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Before RFQ-package is sent out - RFQ Kick-off meeting

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AIAG--Automotive Industry Action Group ... Supplier Program Reviews - PFMEA Strategy - Timing Charts / Open Issues - Control Plan ... – PowerPoint PPT presentation

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Title: Before RFQ-package is sent out - RFQ Kick-off meeting


1
Supplier Program Review Meeting 1
APQP Kick-off Meeting (Long Version)
GM1927-15
2
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
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 SQEs 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
  • General Motors Global APQP
  • GM-1927 is the General Motors
  • Common Global APQP Manual
  • GMs 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 GMs 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
(No Transcript)
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 completed properly and on time
    should 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 _at_ Rate (GP-9)
  • - Design Review - Lessons Learned

20
Global APQP
  • Manual Contents
  • Preface
  • Table of Contents
  • RASIC
  • Explanation of PMIs
  • (Process Model Integration)
  • PMIs for 17 Tasks / Deliverables
  • Appendices
  • Glossary

The 17 Tasks are the Key for Success!
21
Combination of the Best Processes
Primary
22
APQP Project Plan
  • APQP At a Glance
  • Shows the linkage of the 17 deliverables to
  • GMs 4 phase timing
  • GMs 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
APQP Project Plan
Start Here Task 4
Supplier Activities
25
Task 4) Supplier Program Reviews
Overview
Primary
26
Task 4) Supplier Program Reviews
  • Supplier Program Review 1 (PR1)
  • 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 (PR1)
  • 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 (PR1)
Who to Contact? GM1927-17 List the Key
Positions needed to Manage New Programs
29
4) Supplier Program Reviews
  • Supplier Program Review 1 (PR1)
  • 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
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 (PR1)
  • 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
4) Supplier Program Reviews
Lessons Learned
34
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 (PR2)
  • 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 GMs 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 -- (PR3)
  • 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 GMs 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
  • KPCs should have been identified through the
    KCDS Workshop process
  • GDT 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 GMs 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 GMs 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

51
4) Supplier Program Review 4
  • Specific Review Items
  • Items designated on the APQP Project Plan GM
    1927-1 with a 4 in Program Review column
  • All Quality documentation at this review is to be
    ready for PPAP submission
  • 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
  • Feasibility Letter 4- Supplier Manufacturing
    Assessment of Manufacturing Process Capability
    and Production Readiness
  • Flow Chart--Ready for PPAP submission

52
4) Supplier Program Review 4
  • Insert copy of Supplier manufacturing Assessment
    of Manufacturing Process Capability and
    Production Readinesss
  • GM 1927-19 letter 4

53
4) Supplier Program Review 4
  • Specific Review Items (continued)
  • All Quality documentation (continued)
  • DFMEA--completed if supplier is design
    responsible
  • Gage/Tooling Review
  • Gage RR should be reviewed and acceptable
  • Corrective Action plan reviewed if RR is
    unacceptable
  • Specific tooling timing at this point should be
    completed to schedule
  • Any tooling issue is a Launch Alert candidate

54
4) Supplier Program Review 4
  • Specific Review Items (continued)
  • All Quality documentation (continued)
  • PFMEA Strategy--review and verification of
    evidence that supports RPN reductions throughout
    the manufacturing process (see Lessons Learned)
  • Control Plan--review and verification of evidence
    that indicates error proofing techniques are in
    place and that all process operation are
    controlled
  • GP-12--review of the specific controls put in
    place to prevent defective parts from reaching
    the GM manufacturing site
  • This is the suppliers Pre-Launch Control Plan,
    reference GM 1920

55
4) Supplier Program Review 4
  • Specific Review Items (continued)
  • Run _at_ Rate--final details for the Run _at_ Rate
    should be confirmed, this includes those parts
    designated as Customer or Supplier Monitored
  • Confirm with the supplier the quantities required
    i.e. LCR and Contracted Tool Capacity
  • Lessons Learned -- ensure all lessons learned
    during the entire APQP process have been
    documented in the appropriate quality documents
  • DFMEA
  • PFMEA
  • Control Plans
  • This documentation is critical for future
    programs success

56
5) Timing Charts / Open Issues
Primary
57
6) Manufacturing Assessment Letters
Purpose Supplier Evaluates Manufacturability
of the Part
  • Manufacturing Assessments
  • Design -- can the Design be Manufactured to
    Conform to
  • all GM Performance Requirements?
  • Prototype -- using the Intended Production
    Process,
  • will all Parts Conform to GM
    Requirements?
  • Process Capability -- will the Production
    Process Provide
  • Parts that Conform to GM
    Requirements?
  • Supplier Responsibility
  • Evaluate Feasibility during 3 stages of program
    development
  • Submit Letters Signed by the Manufacturing Plant
    Manager

58
6) Manufacturing Assessment Letters
59
7) Flow Chart
Primary
60
8) Design Failure Mode and Effects Analysis
Primary
61
9) Design Reviews
Primary
62
10) Gage, Tooling Equipment Reviews
63
11) GP 11 Prototype
Primary
64
12) PFMEA Strategy
Primary
65
13) Control Plans
Primary
66
14) GP 12 Early Production Containment
  • Purpose
  • 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.
  • SQE Responsibility
  • Provide GP-12 Timing to the Supplier
  • Review the Suppliers Process and Pre-Launch
    Control Plan
  • Verify that any PRR, Prototype or Pilot Issues
    are in Control
  • Verify that the Supplier used PFMEA
    Statistical Data to Set Controls
  • Supplier Responsibility
  • Develop the Pre-Launch Control Plan Based on
    Experience from Prior Issues
  • Implement the Pre-Launch Control Plan
  • Monitor GP 12 Data and Modify Internal Process
    to Eliminate Issues
  • Monitor Customer Issues and PRRs, Update
    Control Plans

Primary
67
15) Production Part Approval Process
  • Purpose
  • Determine if All Customer Engineering Design
    Records Specifications
  • Requirements are properly understood by the
    Supplier and that the Process has
  • the Potential to Produce Product Meeting these
    Requirements during Production
  • at the Quoted Rate.
  • SQE Responsibility
  • Review PPAP Documentation Prior to Submission
  • - Verify Completion of all 19 Required Items
  • - Many Documents Can be Reviewed in Advance of
    PPAP Submission
  • Follow-up on PPAP Rejections
  • Supplier Responsibility
  • Produce Parts in the Production Environment
  • Complete all Documents and Test Requirements in
    Advance of PPAP Date
  • Target for Full PPAP on First Submission

Primary
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69
17) Lessons Learned
  • Purpose
  • Review Experience from Previous Programs and
    Consider Opportunities to
  • Improve Performance on New Programs.
  • SQE Responsibility
  • Acquire Information about Previous Experiences
    with Similar Commodities
  • - Other SQEs, Local or in Other Regions
  • - Product Engineers
  • Share Personal Knowledge and Experience
  • Verify that the Supplier Applies Lessons Learned
    in New Process
  • Supplier Responsibility
  • Share Lessons Learned from Similar Commodities
  • Evaluate Lessons Learned from External Sources
  • Incorporate All Applicable Items into Production
    Process and Tool Designs

Primary
70
Summary
  • Proactive Conformance to AIAG APQP Requirements
  • and GM APQP Tasks
  • Supplier Drives Tasks 4 through 17 to Completion
  • Identify Issues Early in Program and Drive
    Correction
  • Maintain Communication with GM on Program Status
  • and Issues
  • -- Manufacturing Assessment Letters
  • -- Schedule Program Review 2,3,4 with the SQE
  • Expect these Same Requirements from Sub-Suppliers

Lets Get Going!!
Primary
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