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MOTORS SUPPLIER DEVELOPMENT
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GENERAL PROCEDURE
RUN @ RATE GP-9
I.
PURPOSE
The purpose of a Run @ Rate is to verify:
A. the supplier's actual manufacturing process is capable of producing components that meet GM's on-going
quality requirements, as stated in the Production Part Approval Process (PPAP), at quoted tooling
capacity for a specified period of time; and
B. the supplier's actual manufacturing process conforms to the manufacturing and quality plan documented
by the supplier in PPAP, GP-12 and other required documentation.
During a Run @ Rate, all production tooling is to be in place and running at full capacity, utilizing all regular
production, direct and indirect, personnel and support systems.
II.
SCOPE
All new parts require a Run @ Rate, unless exempted by the supplier quality engineer and approved by the
Supplier Quality and Purchasing Directors of the procuring division.
III.
SELECTION PROCESS
All new part numbers will be evaluated by GM, taking into consideration factors such as the following:
history; new technology; irreversible tooling changes; and new supplier facilities. The need for the Run @
Rate will be confirmed by the Supplier Quality Engineer, and approved by the Supplier Quality and
Purchasing Director(s) of the procuring division. The supplier will be notified of the need to perform a
customer monitored or supplier monitored Run @ Rate as early in the Advanced Product Quality Planning
Process as possible. Note: See Section VIII for Additional Requirements for Supplier monitored Run @ Rate.
IV.
GENERAL INFORMATION
A. DURATION OF RUN @ RATE
The number of components to be produced during the Run @ Rate should be sufficient to demonstrate
manufacturing process capability and should be predetermined by the supplier and the procuring
division's Supplier Quality Engineer(s). Factors such as product complexity, shelf life, storage, cost and
single shift vs. multiple shift operations are taken into consideration in determining the length of the Run
@ Rate. The default length of the Run @ Rate is one day of the customer's daily production requirement
at full acceleration.
B. TIMING OF RUN @ RATE
The Run @ Rate should be performed after the supplier has attained an acceptable PPAP submission and
prior to start of production acceleration. Although encouraged to be performed as early as possible, a key
consideration in establishing the Run @ Rate date is the stability of the design. The exact date should be
predetermined by the procuring division and the supplier.
C. REQUIRED PARTICIPATION
1. Customer Monitored –
Customer - A representative from the procuring division is to be present for the entire Run @
Rate. No portion of the Run @ Rate is to be performed without representation of the procuring
division, without prior approval. The lead GM representative typically will be the Supplier
Quality Engineer, with participation of the Buyer and/or Release Engineer upon request.
Supplier - The lead supplier representative is to be the project manager or manager appointee.
2. Supplier Monitored –
The lead supplier representative is to be the project manager or manager appointee.
Note: Equipment and/or subcontractors may be asked to participate.
D. SUPPLIER PREPARATION FOR RUN @ RATE.
To make effective use of time, the supplier should conduct a practice Run @ Rate and/or production
simulations, as well as complete as much of the Run @ Rate Worksheet (Attachment B), before the
official Run @ Rate is conducted.
E. INVENTORY.
If parts are produced ahead of production schedules, the supplier will hold all parts produced until
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General Motors Corp.
Revised March 1995
GM-1960
Published by Worldwide Purchasing
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GENERAL PROCEDURE
authorized to ship. The supplier will ensure that sufficient production containers and packaging are
available to prevent part damage.
V.
RUN @ RATE REVIEW CONTENT
The Run @ Rate will verify that the results of the supplier's actual manufacturing process meet customer
requirements for on-going quality, as stated in PPAP, and quoted tooling capacity. Also, it will verify that the
supplier's actual process is to plan, as documented in PPAP, GP-12 and the other documentation listed below.
During the Run @ Rate, the following will be reviewed: documentation; the manufacturing process and
results; part quality requirements and results; sub-supplier requirements and Run @ Rate results; and
packaging.
A. DOCUMENTATION:At the time of the Run @ Rate, the following support documentation should be
available for review:
1. PPAP package including:
a) Process flow diagram
b) Process control plan, with reaction plan
c) DFMEA/PFMEA
d) Master part(s)
2. GP-12 (Pre-launch) control plan
3. Tool capacity information
4. Operator/inspection instructions
5. Prototype/pilot concerns (PR/R's)
6. Sub-contractor control/capacity data
7. Sub-contractor material schedules and transportation
8. Packaging/labeling plan
9. Acceleration plan.
Note: All documentation must be complete and correct.
B. MANUFACTURING PROCESS – ACTUAL TO PLAN
1. The product is being manufactured at the production site using the production tooling, gaging,
process, materials, operators, environment, and process settings.
2. The actual process flow agrees with the process flow diagram, as documented in PPAP.
3. Operator instructions/visual aids are available and adhered to at each work station.
4. All in-process documents, such as process control charts, are in place at the time of the Run @ Rate.
The documentation is utilized to drive a defined reaction plan and corrective action process.
5. Production boundary samples, when required, are available at required work stations.
6. Maintenance plans are in place; repair and maintenance parts are available; and there is planned
downtime for preventative maintenance.
Note: All of the preceding requirements must be met to pass the Run @ Rate.
C. MANUFACTURING CAPACITY RESULTS
The following will be verified while the process is running.
1. Net output from each operation can support quoted capacity.
2. During the Run @ Rate, the tooling must meet the quoted up time requirements (net vs. gross quoted
output). Any unexpected downtime must be documented and corrective action taken.
3. All line changeovers, if any, can be performed within the quoted tooling capacity requirements.
4. The net through-put of good pieces (scrap taken out, any allowable rework) meet daily quoted
capacity.
5. The acceleration plan is sufficient to meet requirements.
Note: All of the preceding five requirements must be met to pass the Run @ Rate.
D. PART QUALITY PLAN TO ACTUAL
1. All production checking fixtures must be complete, with acceptable measurement system studies (i.e.,
gage R and R) performed, and operator instructions/visual aids available.
2. All in process gaging and controls must be complete, functional and in place.
3. The process control plan (normal and GP-12) must agree with the actual process. Production part
checks and statistical monitoring must take place as outlined on the process control plan.
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General Motors Corp.
Revised March 1995
GM-1960
Published by Worldwide Purchasing
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4.
5.
GENERAL PROCEDURE
Potential failure modes, as identified in the PFMEA, are addressed through error-proofing or the
control plan.
The process control plan reaction plan as well as the supplier's corrective action process to ensure
containment and correction should be available for review.
Note: All of the preceding five requirements must be met to pass the Run @ Rate.
E. PART QUALITY RESULTS
1. All parts produced off production tooling during the Run @ Rate meet GM's requirements for
ongoing quality, as stated in PPAP.
2. The manufacturing process is in control.
3. The manufacturing process demonstrates the required capability.
4. The process control plan is sufficient to effectively meet the design record requirements (i.e., control
points, frequency of checks, etc.).
5. Nonconformances
Note: The total number of parts produced, the pieces rejected and the pieces reworked need to be
documented on the summary sheet.
a) The non-conformances yielded by the process were identified by the normal PPAP control plan.
If identified by the GP-12 Process Control Plan or an activity outside documented plans,
corrective action is required.
b) The PFMEA identified the potential failure modes. If not, the PFMEA needs to be updated and
corrective action put in place.
c) All rework and repairs effectively correct the nonconformance(s).
d) All prototype and pilot concerns, if any, have been corrected and validated.
Note: All of the preceding five requirements must be met to pass the Run @ Rate.
F.
SUBCONTRACTOR REQUIREMENTS
1. Subcontractor(s)' abilities to meet the customer's quality and capacity requirements must be
confirmed by the supplier prior to the Run @ Rate being conducted at the supplier's facility.
Verification of the subcontractor(s)' manufacturing processes should be accomplished through a Run
@ Rate or similar process conducted by the supplier.
2. Controls must be in place to isolate incoming material until it has been approved.
Note: The preceding requirements must be met to pass the Run @ Rate.
G. PACKAGING AND HANDLING
1. In process and final shipment packaging will be reviewed for preservation of part quality and ease of
use by supplier's operators loading and unloading parts. (Refer to GM 1738 for requirements.)
2. The supplier's method for in process and final shipping packaging and handling must effectively
eliminate the potential for process errors or mixed stock.
VI.
CORRECTIVE ACTIONS REQUIRED
A. Actual to Requirements. If the results of the actual manufacturing process do not meet customer
requirements for on-going quality and quoted tool capacity, corrective action must be taken to correct any
non-conformances.
B. Actual to Plan. If the manufacturing and quality plan do not agree with the actual process, changes must
be made to bring them into agreement.
C. Nonconformances. If nonconformances occurred during the Run @ Rate which were not identified
previously by the normal PPAP control plan, a corrective action plan needs to be put in place (i.e., error
proofing or a change in the control plan) and documented in the PFMEA and/or process flow diagram.
VII.
APPROVAL
Upon completion of the Run @ Rate, the worksheets must be reviewed for completeness and a decision made
whether or not to approve the review. The Run @ Rate can have one of three results: pass; open or fail.
A. Pass
1. Definition
Pass indicates that all Run @ Rate requirements were met. The supplier demonstrated the capability
to produce parts that meet GM's on-going quality requirements at quoted capacity (net output). All
key product characteristics were monitored and meet Cpk/Ppk requirements. GP-12 requirements
were met. The supplier's actual manufacturing process agreed with the manufacturing and quality
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General Motors Corp.
Revised March 1995
GM-1960
Published by Worldwide Purchasing
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GENERAL PROCEDURE
plan, as documented by the supplier in PPAP, GP-12 and other required documentation. Quality
systems were documented and practiced.
B. Open
1. Definition Open indicates that some minor non-conformances to the requirements were found that
need to be corrected. Examples of this are net output meets volume requirements but not quoted
capacity; quality systems have minor deficiencies (i.e., preventative maintenance system lacking, lack
of error proofing, incomplete or inadequate operator instructions/visual aids, operator training not
complete, minor deficiencies in meeting customer's ongoing quality requirements).
2. Corrective Action Required A documented Action Plan to correct the non-conformances is required.
At a minimum, it must include the name of the individual at the Supplier who is responsible for
implementing the Corrective Action and the timing and validation of the Corrective Action Plan. This
plan is due to the GM Run @ Rate Supplier Quality Engineer for approval, within two (2) business
days of the completion of the Run @ Rate.
3. Verification of Corrective Action GM verification of successful completion of the corrective action
plan can be accomplished in several different ways, for example, through correspondence, a part
review or a plant visit. Generally an additional Run @ Rate is not required. Once the Corrective
Action plan is successfully completed, the Supplier Quality Engineer will change the Run @ Rate
result from open to pass.
C. Fail
1. Definition Fail indicates a serious non-conformance exists that requires significant action by the
supplier to correct, such as quality systems are not in place and serious non-conformances exist; Ppk
values (Cpk values) do not meet requirements for KPC’s; or supplier fails to meet Volume
Requirements. An additional Run @ Rate will be required.
2. Corrective Action Required A documented Action Plan to correct the non-conformances is required.
At a minimum, it must include the name of the individual at the Supplier who is responsible for
implementing the Corrective Action and the timing and validation of the Corrective Action Plan. This
plan is due to the GM Run @ Rate Supplier Quality Engineer for approval, within two (2) business
days of the completion of the Run @ Rate.
3. Verification of Corrective Action. Once the Corrective Action plan is completed, the Supplier Quality
Engineer will schedule the new Run @ Rate to verify the successful implementation of the corrective
action plan.
VIII.
Supplier Monitored Run @ Rate Additional Requirements
A. All Run @ Rate requirements identified in Sections IV. V, VI and VII of this procedure apply to both
supplier monitored and customer monitored Run @ Rates.
Note: The scheduled date for the Run @ Rate must be approve by The Supplier Quality Engineer.
B. Since a customer representative will not be present during the Run @ Rate, the following must be
completed.
1. Within twenty-four hours of completing the scheduled Run @ Rate, the supplier must complete the
Run @ Rate Summary and Worksheets (Attachments A and B) and provide them to the responsible
customer Supplier Quality Engineer, with a recommendation for the result of the Run @ Rate.
2. In addition, if any non-conformances were identified, the supplier will develop and implement a
corrective action plan, using Sections VI and VII as reference. Within two days of completing the
scheduled Run @ Rate, the supplier will provide this information to the responsible customer
Supplier Quality Engineer.
3. Based on the information provided by the supplier, the customer Supplier Quality Engineer will:
a) Determine whether the Run @ Rate results in a pass, open or fail.
b) Review and approve the corrective action plan.
c) Determine the need for an additional Run @ Rate.
d) Communicate the results of the above review to the supplier.
4. If the result of the Run @ Rate is open or fail, the process described in Section VII applies.
Note: If the supplier monitored Run @ Rate results in a fail, another Run @ Rate must be scheduled with a customer
representative present
PRINTED IN U.S.A.
General Motors Corp.
Revised March 1995
GM-1960
Published by Worldwide Purchasing
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GENERAL PROCEDURE
GP-9 RUN @ RATE SUMMARY
ATTACHMENT A
Part Description_______________________________________
Supplier_____________________________________________
Part #_________________
Mfg. Location____________________________ Z-code_______
Drawing #______________
Supplier Quoted Production Rate _________/Hr _________/Day
Change Level___________
Customer______________________________________
Buyer_______________________________
Phone #
SQE________________________________
Phone #
Planned Usage: Daily____________ Weekly__________
Planned Run Date_____________________________________
GOAL (net good parts)
Planned Hours To Run__________________________________
___________________/Hour
Planned Shifts_______________ Planned Downtime__________
___________________/Shift
Reason for Planned Downtime: ___________________________
___________________/Day
RESULTS
Actual Hours______________ From _________ To__________
ACTUAL (net good parts)
Actual Shifts______________
___________________/Hour
Date ____________
Actual Downtime Hours _____________(planned & unplanned)
___________________/Shift
Explain: _______________________________________
___________________/Day
______________________________________________
______________________________________________
Total Produced _____________________ - Total Rejected ______________________ = Net _____________
Comments/Open Issues:
_________________________________________________________________________________________
_________________________________________________________________________________________
Supplier Run At Rate Recommendation:
PASS
OPEN
FAIL
Rerun Date________
Comments: _______________________________________________________________________________
_________________________________________________________________________________________
_________________________________________________________________________________________
__________________________
_________________
_______________
___________
Supplier Signature
Title
Phone
Date
For Customer Monitored Run At Rates
Run At Rate Summary:
PASS
OPEN
FAIL
Rerun Date_______
_________________________________________
__________________________
_______________
Authorized Customer Supplier Quality Signature
Title
Date
Attachment A to GM-1960
GM-1965 (2/95)
GENERAL
MOTORS SUPPLIER DEVELOPMENT
Page 6 of 10
GENERAL PROCEDURE
COMMENTS:
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RUN @ RATE GP-9 -- RUN @ RATE WORKSHEET
ATTACHMENT B
Supplier Name: _________________________________ Part Number(s):___________________________
RUN @ RATE REVIEW CONTENT
The Run @ Rate will verify that the results of the supplier’s actual manufacturing process meet customer requirements
for on-going quality, as stated in PPAP, and quoted tooling capacity. Also it will verify that the supplier's actual process is
to plan, as documented in PPAP, GP-12 and the other documentation listed below.
During the Run @ Rate, the following will be reviewed: documentation; the manufacturing process and results; part
quality requirements and results; sub-supplier requirements and Run @ Rate results and packaging.
A.
Documentation
At the time of the Run @ Rate, the following support documentation should be available for review:
Available Y/N
PPAP package including:
1.______
a) process flow diagram
a._____
b) process control plan, with reaction plan
b._____
c) DFMEA/PFMEA
c._____
d) Master part(s)
d._____
2.
GP-12 (Pre-launch Control) plan
2.______
3.
Tool capacity information
3.______
4.
Operator/inspection instructions
4.______
5.
Prototype/pilot concerns (PR/R's)
5.______
6.
Sub-contractor control/capacity data
6.______
7.
Sub-contractor material schedules and transportation
7.______
8.
Packaging/labeling plan
8.______
9.
Acceleration plan
9.______
Note: All documentation must be complete and correct.
MANUFACTURING PROCESS -- ACTUAL TO PLAN
1. Is the product being manufactured at the production site using the production tooling, gaging, process,
materials, operators, environment, and process settings? Yes _____No _____
Comments:_______________________________________________________________________________
1.
B.
2.
3.
4.
________________________________________________________________________________________
Does the actual process flow agree with the process flow diagram, as documented in PPAP? (Review the
facility plan and layout. Walk the process with the flow diagram.) Yes _____No _____
Comments:_______________________________________________________________________________
________________________________________________________________________________________
Are operator instructions/visual controls available and adhered to at each work station?
Yes _____ No _____ Comments:_____________________________________________________________
________________________________________________________________________________________
Is all in-process documentation, such as process control charts, in place at the time of the Run @ Rate? Is the
documentation utilized to drive a defined reaction plan and corrective action process?
Yes_____No_____Comments:_______________________________________________________________
5.
________________________________________________________________________________________
When required, are production boundary samples available at required work stations? Are the boundary
samples approved by GM? Yes _____No _____ Comments:_______________________________________
6.
________________________________________________________________________________________
Are maintenance plans in place? Are repair and maintenance parts available? Is there planned downtime for
preventative maintenance? Yes _____No _____ Comments: _______________________________________
________________________________________________________________________________________
Note: All of the preceding requirements must be met to pass the Run @ Rate.
Attachment B to GM-1960
GM-1965 (2/95)
GENERAL
MOTORS SUPPLIER DEVELOPMENT
Page 8 of 10
GENERAL PROCEDURE
RUN @ RATE GP-9 -- RUN @ RATE WORKSHEET
ATTACHMENT B
Supplier Name: __________________________________ Part Number(s): _________________________________
C.
MANUFACTURING CAPACITY RESULTS
The following will be verified while the process is running.
1. Can net output from each operation support quoted capacity? Yes _____ No _____
Comments:__________________________________________________________________________________
Operation
_________________________________________
_________________________________________
_________________________________________
_________________________________________
_________________________________________
_________________________________________
_________________________________________
_________________________________________
_________________________________________
2.
Quoted Capacity
____________________
____________________
____________________
____________________
____________________
____________________
____________________
____________________
____________________
Rate
_________________
_________________
_________________
_________________
_________________
_________________
_________________
_________________
_________________
During the Run @ Rate, did the tooling meet the quoted up time requirements (net vs. gross quoted output)?
Make note of any unexpected downtime and corrective action plans required. Yes _____ No _____
Comments: ______________________________________________________________________________
3.
________________________________________________________________________________________
Can all line changeovers, if any, be performed within the quoted tooling capacity requirements?
Yes _____ No _____ Comments: ____________________________________________________________
4.
________________________________________________________________________________________
Does the net through-put of good pieces (scrap taken out, any allowable rework) meet daily quoted capacity?
Yes _____ No _____ Comments: ____________________________________________________________
5.
________________________________________________________________________________________
Is the acceleration plan sufficient to meet requirements? Yes _____ No _____
Comments: ______________________________________________________________________________
________________________________________________________________________________________
Note: All of the preceding five requirements must be met to pass the Run @ Rate.
D.
PART QUALITY PLAN TO ACTUAL
1. Are all Production checking fixtures complete, with acceptable measurement system studies (i.e., gage R and
R) performed, and operator instructions/visual aids available? Yes _____ No _____
Comments: ______________________________________________________________________________
2.
3.
________________________________________________________________________________________
Are all in process gaging and controls complete, functional and in place? Yes _____ No _____
Comments: ______________________________________________________________________________
________________________________________________________________________________________
Do the process control plans (normal and GP-12) agree with the actual process? Do production part checks
and statistical monitoring take place as outlined on the process control plan?
Yes _____ No _____ Comments: ____________________________________________________________
________________________________________________________________________________________
1960
GENERAL
MOTORS SUPPLIER DEVELOPMENT
Page 9 of 10
GENERAL PROCEDURE
RUN @ RATE GP-9 -- RUN @ RATE WORKSHEET
ATTACHMENT B
Supplier Name: __________________________________ Part Number(s): _____________________________
D. PART QUALITY PLAN TO ACTUAL (CONTINUED)
4. Are potential failure modes, as identified in the PFMEA, addressed through error-proofing or the
control plan? Yes _____No _____ Comments: ______________________________________
____________________________________________________________________________
5. Do the process control plan reaction plan and the supplier's corrective actions ensure effective
containment and correction? Yes _____No _____ Comments:__________________________
____________________________________________________________________________
Note: All of the preceding five requirements must be met to pass the Run @ Rate.
E. PART QUALITY RESULTS:
Note: The total number of parts produced, the pieces rejected and the pieces reworked must be
documented on the summary sheet.
1. Do the parts produced off production tooling during the Run @ Rate meet GM's requirements for
on-going quality, as stated in PPAP? Yes _____No _____ Comments: _____________________
______________________________________________________________________________
2. Is the manufacturing process in control? Yes _____No _____ Comments: ___________________
______________________________________________________________________________
3. Does the manufacturing process demonstrate the required capability? Yes _____No _____
Comments: _____________________________________________________________________
_______________________________________________________________________________
4. Is the process control plan sufficient to effectively meet the design record requirements, i.e., control
points, frequency of checks, etc.? Yes _____No _____ Comments: _________________________
_______________________________________________________________________________
5. Nonconformances
a) Were the non-conformances yielded by the process identified by the normal PPAP control plan?
Yes _____ No _____ If identified by the GP-12 Process Control Plan or an activity outside
documented plans, corrective action is required.
b) Did the PFMEA identify the potential failure modes? Yes _____ No _____ If not, the PFMEA
needs to be updated and corrective action put in place.
c) Do all the observed rework and repairs effectively correct the nonconformance(s)?
Yes _____ No _____
d) Are there any open concerns from prototype or pilot (PR/R)? Yes _____ No _____
Comments: _________________________________________________________________
___________________________________________________________________________
Note: All of the preceding requirements must be met to pass the Run @ Rate.
Attachment B to GM-1960
GM-1965 (2/95)
GENERAL
SUPPLIER DEVELOPMENT
Page 10 of MOTORS
10
GENERAL PROCEDURE
RUN @ RATE GP-9 -- RUN @ RATE WORKSHEET
ATTACHMENT B
Supplier Name: _______________________________ Part Number(s): ____________________________
F. SUBCONTRACTOR REQUIREMENTS
1. Were subcontractors' abilities to meet the customer's quality and capacity requirements confirmed
by the supplier prior to the Run @ Rate being conducted at the supplier's facility? Was verification
of the subcontractors' manufacturing processes accomplished through a Run @ Rate or similar
process conducted by the supplier?
Yes _____No _____ Comments: ____________________________________________________
_______________________________________________________________________________
2. Are Controls in place to isolate incoming material until it has been approved?
Yes _____No _____ Comments: ____________________________________________________
_______________________________________________________________________________
Note: The two preceding requirements must be met to pass the Run @ Rate.
G. PACKAGING AND HANDLING
1. During the review of in process and final shipment packaging for preservation of part quality and
ease of use by supplier's operators loading and unloading parts, were any problems identified?
Yes _____No _____ Comments: ____________________________________________________
2.
_______________________________________________________________________________
Does the supplier's method for in process and final shipping packaging and handling effectively
eliminate the potential for process errors or mixed stock? Yes _____No _____
Comments: _____________________________________________________________________
_______________________________________________________________________________
COMMENTS:
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
Completed by: ______________________________ Phone: ____________________ Date: ____________
1960