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General Motors Corporation GM Global APQP Advanced Product Quality Planning Worldwide Purchasing October 2002 Revision 2 October 2002 GM 1927

Preface

This Reference Manual represents the collaborative efforts of a GM worldwide team engaged to develop a GM Common APQP process. Prior to this, each General Motors Supplier Quality

organization facilitated the implementation of the APQP process using divisional and regional specific methodologies.

The global team harmonized and standardized the various divisional and regional APQP processes and developed this GM APQP Manual (GM1927). This manual defines GM’s common global product quality planning requirements that are necessary to develop and implement an APQP process for a product or service. It is intended as a standard to provide the Supplier Quality Engineer, and the supplier, a common format from which to proceed with all steps of APQP.

This document is the second revision to the initial release and has been updated to reflect the most recent requirements set by General Motors for all Global Suppliers. As part of this update, a Revision History section has been added to provide a brief description of the October 2002 changes.

Approvals for this revision are as follows:

M. Wolf M. Moretti Worldwide Purchasing Latin American Operations Supplier Quality Supplier Quality

T.Nejman M. Aldea Powertrain Asian Pacific Operations Supplier Quality Supplier Quality

W. Kraatz M. Sch?enleber North American Vehicle Operations European Operations Supplier Quality Supplier Quality

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Table of Contents

Preface…………………………………………………………………………..I Table of Contents …………………………………………..………..….……..II Manual Content Explanation …………………………………..………..…....IV Customer Monitored/Supplier Monitored Matrix ………………...……….…..V APQP Process Model Flow ……………………………………………….…..VI Revision History……………………………………………………………...VII

APQP Task Definitions

Task 1: Commodity Sourcing Strategy Meeting …………………….………........1 Task 2: Technical Reviews ……………… ……………………………….……...3 Task 3: Risk Assessment & Sourcing…………………………………………….5 Task 4: Supplier Program Reviews …………………………………….………...7 Task 5: Timing Charts/Open Issues …………………………………………….12 Task 6: Feasibility & Manufacturing Assessment Letters ……………………...13 Task 7: Flow Chart ……………………………………………………….……..15 Task 8: DFMEA ………………………………………………………………...16 Task 9: Design Reviews ………………………………………………………..18 Task 10: Gage, Tool & Equipment Reviews ...…………………………………20 Task 11: GP-11 Pre-prototype & Prototype Material...……………………..…..23 Task 12: PFMEA Development………………………………………………....25 Task 13: Control Plan …………………………………………………………..27 Task 14: GP-12 Early Production Containment …………………………….....29 Task 15: PPAP ……………………………………………………………….....31 Task 16: Run @ Rate (GP-9) …………………………………………………..33 Task 17: Lessons Learned ………………………………………………….......36

Appendices

Appendix 1—Document Usage Guidelines by Global Region…………..…..38

GM 1927-1 GM 1927-2 GM 1927-3 GM 1927-4 GM 1927-5 GM 1927-6 GM 1927-7 GM 1927-10 GM 1927-12 GM 1927-13 APQP Project Plan APQP Timing Chart

Supplier Quality Statement of Requirements (SOR) Required Quality Information Letter APQP Open Issues Form

Commodity Sourcing Strategy Meeting Checklist WWP APQP Assessment

Lessons Learned Process Overview Lessons Learned Criteria Checklist Technical Review Checklist

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October 2002 GM 1927