GM Confidential

GM1927-11 APQP Kick Off and SRV Workbook

Revision 31Jan2016

SQE Name:
DRE Name:
SVE Name:
Buyer Name:
Additional Attendees:

Part Number(s) and Part Name:

Supplier Name:
Duns Number:
Supplier Contact:
Date:
Scorecard Element
Question
Order

Element

Open Issues and

Timing

Open Issues and

Timing

Open Issues and

Timing

Lessons Learned
Review

Lessons Learned
Review

Char
Question
Count Number

22

22

22

22

22

Question (50
Character limit)

Char
Count

Question Detail (300 Character limit)

Char
Count

Comments (500 Character limit)

Review: _______

Status
(R/G)

Char
Count

PT / APQP SRV 1 SRV 2 SRV 3

VEH Kickoff

Are there open issues

that impact Program
49
Timing?

1) Are there late or new issues that will impact Program Timing?
2) Does Supplier allow appropriate time for tuning loops or a
modification period?
3) Will open Work Orders affect program timing?
4) Are there issues with Directed Buy component timing?

251

PT /
VEH

Does Supplier have a

41
Program Timing plan?

1) Does Supplier have latest Appendix B or B1?

2) Does timing include all milestone events from Appendix B, along
with P.O. deadlines for all capital, tooling, and gages?
3) Does timing include Tiered Supplier PPAP and P.O. deadlines?
4) Are APQP deliverables and SRV reviews included in Timing?

295

PT /
VEH

List attendees and

42
location of SRV Review.

1) Please list contact info and functions of attendees (Supplier and GM)
for Valve Review.
2) Indicate location of review (On-site at Supplier, WebEx, GM facility,
281
etc.)
3) Turn this to Green status, unless there are issues getting support or
attendance from a particular function.

PT /
VEH

Are applicable SQ part

specific SORs
50
comprehended?

1) Have all applicable SQ SORs been selected and understood?

2) For each, does the supplier have a plan for 100 percent compliance
prior to PPAP approval?
287
3) Have new versions been published since sourcing? If so, has Supplier
identified any gaps to the new revision(s) for GM SQ review?

PT /
VEH

Are there GM Lessons

Learned that Supplier 49
needs?

1) GM SQ, DRE, and SVE to facilitate lessons learned to Supplier.

(Consider all sources for data including Suppliers internal Lessons
Learned, PRTS, warranty, PRR, past PV or DV test failures, and relevant
291
databases.)
2) Does Supplier have access to required GM systems listed in GM192703?

PT /
VEH

288

PT

Design Reviews

14

Has a Design Review

been completed with
Supplier?

49

1) Does PDT understand the critical nature of the interfaces with the
Customer application of their mating parts and reviewed specific
requirements (Legal, KPC, PQC, AQC, GDandT)?
2) Does PDT have any concerns regarding Design?
3) Do DRE, SQE, and Supplier agree to design responsibility?

PT

VEH
Q ID 62

Design Reviews

14

Has a Design Review

been completed with
Supplier?

49

1) When required, is Vehicle DTS available and does Design correlate?

2) Is Supplier in agreement with Design?
3) Verify Supplier understands GM requirements for dimensional data
submissions throughout program, e.g., Prototype, Matching, PPV, and
NS.

250

VEH

Design Reviews

14

Is Design feasible for

manufacturing?

37

1) In the case of new technology or tighter than historical tolerances, is

the Design feasible and capable for manufacturing?
2) Are there any new types of materials used that Supplier has no
287
experience with?
3) Does Supplier have plan to meet process capability for full PPAP
approval?

PT /
VEH

Validation Plan

15

Is ADV Plan approved

and testing on track?

42

1) Has the GM1829 ADV Plan been approved by the SVE (DRE for
Powertrain)?
2) For software, has the CG2999 ADV Plan been approved by SVE?
3) Are DV and PV testing on track per ADV plan(s)?
4) Does PV testing represent production intent parts off homeline?

254

PT /
VEH

46

1) Were Prototype parts used for Validation?

2) If yes, were Prototype parts within Design Specification?

106

PT /
VEH

PT /
VEH

PT

VEH
Q ID 68

PT, VEH
Q ID 63

Validation Plan

15

10

Are prototype parts

being used for
Validation?

Validation Plan

15

11

Does Gamma
represents production 48
intent tooling?

Powertrain: Were Gamma parts built off of production intent tooling and
process?
178
Vehicle: If required, will Matching parts be built off of production intent
tooling and process?

47

1) Is Barcode, 2D matrix, label identification for traceability, error

proofing in the Design record?
2) Did DRE complete CG2503 Bar Code Label Content Validation Form
by SOR sourcing or P2 Release and provide to Supplier?
3) Has Barcode or 2D Matrix been approved by the plant prior to Full
PPAP?

300

PT /
VEH

43

1) For APQP Kickoff, has ADV plan been started by Suppler?

2) Verify validation testing will meet Validation Test Complete (VTC) and 155
PPAP milestone timing.

PT /
VEH

Validation Plan

15

12

Is Part Marking
Validation required
(GMW15862)?

Validation Plan

15

13

Is Validation on track
to meet PPAP timing?

Validation Plan

15

14

Any changes since the

42
start of validation?

1) Has the PDT verified that no undocumented changes to materials,

processes, or Suppliers have occurred in the value stream which could
lead to an issue in production including a potential field action?
2) Were all solutions to DV and PV test failures captured in design or
process changes?

291

PT /
VEH

Is DFMEA complete
and reviewed with
Supplier?

45

1) Has DRE reviewed baseline DFMEA at the dimension or characteristic

level with Supplier?
2) Have all line items in the DFMEA pertaining to design attributes that 267
are process sensitive been identified?
3) Were the SOR requirements reviewed in developing the DFMEA?

PT /
VEH

34

1) If TKO or tool PO(s) have been delayed, is there a risk to downstream

timing or deliverables (VTC, PPAP, etc.)?
242
2) If TKO or Tool PO(s) have been delayed, is there an adequate
recovery or expediting plan to meet Tier 1 and GM requirements?

PT /
VEH

PT /
VEH

DFMEA

15

Commercial Issues 17

16

Are all Tool PO(s)

issued on time?

Commercial Issues 17

17

Are there any Directed

43
Buy contract issues?

1) Is there a signed directed buy letter?

2). Are there any Directed Buy contract issues?

Commercial Issues 17

18

Does Supplier need to

45
develop a new facility?

1) If yes, is there a plan to track facility readiness and report progress

to GM SQE? (Review Greenfield Development Assessment, GM 1927-31,
with Supplier for minimum requirements.)
298
2) Does Supplier have knowledge of any Tiered or Directed Buy
Suppliers requiring a new facility to support volumes?

PT /
VEH

Commercial Issues 17

19

Does Supplier have

any open Commercial 46
Issues?

1) Are there any new commercial issues not already covered in prior
questions?
180
2) If applicable, is part grouping necessary for any components related
to capacity planning and SDC?

PT /
VEH

14

20

Has intended Rust

Preventative (RP) been 50
approved?

1) Has the use of rust preventative been considered and documented

for metallic parts?
228
2) If required, is the intended RP on the GM approved source list (e.g.,
RP Coatings approved for Trans fluid or Engine Oil compatibility)?

PT /
VEH

Design Appearance
24
Review

21

Are Appearance
Requirements
understood?

39

1) Does Appearance Approval (e.g. GIF, TALC, AAR, FATG) timing meet
Program timing?
2) Will acceptance criteria be listed in all process documentation (e.g.
302
Control Plan, PFMEA) for PPAP approval?
3) Where required, have boundary samples been approved by the DRE
or Technical Expert (e.g. SQE, QE, DQ)?

PT /
VEH

Design Records

89

Dimensional Plan

16

22

Any rework to out of

42
tolerance dimensions?

1) For Powertrain, if rework at Beta or Gamma was performed has the

DRE initiated an EWO to correct the design?
2) Where rework is permitted, is the rework process documented in the 260
Process Flow Diagram, PFMEA, and Control Plan as a normal part of the
process?

PT /
VEH

10

Plant Layout and

Process Flow

29

23

Is the Mfg. Process

Flow and Plant Layout 50
updated?

1) Has Supplier provided an updated Manufacturing Process Flow

(Manufacturing Block diagram with all capacity assumptions)? Required
at APQP Kickoff.
297
2) Has Supplier provided an updated Plant Floor Layout for new
program? Confirm Capital Equipment timing (delivery and tryout) is on
track to plan.

PT /
VEH

11

Gage, Tooling, and

36
Equipment Reviews

24

Has the tooling and

gage breakdown been 49
reviewed?

Has Supplier identified and quoted all necessary gages, tooling, and
capital equipment for the program (e.g. reference RFQ and GM1810)?

135

PT /
VEH

11

Gage, Tooling, and

36
Equipment Reviews

25

1) Has tooling, gaging, and equipment Kick Off been completed and
verified to the latest EWO?
2) Did construction start according to planned timing?
3) Are there any delays that impact timing milestones?

205

PT /
VEH

Has Tool Kick Off been

completed by
46
Supplier?

VEH / PT
Q ID 64

11

Gage, Tooling, and

36
Equipment Reviews

26

Has the Gage Concept

35
been approved?

1) Verify that the initial Gage Concept review is complete, the Concept
meets Design requirements (GM 1925), and agreed upon revisions are
tracked on the Open Issues List.
2) Has the Gage Concept document been signed off?
3) Has Gage RandR been reviewed and approved?

267

PT /
VEH

VEH / PT
Q ID 65

11

Gage, Tooling, and

36
Equipment Reviews

27

Is tooling and
equipment running in
homeline?

45

1) Is production tooling and equipment complete, on site, and running

at the production location?
2) Is the production tooling on time to plan?
3) Have all cycle times been verified?
4) Have tool changeover times been verified?
5) Not required for Powertrain at SRV2.

268

PT /
VEH

28

Is PFMEA complete and

reviewed with
45
Supplier?

1) Has a Baseline Gap Analysis been conducted with a cross functional

team prior to TKO?
2) Have all requirements been comprehended?
3) Has priority been established using Risk Limiting Method or similar
technique? Does Supplier consistently adhere to AIAG Severity,
Occurrence, Detection chart?

295

PT /
VEH

PT

VEH
Q ID 66

PT, VEH
Q ID 67

12

PFMEA and Error

Proofing

12

PFMEA and Error

Proofing

24

29

Are Tier 2 passthrough features

accounted for?

47

1) Has Tier 1 verified if potential causes from DFMEA and PFMEA are
related to potential failure modes from a Tiered Supplier?
2) Are DFMEA and PFMEA Severities aligned between Tier 1 and Tier 2? 299
3) Does Control Plan inspection verify these features at an acceptable
frequency at Tier 1 or Tier 2?

PT /
VEH

12

PFMEA and Error

Proofing

24

30

Is DFMEA to PFMEA
Gap Analysis
complete?

40

For Severity 9s and 10s that do not have a Detection of 3, is there a

plan in place to target a Detection of 3 by SRV3 for all Gaps?

132

PT /
VEH

12

PFMEA and Error

Proofing

24

31

Are the DFMEA and

PFMEA aligned?

32

1) Have high risk items been reviewed (Severity 9s and 10s)?

2) Will alignment Gaps be closed by SRV3?
3) If applicable, have all critical characteristics been identified in
Process Flow, DFMEA, PFMEA, Process Control Plan, and Work
Instruction? Are applicable work stations identified as critical?

298

PT /
VEH

34

1) Has the Tier 1 submitted their GP-12 Plan for review and is it
approved by SQE (Control Plan, Timing Plan, Location, etc.)?
2) Not required for Powertrain at SRV2.

167

PT /
VEH

24

13

Process Control Plan 20

32

Has the GP-12 Plan

been submitted?

13

Process Control Plan 20

33

Is latest design record

37
comprehended?

1) Are the DFMEA, PFMEA and Control Plan up to date with the latest
design record?
2) Is every dimension and note in the latest design record
comprehended in the Control Plan and PFMEA?

185

PT /
VEH

14

Tiered Supply Base 18

34

Has Tier 1
communicated
requirements to all
Tiers?

50

1) Has source selection for Tiered Supply Base been completed?

2) Have the SOR-Subtier (1927-03) and all applicable part-specific SQ
SOR requirements been communicated to sub-tier suppliers?
3) Have EDI orders been sent to Directed Buys?

237

PT /
VEH

14

Tiered Supply Base 18

35

If applicable have CQI

requirements been
50
reviewed?

1) Do any components undergo Heat Treating CQI- 9, Plating CQI-11,

Welding CQI-15, Solder CQI-17, Coating CQI-12, Molding CQI-23, or
USCAR 21 (Wire Crimping)?
2) Will the Supplier or Sub-tier Supplier have a current approved CQI
audit or a planned assessment prior to PPAP submission for all parts?

298

PT /
VEH

1) Is the Staffing Plan and Training timed appropriately for program

launch?
2) Will Operators have sufficient experience running production line,
including flow of material through Value Stream, prior to SORP?
(Plan in place to ramp up Operator requirements throughout each
phase of the Launch.)

15

Operator Training
Plan

22

36

Does the Plan ramp up

operator
44
requirements?

297

PT /
VEH

15

Operator Training
Plan

22

37

Do other customer
launches affect
resources?

44

1) Does Supplier have Corporate Leadership support to implement

additional manpower or resources during other programs or OEM
[customer] launches that overlap this program?

172

PT /
VEH

16

PPAP

38

Have PPAP Forecast

dates been loaded in
SQMS?

45

Have PPAP Forecast dates (Non-Saleable, Saleable, if applicable, and

Approved PPAP) been loaded in SQMS and been re-verified that they
meet Program Timing?

156

PT /
VEH

16

PPAP

39

Will PPV represent

production?

30

1) Will PPV represent 100 percent production tooled parts?

2) Will PPV represent 100 percent production process?
298
3) Will part have at a minimum a Non-Saleable Status at PPV?
4) For items that do not meet 100 percent dimensional requirements, is
there a low-risk plan in place to meet requirements?

PT /
VEH

16

PPAP

40

Are there any issues

42
with IMDS submission?

1) Does Supplier know the GM Code and have access to upload IMDS?
2) Does Supplier have complete material information of every
component from all tiered suppliers?
3) Has IMDS been submitted for the finished part?

PT /
VEH

Page 1

12/05/2016

213

SRV Overall Results Summary

Function

Total
27
6
7
5
4
49

Supplier Quality
Engineering
Purchasing
Validation
Containerization
Total

Overall

0
0
0
0
0
0
0%

0
0
0
0
0
0
0%

*Note that Supplier is responsible for answering all questions.

Sources of input can come from different functions.

Criteria for Overall rating:

All elements statused as green -ORsome are not complete but they have a low risk plan in place that does no
impact program timing.
Not Complete with No Plan or a High Risk Plan -ORNot Complete and Plan is Late to Program Timing.

GM Confidential

12/05/2016

Page 2

ns.

w risk plan in place that does not

Plan -ORm Timing.

GM Confidential

G
R

12/05/2016

Page 3

Revision History
GM1927-11 APQP Kick Off and SRV Workbook

Date

Revision

10/21/2014
12/16/2014 Global Focus Group complete overhaul of questions and # of questions
6/24/2015 Global Focus Group complete enhancement of questions and # of questions
2/1/2016 Global Focus Group complete enhancement of questions and # of questions
14-Mar-16 Revised Containerization questions (41 & 42) - Removed SRV 1 requirement
14-Mar-16 Revised Design Review duplicate questions (6 & 7) - Applied one to PT and the other to Vech as
appropriate for Scorecard
7-Nov-16 Added GM Confidential footer to all tabs

History

ff and SRV Workbook

Reason for Revision

Date Approved by
Global Business
Process Team

10/21/2014, JV
12/16/2014
6/24/2015
1/31/2016
14-Mar-16
14-Mar-16
11/7/2016