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BasicsofSupplierQuality(21519)BasicsofSupplierQualityTrainingCopyright©GeneralMotorsCorporationWorldwidePurchasing,Warren,MI.AllRightsReserved.Nopartofthismaterialmaybereproducedinanyformoranymethod(electronic,photocopy,microfilm,etc..)foranypurpose,withoutthewrittenpermissionofGeneralMotorsWorldwidePurchasing.RevisedMarch,2004BasicsofSupplierQualityCTISNumber215192003SecondRevisionJune2003FirstrevisionApril2001byGeneralMotorsWorldWidePurchasingGeneralMotorsCorporationNorthAmericanVehicleOperationsGeneralMotorsTechnicalCenterWarren,MichiganUSAAllrightsreserved.NopartofthebookmaybereproducedinanyformorbyanymeanswithoutthepermissioninwritingfromtheGeneralMotorsCorporation.PrintedintheUnitedStatesofAmericaTableofContentsIntroductionsWhyAreWeHere?ImpactofSupplierQualityImpactofWorldwidePurchasingThe16-StepProcessAdditionalTrainingOpportunitiesQ&AAppendix1–HistoryofGM•Purpose:ToprovideabasicunderstandingofSupplierQualityprocesses,systemsandmeasurements•Attheendoftoday’straining,weshouldbeableto•RecognizeS.Q.processesandfunctions•Knowwheretogotogetadditionalinformation/trainingWhyAreWeHereToday?GlossaryAPQP,AdvancedProductQualityPlanningistheGMprocessusedfordesigningandlaunchingproducts.Availability,Thepercentageoftimeapieceofequipmentwilloperatewhenrequired.BathtubCurve,Agenericconceptualmodelillustratingthethreefailureratesofaproduct’slifecycle.Capability,Measurestheabilityofaprocesstoproduceapartstothespecification.ControlChart,isastatisticaltoolusetoseparateSpecial-CausevariationfromCommon-Causevariation.-Common-Cause,Causesthatareconsideredtobepartoftheprocess.-Special-Cause,Isacausethatisnotconsideredtobepartofthedesignorprocess.ThepresenceofSpecialCausesindicateanout-of-controlcondition.ControlPlan,Thedocumentusedbymanufacturingthatcontainstheoverallstrategyforquality.ItcontainstheKPC(KeyProductCharacteristics)andKCC(KeyControlCharacteristics).Cpk,Aprocesscapabilityindicatorthatcompares1)theprocessvariationandtheprocessaveragetothedesigntolerances.Note:CpkdoesnotalignwiththedefinitionsforKPC,KCCandtheRobustDesignInitiative!ControlledShipping(Level-I),isarequirementtosupplierstoimplementadoubleinspectionsystem,withacontainmentandproblemsolvingstrategy.GP-5ControlledShipping(Level-II),isarequirementtosupplierstoimplementatripleinspectionsystem,oneconductedbyathirdparty,withacontainmentandproblemsolvingstrategy.GP-5GlossaryDesignLife,Istheexpectedlifeofaproduct.Forexamplethedesignlifeofanautomobileisestimatedatsevenyearsoronehundredthousandmiles.FMEA,FailureModesandEffectsAnalysisisariskassessmentandriskmanagementtoolforintroducingnewdesigns/processesanddesign/processchanges.DFMEA,PFMEAGP,GeneralProceduresGP-5,istheGMstandardprocedureforSupplierQualityandMeasurementGP-9,istheGMstandardprocedureassessingthesupplier’scapacity.A.k.a.Run@RateGP-11,istheGMstandardprocedureforvalidatingpre-prototypesandprototypes.GP-12,istheGMstandardprocedureforEarlyProductionContainment.NBH,NewBusinessHoldstatusrestricttheplacementofadditionalcontractstosuppliers.PPAP,TheProductionPartApprovalProcessistheGMprocedureforqualifyingpartsforproduction.PR/R,ProblemReportingandResolutionisadocumentissuedtosupplieridentifyingaproblemandreportingresolutionoftheproblem.PSA,PotentialSupplierAssessmentQuality,ProducingONTARGETwithMINIMUMVARIATION.ImpactofSupplierQualityFor2004,TheIndustryImproved11%167154147133133119100110120130140150160170180199920002001200220032004PP1008%5%10%0%•Competitionallgettingtougher•EveryoneisfocusedonIndustryLeadership11%2003J.D.PowerIQS-ChinaBuickSail-EnginePP100EnginePP100:83.334.811.811.09.27.03.12.81.01.01.00.60.05.010.015.020.025.030.035.040.0ExcessiveFuelConsumptionIdlesTooRough/FastEngineLacksPowerOtherEngineProblemsStumbles/Hesitates/DiesCheckEngineLightComesOnOilLeaksHardtoStartWon'tStartatAllComputerPCMExcessiveOilConsumptionGMPOWERTRAIN2003J.D.PowerIQS-ChinaBuickRegal-EnginePP100EnginePP100:47.232.64.22.82.02.02.01.00.60.00.00.00.00.00.00.00.05.010.015.020.025.030.035.0ExcessiveFuelConsumptionEngineLacksPowerOtherEngineProblemsStumbles/Hesitates/DiesUnusualEngineNoisesEmissionsComputerPCMExcessiveOilConsumptionCheckEngineLightComesOnOilLeaksHardtoStartWon'tStartatAllIdlesTooRough/FastExhaustSystemproblemsOtherGMPOWERTRAIN2003J.D.PowerIQS-ChinaBuickGL8-EnginePP100EnginePP100:21.812.84.71.51.51.30.00.00.00.00.00.00.02.04.06.08.010.012.014.0ExcessiveFuelConsumptionExcessiveOilConsumptionCheckEngineLightComesOnIdlesTooRough/FastOtherEngineProblemsUnusualEngineNoisesEngineLacksPowerOtherHardtoStartOilLeaksWon'tStartatAllGMPOWERTRAINWeHaveMuchtobeProudOf!•Solid10%improvementduringsignificantlaunchyear•Twosegmentawards•Toptwoplantsforthreeconsecutiveyears–Sevenoftop15assemblyplants•LansingGrandRiver#3intheworld–Hamtramckalsointop10globally•CadillacclosedthegaptoLexus•CadillaccarsoutperformedLexuscars•Improvedlaunchperformance•TiedwithToyotawith14modelsintopthree•Allbrandsimproved•Threeoftop10modelsinindustry–Century,CTS,XLR•16plantswithdouble-digitimprovements–Sevenimprovedmorethan20%AlsoSomeDisappointmentsand