1(PR#1) • Define Program Timing Elements • -Major Program Benchmark Dates are provided by the SQE • - GM 1927-2 provides the Minimum list of activities that must be tracked by the supplier • Suppliers Complete the form and return it to the SQE • - Updates showing progress are forwarded to the SQE • - Detailed evaluations are conducted as part of future Program Reviews.

  33. Review Lessons Learned in GM SupplyPower website • - Obtain worksheet on major components • - Evaluate Lessons for application to new part • Discuss other Lessons Learned from similar parts • Objective of this activity is --- Avoid Repeat Issues 4) Supplier Program Reviews Lessons Learned

  34. Meeting Subjects Include: 4) Supplier Program Reviews Supplier Program Reviews 2,3,4 • 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 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 Task 6 Suppliers need to be prepared for each meeting with supporting documents SQEs will Review Documents at Meetings Primary

  35. 4) Supplier Program Reviews Timing Supplier Program Review #2 (PR#2) • Program Review #2 (PR2) conducted 2 weeks prior to the Beta Prototype Build Review • Supplier conducts the meeting and reports the status of the deliverables due for this review • Purpose--Supplier Program Review #2 • Ensure the suppliers manufacturing process is capable of meeting GM’s requirements for the Beta Prototype Build Review (applicable for suppliers providing parts for Beta) • Communicate issues that have been identified during the preparation for the Beta Build Review. • Verify program timing for remaining APQP deliverables

  36. 4) Supplier Program Review #2 Specific Review Items • Items designated on the APQP Project Plan GM 1927-1 with a 2 in Program Review column • Timing Chart GM 1927-2 • Verify timing is on track • Only require detail on items where timing has slipped • APQP Open Issues list GM 1927-5 • Feasibility Letter #2- Supplier Manufacturing Assessment of Design • Flow Chart-should be more detailed than the initial one due at the Technical Review • DFMEA - status if design responsible, availability of data if GM design responsible

  37. 4) Supplier Program Review #2 Specific Review Items-(continued) • Control Plan--review and verification of continued development since initial review during the APQP Kick-Off/Pre-Production meeting • The same logic that applied to the PFMEA applies here • If supplier currently produces a similar part, the Control Plan should be very detailed • If this is a new process for the supplier the level of detail will not be as complete • This build event and the Prototype events are where the supplier clearly identifies where error proofing techniques and audit type controls are necessary

  38. 4) Supplier Program Review #2 Specific Review Items -(continued) • PFMEA Strategy--review and verification of continued development since initial review during the APQP Kick-Off/Pre-Production meeting • If supplier currently produces a similar part, the PFMEA should be very detailed • If this is a new process for the supplier the level of detail will not be as complete • Detail of Recommended Actions may not be identified for all listed Potential Failure Modes • Recommended Actions may not be completed

  39. 4) Supplier Program Review #2 Specific Review Items -(continued) • Design Review-discussions should be around a KCDS workshop • GM design responsible-GM leads workshop • Supplier design responsible- Supplier leads the workshop or appropriate activity to identify the Key Product Characteristics • Gage, Tooling & Equipment Review • Gage Concept approval status • Specific tooling timing-ensure timing is meeting the plan for the program timing • GP-11--Discussions should take place between the supplier and the GM engineer on the plan to provide parts for the Prototype build • plan should include dimensional data requirements and the method of collection necessary i.e. , CMM holding fixture, what is the serialization process required etc.

  40. 4) Supplier Program Review #2 Specific Review Items-(continued) • Lessons Learned -- update of lessons learned identified during the process to date • Include design items and manufacturing items • Items should be tracked back to the DFMEA if supplier is design responsible • Track manufacturing items back to PFMEA

  41. 4) Supplier Program Review #2 • Insert a copy of GM 1927-10 and GM 1927--11 • these show overviews of how the Lessons Learned process was developed and should function

  42. 4) Supplier Program Review #2 • Insert copy of GM 1927-12--this is a copy of the ACTUAL Global Lessons Learned criteria check-sheet that was developed for Exterior Mirrors.

  43. 4) Supplier Program Review #3 Timing Supplier Program Review #3 -- (PR#3) • Program Review #3 (PR3) conducted 2 weeks prior to the Gamma Prototype Build Review • Supplier conducts the meeting and reports the status of the deliverables due for this review • Purpose--Supplier Program Review #3 • Ensure the suppliers manufacturing process is capable of meeting GM’s requirements for the Prototype review (applicable for suppliers providing parts for Prototype) • Communicate issues that have been identified during the preparation for the Gamma Prototype Build Review. • Verify program timing for remaining APQP deliverables

  44. 4) Supplier Program Review #3 Specific Review Items(continued) • Items designated on the APQP Project Plan GM 1927-1 with a 3 in Program Review column • Timing Chart GM 1927-2 • Verify timing is on track • Only require detail on items where timing has slipped • These items are candidates for a “Launch Alert” • APQP Open Issues list GM 1927-5 • What is the status of major items since the last review • Feasibility Letter #3- Supplier Manufacturing Assessment of Prototype • Signature required by manufacturing location plant management

  45. 4) Supplier Program Reviews • Insert a copy of “Supplier Manufacturing Assessment Of Prototype” GM 1927-19 letter 3

  46. 4) Supplier Program Review #3 Specific Review Items(continued) • Design Review • KPC’s should have been identified through the KCDS Workshop process • GD&T discussions should also be completed by the Prototype build event • Gage/Tooling Review • Gage Design approval status • Specific tooling timing • Require detail on any item where timing has slipped in relation to GM’s program timing

  47. 4) Supplier Program Review #3 Specific Review Items(continued) • GP-11--confirm the supplier has met the engineering requirements for Pre-Prototype and Prototype builds • This should include a review of the dimensional results and any quality issues identified during the Prototype build • Ensure the GM engineer is involved to approve any dimensional issues • PFMEA Strategy--review and verification of continued development • emphasis on items identified during any and Prototype manufacturing processes (see Lessons Learned)

  48. 4) Supplier Program Review #3 Specific Review Items(continued) • Control Plan--review and verification of continued development since Supplier Program Review #2 meeting • This should include all necessary controls and error proofing techniques identified during all early build events • Lessons Learned -- update of lessons learned that were identified during the Prototype build process • Include design items and manufacturing items • These items should be tracked back to the DFMEA if design responsible • Manufacturing items tracked back to PFMEA

  49. Risk Assessment • Risk Assessment is updated for the current status in program • Review of the overall risk associated with the program is updated by the SQE after Supplier Program Review #3 • This is reported to internal GM Program Management

  50. 4) Supplier Program Reviews Timing Supplier Program Review #4 (PR #4) • Program Review #4 (PR4) conducted 2 weeks prior the the Pilot Build Review • Supplier conducts the meeting and reports the status of the deliverables due for this review • Purpose Supplier Program Review #4 • “Dress Rehearsal” for PPAP • Ensure the suppliers manufacturing process is capable of meeting GM’s requirements for the Pilot build. • Manufacturing process and all support is to be representative of ALL Production systems and processes • Communicate issues that have been identified since the Prototype Build Review • Verify program timing for remaining APQP deliverables

More Related