1. Supplier Quality Base Requirements




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Supplier Quality Statement of Requirements


1.Supplier Quality Base Requirements:


  • (From General Terms and Conditions) Seller agrees to participate in Buyer’s supplier quality and development program(s) and to comply with all quality requirements and procedures specified by Buyer, as revised from time to time, including those applicable to Seller as set forth in Quality System Requirements QS-9000. In addition, Buyer shall have the right to enter Seller’s facility at reasonable times to inspect the facility, goods, materials and any property of Buyer covered by this contract. Buyer’s inspection of the goods, whether during manufacture, prior to delivery or within a reasonable time after delivery, shall not constitute acceptance of any work-in-process or finished goods.

  • All suppliers are expected to supply parts to General Motors with zero defects. Parts shall meet all engineering specifications and function with no abnormalities according to intent.

  • Funding is to be identified in the initial quote and subsequent quotes to reflect error occurrence detection (poka yoke, error proofing devices, etc) and defect outflow prevention to customers. Controls implemented at a later date are the financial responsibility of the supplier.

2.ISO/TS 16949 or QS-9000 - Quality System Requirements


  • All providers of a) production materials, b) production or service parts, or c) heat treating, plating, painting or other finishing services directly to General Motors must be certified to ISO/TS 16949 or QS-9000 and have a current certificate available demonstrating compliance to GM supplements. All suppliers should migrate to ISO/TS 16949 at the expiration of their current QS9000 certificate but before December 14, 2006..

  • Suppliers not certified to ISO/TS 16949 or QS-9000, or those suppliers constructing or purchasing facilities to manufacture the parts being quoted, must include an outline of their certification attainment plan with their quote for further consideration.

3.General Motors Procedures and Reference Documents


  • Suppliers are to adhere to the requirements contained in the following documents:




REGION / DIVISION

PROCEDURE

GMNA

GME

GMAP

LAAM

SPO

Advanced Product Quality Planning & Control Plan Reference Manual (AIAG)

X

X

X

X

X

Potential Failure Mode and Effects Analysis (FMEA) Reference Manual (AIAG)

X

X

X

X

X

Fundamental Statistical Process Control (SPC) Reference Manual (AIAG)

X

X

X

X

X

Measurement Systems Analysis (MSA) Reference Manual (AIAG)

X

X

X

X

X

Production Part Approval Process (PPAP) Manual (AIAG)

X

X

X

X

X

Key Characteristics Designation System (KCDS) GM-1805QN

X

X

X

X

X

ITEZ1401H – KCDS Manual for ITDC Application




OPEL










GP-5 Supplier Quality Processes and Measurements Procedure GM-1746

X

X

X

X

X

GP-8 Continuous Improvement Procedure. GM-1747

X

X

X

X

X

GP-9 Run @ Rate GM-1960

X

X

X

X

X

GP-10 Evaluation and Accreditation of Supplier Test Facilities GM-1796

X

X

X




X

GP-11 General Procedure for Pre-Prototype and Prototype Material GM-1820

X

SAAB

X

X

X

GM Opel GP11 Handbook




OPEL










GP-12 Early Production Containment GM-1920

X

X

X

X

X

Traceability Identifier Requirement TIR-15-300 GM-1731

X




X




X

Supplier Quality Weld Support Manual

X




X




X

Fixture Standards Requirement GM-1925

X

X

X

X

X

P.E.D. 114

X










X

Principles of Gage Provisions to Suppliers




OPEL










GM Global Supplier Quality Manual GM-1927

X

X

X

X

X

GP-4 Pre-Production /Pilot Material Shipping Procedure. GM-1407

X







X




ASQ&R Guideline for Project Start-up




OPEL










EMM1000/1001










X



Shipping and Delivery Performance Requirements – Ship Direct













X

Packaging and Labeling Requirements – AC Delco and Accessories













X

SQA Boundary Sample Guide

X












4.Quality Planning Requirements:


  • APQP: Suppliers must use an advanced product quality planning process that follows the GM APQP Project Plan (GM1927-1) that ensures production readiness with parts that meet 100% of the product’s specifications.

  • Operator Training: Training plan must address new operators and current operators performing new functions. Training status should be displayed in the area of the manufacturing process.

  • Error Proofing: Suppliers shall implement error-proofing strategies for the control of materials, processes and labeling for all products provided to GM. Supplier shall implement error proofing techniques to ensure that mistakes are detected and corrected before becoming a defect (i.e. make it impossible to produce defective items even if an error occurs). Implementation of error proofing is to be measured by “% Error Proofed.” % Error Proofed is the percent of total steps in the manufacturing process which have been adequately error proofed. The supplier must error proof to a level where it is not possible to ship defective products to GM.

  • Traceability: A Traceability scheme shall be developed in accordance with regional and divisional requirements. Traceability scheme may include manufacturing date code and lot control. Items to be traced shall be determined in during the APQP process.

  • Verification of Customer Used Features: Customer-used part features (examples: fit, form, function, mating surfaces, etc. ) shall be incorporated in the PFMEA, process control plan, layered audits, and error/mistake proofing. Additional items to be checked shall be defined during the APQP process. These features should be verified at a frequency of 100%.

  • Inspection Fixtures and Gages Requirements:

  • Supplier to assume the gage construction orientates the part in vehicle position unless Supplier Quality approves a deviation.

  • All customer monitored APQP parts shall have gage designs approved by the Supplier Quality Engineer or the appropriate customer gage approval group prior to the start of fixture construction (for your regional requirements, contact your supplier quality engineer). Gage designs shall incorporate approved GD&T datum schemes and gages/fixtures must be capable to dimensionally evaluate parts.

  • Supplier shall have hand apply fixtures for sub-datum KPC’s and openings where assembly plant or sequencer/subassembler will install something that impacts a final vehicle specification (e.g. trim plates, extension panel, grilles, glove box door, etc.).

  • Supplier shall have the ability to check a completed assembly. Sub-contractors shall also have the ability to check component parts. Any cubing or build fixture shall have the ability to demonstrate fit to adjoining parts and attachments.

  • Appropriate functional testing and final inspection to ensure product performs as designed under actual vehicle conditions.

  • Supplier shall ensure that fixtures are procured in a timely manner to meet major program benchmarks (i.e. first shots, GP-11 events, Functional evaluations, and PPAP.) Supplier shall, at a minimum, have a CMM (coordinate measurement machine) holding fixture available for the inspection of first parts off prototype and production tooling.

5.Quality Control Requirements


  • Layered Audits: A documented layered audit plan shall exist with a minimum frequency of once per shift. Non-conformities shall be addressed immediately and corrective action shall be documented. Audit plan shall include multiple levels of management. Site leadership shall verify compliance to the documented plan.

  • Containment: All non-conforming and suspect material must be controlled. Method must be clearly defined. Visual controls should be implemented. All non-conforming material must be segregated and identified. GP12 and shall be implemented during launch. Upon request of GM additional levels of proactive containment may be required. Should a problem occur, suppliers are required to implement effective and immediate spill containment and comply fully with GP-5 requirements and the controlled shipping that may result.

  • Quality Performance Metrics: Each Supplier’s Senior Management shall commit to maintain and continuously improve quality. GQTS (Global Quality Tracking System) monitors performance data for PPM, PRRs, Controlled Shipping Level I and II, Major Assembly Plant Disruptions, and QS-9000, ISO/TS16949 and ISO14001 Certifications. Suppliers shall monitor their quality performance, on-line, through GQTS.

  • Production Quality:

  • All suppliers are required to have effective manufacturing practices and procedures to ensure a continuous flow of defect free parts into GM production facilities.

  • Current Product Improvement Process (CPIP): Suppliers shall actively participate in the timely resolution of problems identified by GM’s CPIP. Suppliers shall provide appropriate corrective action documentation and project status updates as requested.

6.Advance Problem Solving Requirements:


  • Suppliers are required to demonstrate their capability to solve complex problems using advanced problem solving techniques such as the “Red X” system at GM.

7.Production Support Requirements:


  • On-Site support during pre-production and launch: Upon request of SQ or GM Plant, Supplier will provide on-site support during all pre-production build phases and production launch activities.

  • Supplier contacts for all shifts: Supplier shall designate a specific supplier representative that will support each of the GM Plant’s shifts. At a minimum the supplier designate should have the responsibility to:

  • Implement immediate countermeasure to contain discrepant parts and to confirm that defective parts are not shipped to GM Plant.

  • Approve GM Plant’s/SQE’s requests for rework and sort.

  • Coordinate and provide resources to rework and sort parts.

  • Provide sub-assemblies / components for required repair, related to quality issues.

  • Provide clear information regarding any defective parts in-route to GM Plant (how to identify defect, disposition guidelines).

  • Coordinate special delivery of certified OK parts.

  • Quality data: Supplier must provide quality-related data (e.g. historic inspection, first time quality, reject data) to GM upon request. This data may be required to determine trends and to root cause quality problems at the GM Manufacturing or Assembly Plant.

8.Tier 1 Responsibilities (including suppliers of complex systems/sub-assemblies)


  • The tier one supplier is responsible for implementing and adhering to AIAG and GM requirements (see section 3) for all components of the assembly including directed buy parts unless otherwise specified by the procuring division. GM may, at their discretion, assign an SQE to work with the tier one’s SQE for the purposes of learning, inputting, and concurring on component related issues.

9.Powertrain Suppliers:


  • Powertrain suppliers must adhere to the Supplier Quality Statement of Requirements Powertrain Addendum

10.Systems and Procedures Access


  • Suppliers shall have Internet access to effectively communicate with General Motors. GM Supplier Quality procedures and systems can be accessed through the GM SupplyPower web page (www.gmsupplypower.com).



  • Suppliers shall have access to the regional warranty reporting system as appropriate (e.g. GMNA -QWIK, GME – WARP)

  • Automotive Industry Action Group (AIAG) documents can be obtained by contacting AIAG at 01-248-358-3003. Documents can also be ordered at www.aiag.org. To obtain these documents in Europe, contact Carwin Ltd. at 44-1708-861333. In Brazil, contact IQA at 5511-5533-4545 or www.iqa.org.br. "

Supplier Quality Statement of Requirements

Powertrain Addendum


1. Requirements
For Key Product Characteristics (KPCs) and Product Quality Characteristics (PQCs).

Reference GM 1805 and AIAG PPAP Manual. clauses 1.2.2.9







6 Requirement















PPAP

On- going Production

CHARACTERISTIC








KPC

Special Characteristics / Extra Care

Cp & Pp ≥ 2.0

Cpk & Ppk ≥ 1.5


Cp & Pp ≥ 2.0
Cpk & Ppk ≥ 1.5


& Continuous

Improvement

PQC

Special

Characteristics /

Extra Care

Cp & Pp ≥ 2.0

Cpk & Ppk ≥ 1.5


Cp & Pp ≥ 2.0
Cpk & Ppk ≥ 1.5




Standard

Product

Characteristics



One Sample checked

Pp ≥ 1.33

Ppk ≥ 1.33

(For Control Plan

& Oper. Instruction

Characteristics being

Regularly Monitored)

If during Product / Process development you believe there will be difficulty meeting the above capability, you MUST immediately notify your Supplier Quality Engineer (SQE) and develop a plan to assure compliance and/or obtain formal written approval to deviate from the capability requirements.



2. Process Failure Mode and Effects Analysis (PFMEA)


  • As a general rule, RPNs should be 40 or below. Processes showing RPNs over 40 must obtain formal written approval from your GM SQE.

  • GM Powertrain PFMEA ranking charts (reference APQP manual GM1927-28) shall be used.


3. Cleanliness Requirements: Part and process cleanliness shall be considered during the development of the PFMEA. Appropriate actions shall be taken during the APQP process as driven by the PFMEA RPNs.
Revision History – March 3, 2005 Changes


Section Number

Section Description

Change

3

General Motors Procedures and Reference Documents


GM Global Advanced Product Quality Planning (APQP) Manual GM-1927 name revised to GM Global Supplier Quality Manual GM 1927

10

Systems and Procedures Access



Requirement to use Powerway.com to communicate/collaborate with GM on Advanced Product Quality Planning projects eliminated.




March 3, 2005 Page of GM1927-3


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