GM-1927-APQP

October2002GM1927GeneralMotorsCorporationAdvancedProductQualityPlanningWorldwidePurchasingOctober2002Revision2GGMMGGlloobbaallAAPPQQPPOctober2002GM1927PrefaceThisReferenceManualrepresentsthecollaborativeeffortsofaGMworldwideteamengagedtodevelopaGMCommonAPQPprocess.Priortothis,eachGeneralMotorsSupplierQualityorganizationfacilitatedtheimplementationoftheAPQPprocessusingdivisionalandregionalspecificmethodologies.TheglobalteamharmonizedandstandardizedthevariousdivisionalandregionalAPQPprocessesanddevelopedthisGMAPQPManual(GM1927).ThismanualdefinesGM’scommonglobalproductqualityplanningrequirementsthatarenecessarytodevelopandimplementanAPQPprocessforaproductorservice.ItisintendedasastandardtoprovidetheSupplierQualityEngineer,andthesupplier,acommonformatfromwhichtoproceedwithallstepsofAPQP.ThisdocumentisthesecondrevisiontotheinitialreleaseandhasbeenupdatedtoreflectthemostrecentrequirementssetbyGeneralMotorsforallGlobalSuppliers.Aspartofthisupdate,aRevisionHistorysectionhasbeenaddedtoprovideabriefdescriptionoftheOctober2002changes.Approvalsforthisrevisionareasfollows:M.WolfM.MorettiWorldwidePurchasingLatinAmericanOperationsSupplierQualitySupplierQualityT.NejmanM.AldeaPowertrainAsianPacificOperationsSupplierQualitySupplierQualityW.KraatzM.SchöenleberNorthAmericanVehicleOperationsEuropeanOperationsSupplierQualitySupplierQualityIOctober2002GM1927TableofContentsPreface…………………………………………………………………………..ITableofContents…………………………………………..………..….……..IIManualContentExplanation…………………………………..………..…....IVCustomerMonitored/SupplierMonitoredMatrix………………...……….…..VAPQPProcessModelFlow……………………………………………….…..VIRevisionHistory……………………………………………………………...VIIAPQPTaskDefinitionsTask1:CommoditySourcingStrategyMeeting…………………….………........1Task2:TechnicalReviews……………………………………………….……...3Task3:RiskAssessment&Sourcing…………………………………………….5Task4:SupplierProgramReviews…………………………………….………...7Task5:TimingCharts/OpenIssues…………………………………………….12Task6:Feasibility&ManufacturingAssessmentLetters……………………...13Task7:FlowChart……………………………………………………….……..15Task8:DFMEA………………………………………………………………...16Task9:DesignReviews………………………………………………………..18Task10:Gage,Tool&EquipmentReviews...…………………………………20Task11:GP-11Pre-prototype&PrototypeMaterial...……………………..…..23Task12:PFMEADevelopment………………………………………………....25Task13:ControlPlan…………………………………………………………..27Task14:GP-12EarlyProductionContainment…………………………….....29Task15:PPAP……………………………………………………………….....31Task16:Run@Rate(GP-9)…………………………………………………..33Task17:LessonsLearned………………………………………………….......36AppendicesAppendix1—DocumentUsageGuidelinesbyGlobalRegion…………..…..38GM1927-1APQPProjectPlanGM1927-2APQPTimingChartGM1927-3SupplierQualityStatementofRequirements(SOR)GM1927-4RequiredQualityInformationLetterGM1927-5APQPOpenIssuesFormGM1927-6CommoditySourcingStrategyMeetingChecklistGM1927-7WWPAPQPAssessmentGM1927-10LessonsLearnedProcessOverviewGM1927-12LessonsLearnedCriteriaChecklistGM1927-13TechnicalReviewChecklistIIOctober2002GM1927Appendix1—GM1927Documents(continued)GM1927-14APQPKick-OffMeetingChecklistGM1927-15APQPKick-OffMeetingPresentationGM1927-16ProcessControlPlanAuditWorksheetGM1927-17GM&SupplierProgramContactListGM1927-18TypicalStakeholdersMeetingAgendaGM1927-19ManufacturingFeasibilityLettersGM1927-20ProcessCapabilityOverTimeGM1927-21RPNReductionSummaryChartMGM1927-22MProgramManagementRASICMGM1927-23MDirectedBuyChecklistMGM1927-24MSupplierProgramReviewsMGM1927-25MSubcontractorProgramStatusMatrixMGM1927-26MSubcontractorDetailedStatusMatrixGM1927-27FixtureDesignMatrixGM1927-28GlobalPowertrainPFMEARiskRankingFormNote:MindicatesdocumentsspecifictosuppliersofComplexSystems/Sub-assembliesAppendix2—ComplexSystems/Sub-assemblyAPQPManagement…………….40PlanAppendix3—GlossaryofTerms…………………………………………………..44IIIOctober2002GM1927ManualContentExplanationEachsectionisreferencedbyatasknumberandincludesthefollowing:TasknameTaskOwner(s)TaskTiming(approximate)TaskDescriptionDeliverablesuponcompletionofthespecifictaskCustomer(s)forthedeliverablesNecessaryInputstocompletethespecifictaskincludingsourceforeachinputListingofResources—thisincludespeopleoforganizationsinvolvedincompletingthetaskMethodology—briefdescriptionofthetaskandpurposeSQEResponsibilities—briefdescriptionofactionsrequiredSupplierResponsibilities—briefdescriptionofactionsrequiredReferencesandadditionalinformation.AppendicesTheAppendicescontainallGMspecificAPQPformsanddocumentsthataretobeusedthroughouttheimplementationoftheAPQPprocess.DirectionsforspecificapplicationofeachformordocumentareexplainedinAPQPTaskDefinitions1through17.DocumentProcurementGMGlobalAPQPAllspecificGMAPQPformsanddocumentsreferencedinthisGMGlobalAPQPmanual(GM1927)arecontainedinthisdocumentandcanbecopiedforuse.ThismanualandalldocumentscanalsobeobtainedthroughGM’sSupplyPowerat(GPs)AllGMGeneralProcedures(GPs)referencedcanbeobtainedbycontactingBoiseCascadeOfficeProductsat1-888-216-0371,Fax[phone].AIAGDocumentsAllAIAGspecificdocumentsreferencedcanbeobtainedbycontactingAIAGat01-2