Guardian Tier 2 PPAP Guidelines All submissions shall follow AIAG 4TH Edition PPAP Submission guidelines with some exceptions. Customer Specific RequirementsDependent upon end customer Table of contents: In AIAG format GMX-215-XLR Decklid Assembly P/N 10346850 1. Design Records 2. Engineering Change Documents 3. Customer Engineering Approval 4. Design FMEA 5. Process Flow Diagram 6. Process FMEA 7. Control Plan 8. Measurement System Analysis Studies 9. Dimensional Results 10. Material, Performance Test Results a) GM7400M, GM7459M-SMC material requirements b) GM3059-Restricted reportable substances c) 4497-Exterior paint performance d) 9523P-Paint conductivity e) 4350M-Painted part performance f) 9984804- Primer conductivity g) 3629M-Adhesive requirements h) 3653-FRP bonding requirements 11. Initial Process Study 12. Qualified Laboratory Results 13. Appearance Approval Report 14. Sample Product 15. Master Sample 16. Checking Aids 17. Records of Compliance (Customer Specific) 18. Part Submission Warrant Design records – Guardian approved print is required. Engineering Change Documents - Required Customer Engineering Approval- Not Required Design FMEA – Required- AIAG Current Edition Process Flow – Required –AIAG Current Edition Process FMEA – Required -–AIAG Current Edition Dimensional resultsA ‘ballooned’ print identifying points inspected must be provided. A CMM roadmap is acceptable for CMM checks. All Engineering Specifications on the print must be provided along with the test data verifying acceptability to the spec. Material certifications must be provided for ALL components including, base material, coatings, grease, wires, tape, etc. Certs must be from PPAP submitted material, current and dated. All IMDS/MSDS information is to be included and submitted to IMDS site 9949. Initial Process Study-A summary with supporting charts and documentation should be included MSA Results – Required – In AIAG Current Edition Qualified Laboratory Results-ISO/TS Certification Control Plan-Required PSW-Required-Must be filled out completely! Run @ Rate (GP-9) must have supporting documentation in – AIAG Current Edition RUN @ RATE GP-9 - RUN @ RATE WORKSHEET Supplier Name: SUPPLIER Part Number(s): NUMBER 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 documentation should be available for review: Available Y/N 1. a. b. c. d. 2. 3. 4. 5. 6. 7. 8. 9. 1. B. 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. 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: 2. 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: 3. Are operator instructions/visual controls available and adhere to at each work station? Yes 4. 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 5. No When required, are production boundary samples available at the required work stations? Are the boundary samples approved by GM? 6. Comments: Yes No Comments: Are maintenance plans in place? Are repair and maintenance parts available? Is there planned downtime for preventive maintenance? Yes No Comments: Note: All of the preceding requirements must be met to pass the Run @ Rate. RUN @ RATE GP-9 - RUN @ RATE WORKSHEET Supplier Name: SUPPLIER Part Number(s): NUMBER Appearance Approval Report-Required for ‘A’ surface parts Bulk Material Requirements – Where applicable Sample Product – Required – must be from PPAP submission trial runs and retained at the supplier location with PPAP documentation Master Sample – Required - Must be retained at Supplier Checking Aids – Required- IF you have any part specific gauges and must include gauge certification. Record of Compliance with CustomerSpecific Requirements - Team Feasibility – Required –AIAG Current Edition TEAM FEASIBILITY COMMITMENT Customer: GM Part Number: NUMBER Date: Part Name: NAME Feasibility Considerations Our product quality planning team has considered the following questions, not intended to be all-inclusive in performing a feasibility evaluation. The drawings and/or specifications provided have been used as a basis for analyzing the ability to meet all specified requirements. All "no" answers are supported with attached comments identifying our concerns and/or proposed changes to enable us to meet the specified requirements. YES NO CONSIDERATION Is product adequately defined (application requirements, etc. to enable feasibility evaluation? Can Engineering Performance Specifications be met as written? Can product be manufactured to tolerances specified on drawing? Can product be manufactured with Cpk's that meet requirements? Is there adequate capacity to produce product? Does the design allow the use of efficient material handling techniques? Can the product be manufactured without incurring any unusual: - Costs for capital equipment? - Costs for tooling? - Alternative manufacturing methods? Is statistical process control required on the product? Is statistical process control presently used on similar products? Where statistical process control is used on similar products: - Are the processes in control and stable? - Are Cpk's greater than 1.33? Conclusion Feasible Product can be produced as specified with no revisions. Feasible Changes recommended (see attached). Not Feasible Design revision required to produce product within the specified requirements. Sign-Off Team Member/Title/Date Team Member/Title/Date Team Member/Title/Date Team Member/Title/Date Team Member/Title/Date Team Member/Title/Date Must include all –AIAG Current Edition A1 through A8 forms A-1 DESIGN FMEA CHECKLIST Customer or Internal Part No. NUMBER Question Yes No Comment / Action Required 1 Was the SFMEA and/or DFMEA prepared using the DaimlerChrysler, Ford, and General Motors Potential Failure Mode and Effects Analysis (FMEA) reference manual? 2 Have historical campaign and warranty data been reviewed? 3 Have similar part DFMEAs been considered? 4 Does the SFMEA and/or DFMEA identify Special Characteristics? 5 Have design characteristics that affect high risk priority failure modes been identified? 6 Have appropriate corrective actions been assigned to high risk priority numbers? 7 Have appropriate corrective actions been assigned to high severity numbers? 8 Have risk priorities been revised when corrective actions have been completed and verified? Revision Date: Prepared By: Person Responsible Due Date A-2 DESIGN INFORMATION CHECKLIST Customer or Internal Part No. NUMBER Question A. General 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Does the design require: l New materials? / l Special tooling? / Has assembly build variation analysis been considered? Has Design of Experiments been considered? Is there a plan for prototypes in place? / Has a DFMEA been completed? / Has a DFMA been completed? Have service and maintenance issues been considered? Has the Design Verification Plan been considered? If yes, was it completed by a cross functional team? Are all specified tests, methods, equipment and acceptance criteria clearly defined and understood? Have Special Characteristics been selected? / Is bill of material complete? / Are Special Characteristics properly documented? B. Engineering Drawings Have dimensions that affect fit, function and durability been identified? Are reference dimensions identified to minimize inspection layout time? Are sufficient control points and datum surfaces identified to design functional gages? Are tolerances compatible with accepted manufacturing standards? Are there any requirements specified that cannot be evaluated using known inspection techniques? C. Engineering Performance Specifications 20 Have all special characteristics been identified? / 21 Is test loading sufficient to provide all conditions, i.e., production validation and end use? 22 Have parts manufactured at minimum and maximum specifications been tested? 23 Can additional samples be tested when a reaction plan requires it, and still conduct regularly scheduled in-process tests? 24 Will all product testing be done in-house? / 25 If not, is it done by an approved subcontractor? / 26 Is the specified test sampling size and/or frequency feasible? 27 If required, has customer approval been obtained for test equipment? Yes No Comment / Action Required Person Responsible Due Date A-3 NEW EQUIPMENT, TOOLING, AND TEST EQUIPMENT CHECKLIST Customer or Internal Part No. NUMBER Question 1 2 3 4 5 6 7 8 9 10 11 Yes No Comment / Action Required Does the design require: l New materials? / l Quick change? / l Volume fluctuations? / l Mistake proofing? / Have lists been prepared identifying: l New equipment? / l New tooling? / l New test equipment? / Has acceptance criteria been agreed upon for: l New equipment? / l New tooling? / l New test equipment? / Will a preliminary capability study be conducted at the tooling and/or equipment manufacturer? 12 Has test equipment feasibility and accuracy been established? 13 Is a preventive maintenance plan complete for equipment and tooling? 14 Are setup instructions for new equipment and tooling complete and understandable? 15 Will capable gages be available to run preliminary process capability studies at the equipment supplier's facility? 16 Will preliminary process capability studies be run at the processing plant? 17 Have process characteristics that affect special product characteristics been identified? 18 Were special product characteristics used in determining acceptance criteria? 19 Does the manufacturing equipment have sufficient capacity to handle forecasted production and service volumes? 20 Is testing capacity sufficient to provide adequate testing? Revision Date Prepared By: Person Responsible Due Date A-4 PRODUCT/PROCESS QUALITY CHECKLIST Customer or Internal Part No. NUMBER Question 1 Is the assistance of the customer's quality assurance or product engineering activity needed to develop or concur to the control plan? 2 Has the supplier identified who will be the quality liaison with the customer? 3 Has the supplier identified who will be the quality liaison with its suppliers? 4 Has the quality assurance system been reviewed using the Chrysler, Ford, and General Motors Quality System Assessment? Are there sufficient personnel identified to cover: l Control plan requirements? 5 / l Layout inspection? 6 / l Engineering performance testing? 7 / 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 l Problem resolution analysis? / Is there a documented training program that: l Includes all employees? / l Lists whose been trained? / l Provides a training schedule? / Has training been completed for: l Statistical process control? / l Capability studies? / l Problem solving? / l Mistake proofing? / l Other topics as identified? / Is each operation provided with process instructions that are keyed to the control plan? Are standard operator instructions available at each operation? Were operator/team leaders involved in developing standard operator instructions? Do inspection instructions include: l Easily understood engineering performance specifications? l Test frequencies? / l Sample sizes? / l Reaction plans? / l Documentation? / Are visual aids: l Easily understood? / Yes No Comment / Action Required Person Responsible Due Date A-5 FLOOR PLAN CHECKLIST Customer or Internal Part No. NUMBER Question Yes No Comment / Action Required 1 Does the floor plan identify all required process and inspection points? 2 Have clearly marked areas for all material, tools, and equipment at each operation been considered? 3 Has sufficient space been allocated for all equipment? Are process and inspection areas: 4 l Of adequate size? / 5 l Properly lighted? / 6 Do inspection areas contain necessary equipment and files? Are there adequate: 7 l Staging areas? / 8 l Impound areas? / 9 Are inspection points logically located to prevent shipment of nonconforming products? 10 Have controls been established to eliminate the potential for an operation, including outside processing, to contaminate or mix similar products? 11 Is material protected from overhead or air handling systems contamination? 12 Have final audit facilities been provided? 13 Are controls adequate to prevent movement of nonconforming incoming material to storage or point of use? Revision Date Prepared By: Person Responsible Due Date A-6 PROCESS FLOW CHART CHECKLIST Customer or Internal Part No. NUMBER Question Yes No Comment / Action Required 1 Does the flow chart illustrate the sequence of production and inspection stations? 2 Were all appropriate FMEA's (SFMEA, DFMEA) available and used as aids to develop the process flow chart? 3 Is the flow chart keyed to product and process checks in the control plan? 4 Does the flow chart describe how the product will move, i.e., roller conveyor, slide containers, etc.? 5 Has the pull system/optimization been considered for this process? 6 Have provisions been made to identify and inspect reworked product before being used? 7 Have potential quality problems due to handling and outside processing been identified and corrected? Revision Date Prepared By: Person Responsible Due Date A-7 PROCESS FMEA CHECKLIST Customer or Internal Part No. NUMBER Question Yes No Comment / Action Required 1 Was the Process FMEA prepared using the Chrysler, Ford, and General Motors guidelines? 2 Have all operations affecting fit, function, durability, governmental regulations and safety been identified and listed sequentially? 3 Were similar part FMEA's considered? 4 Have historical campaign and warranty data been reviewed? 5 Have appropriate corrective actions been planned or taken for high risk priority items? 6 Have appropriate corrective actions been planned or taken for high severity numbers? 7 Were risk priorities numbers revised when corrective action was completed? 8 Were high severity numbers revised when a design change was completed? 9 Do the effects consider the customer in terms of the subsequent operation, assembly, and product? 10 Was warranty information used as an aid in developing the Process FMEA? 11 Were customer plant problems used as an aid in developing the Process FMEA? 12 Have the causes been described in terms of something that can be fixed or controlled? 13 Where detection is the major factor, have provisions been made to control the cause prior to the next operation? Revision Date Prepared By: Person Responsible Due Date A-8 CONTROL PLAN CHECKLIST Customer or Internal Part No. NUMBER Question Yes No Comment / Action Required 1 Was the control plan methodology referenced in Section 6 used in preparing the control plan? 2 Have all known customer complaints been identified to facilitate the selection of special product/process characteristics? 3 Are all special product/process characteristics included in the control plan? 4 Were SFMEA, DFMEA, and PFMEA used to prepare the control plan? 5 Are material specifications requiring inspection identified? 6 Does the control pan address incoming (material/components) through processing/assembly including packaging? 7 Are engineering performance testing requirements identified? 8 Are gages and test equipment available as required by the control plan? 9 If required, has the customer approved the control plan? 10 Are gage methods compatible between supplier and customer? Revision Date Prepared By: Person Responsible Due Date All pre-production and initial job launch components must have GP-12 inspection. A review of the GP-12 inspection process may be requested. A separate APQP file must be obtained prior to PPAP and include the following documents. REQUIREDAPQP Open Issues REQUIRED Lessons Learned Process Overview SQE High Impact Assesment/Supplier Assessment REQUIRED APQP Kick-off Meeting Checklist REFERENCE Process Control Plan Audit Worksheet REQUIREDGuardian and Supplier Program Contacts REQUIREDRPN Reduction Summary Chart REQUIRED Directed Buy/Directed Source Checklist] REQUIRED Subcontractor Program Status Matrix SQE Subcontractor Detailed Status Matrix REFERENCE Fixture Design Matrix REQUIRED Packaging approval 1927-5 1927-10 HIA 1927-14 1927-16 1927-16 1927-21 1927-23 1927-25 1927-26 1927-27 PPPA APQP Open Issues Supplier/ Mfg Location: Duns Number: Supplier Contact: GM SQE Contact: *Type Key: Issue No. Issue Date Part Number(s): Program(s): Part Name: S = Design-Supplier G = Design-GM F = Facilities Severity T = Tooling C = Capacity L = Late Release Issues Description and/or Sketch Status: 25% Issue Identified 50% Action Plan Proposed 75% Action Plan Implemented 100% Issue Resolved M = Manufacturing/Process O = Other :_ _ P = Purchasing Person Responsible (Name) * Type R = Production Control A - Appearance K – Packaging Engineering Action Plan & Progress to Plan Severity: 1 - Director Support 2 - Manager/Supervisor Support 3 - SQE Support I - Logistics Forecast Completion Date Status Reviewed by __________________ Date __________ Program 0 Date: Commodity Customer Gate 6 Meeting Attendees 0 Program Team Issues Gate 1 Lessons Learned Responses Responsible Dept/Group Recommended and Corrective Actions DATE: PROJECT/ PROGRAM: PART NO: SUPPLIER: PART DESCRIPTION: MANUFACTURING LOCATION MANUFACTURING LOCATION DUNS # Guardian SQE to confirm manufacturing location is the same as stated on the supplier RFQ response and Guardian contract. Prior to the Kick Off Meeting supplier should ensure full understanding of the APQP Project Plan (1927-1) and all related procedures. Any issue requiring clarification needs to be addressed to Guardian SQE. Section 1. Customer Requirements - All unresolved items must be added to Open Issues List 1. Does the supplier have and understand the latest information about program timing (e.g. Design release, Tooling Order, Prototype, Matching, PPV, MVBns, MVBs, SORP)? Is the supplier familiar with the quality requirements by build level? Yes No Explain: Review Program Milestones with supplier. Key Project Milestones Dates Key Project Milestones Dates 2. Does the supplier have a clear understanding which GM receiving plant(s) he will supply? Are there any requirements for supplier support at a GM location other than the receiving location? E.g. remote Pilot Line. Yes No Explain: Review GM Receiving plants with supplier. Ensure relevant Guardian plant contacts are included in Guardian & Supplier Program Contacts. Guardian Receiving Plant Guardian Receiving Plant 3. Does the supplier have a clear understanding If “ no” , the supplier shall review with the plant? Yes No Explain: of the Guardian receiving plant GCA standards? 4. Is contact established between supplier and Guardian supply chain? Review packaging or shipping open issues. Yes No Explain: 5. Does supplier understand that APQP performance is linked to the bidders list? For example Program Management SCAR’s. Yes No Explain: Section 2. Product Design & Development - All unresolved items must be added to Open Issues List 6. Does the supplier have and understand all of the latest drawings and specifications including Statement of Requirements (SOR), Sub System Technical Specification (SSTS), Component Technical Specification (CTS) and all Guardian Standards (STD)? Yes No Explain plans to obtain: 7. Specify who is responsible for design, Guardian or supplier. GM Supplier Comments: GUARDIAN AND SUPPLIER PROGRAM CONTACTS Part Name: Program: Supplier Name: Manufacturing Location Address: Manufacturing Manager: Position SQE Name Part Number: Model Year: Duns # Phone Phone GUARDIAN Phone E-mail Position Name Proj/Prog Manager Buyer Sales Mgr Design Engineer Validation Engineer Design Engineer Quality Manager Quality Engineer Manufact uring VLE/PPM Mfg Engineer Guardian Plant Rep Lab Spv Proj/Prog Manager Pkg Engineer 1st shift contact 2nd shift contact 3rd shift contact Sales Mgr Logistics GD&T Containeriz ation Logisitics SUPPLIER Phone E-mail Process Capability Over Time Supplier Name: Supplier DUNS No.: Commodity: Part Description: Part number: Drawing Date: KPC PQC 1 2 3 ____________________________________ Date Revised: _________________________ ____________________________________ Program: _________________________ ____________________________________________________ Model Year: _________________________ _________________________________________________________________________________________ _________________________________________________________________________________________ _________________________ Engineering Change Level:_________________________ EWO #________________________ Product Characteristic Selection Rational DIM. SPEC. TOLERANCE Supplier Program Review 3 PPAP APPROVAL Supplier Program Review 4 Avg Std Ppk Dev Avg Std Ppk Dev Avg Std Ppk Dev CONTINUOUS IMPROVEMENT GP-8 Avg Std Dev Cpk Directed Buy / Directed Source Checklist Complex System/Sub-assembly: Guardian SQE: Guardian Buyer: Guardian Product Engineer: Type Name Date: Manufacturing Location: Directed Buy Subcontractor: Sub Components: Signature Tier I GA Directed Supplier Design Responsibility Is there any problem with the tier I supplier gaining access to APQP Responsibility directed supplier's manufacturing location, to review manufacturing Tooling Payment and quality processes due to proprietary or competitor reasons? Production / Functional / FMVSS Testing Technical Specifications If so, How do we handle these? Quality Issues Ownership at Assembly Plant Scheduling Responsibility Packaging Responsibility PPAP Responsibility Ensure all issues are resolved by the GM Buyer, Tier I, and the Directed Run @ Rate Responsibility Supplier. Engineering Change Coordination Additional Comments: Support During Build and Launch at Assembly Plant DFMEA / PFMEA / SFMEA Signature Directed Buy Program Manager: Directed Supplier President/CEO/Owner Date Complete the Checklist during the Commodity Sourcing Strategy meeting and review it during the APQP Kick-Off meeting - Supplier Gate Review #1. Signature Date Tier I Program Manager: Subcontractor Program Status Matrix Date: Tier 1 Supplier / Plant: Tier 1 Supplier Key Contact: Directed Buy (yes/no) Subcontractor Subcomponent If Yes, % Complete SQE: Facilities: Greenfield / Transplant Y/N Programs: Status / GYR System/Sub-assembly: Prod. Tooling % Prod. Complete Tool PPAP Date Complete Date * This document should be reviewed at all Gate Reviews for all sub components. Revision: PPAP Status & Comments Run @ Rate Date Run @ Rate Status Guardian Tier 2 Suppliers Thank You!