Supplier Program Review Meeting #1

1. Advanced Product Quality Planning Supplier Program Review Meeting #1 APQP Kick-off Meeting GM1927-15

2. Supplier Program Review Meeting #1 • Purpose: • Communicate the process that will be used to provide program updates for APQP Deliverables. • Confirm APQP communication Channels between Supplier and GM. • Ensure that GM requirements are understood. • Understand current program status to ensure conformance to GM Timing. • Provide a formal process to raise open issues for resolution. • Form joint focus on future steps.

3. GM General Motors Corporation Advanced Product Quality Planning Worldwide Purchasing November 2000 Agenda • Background • - APQP • - Global APQP Development • APQP Project Plan Overview • APQP Kick-off Meeting • - SQ Requirements • - Program Timing • - Review Checklists • - Identify Open Issues • Summary

4. Background APQP • Definition: • Advanced Product Quality Planning -- APQP • Structured method defines and establishes steps • necessary to ensure product meets customer requirements • Required for all new parts • Responsibility of the supplier • Purpose & Structure: • Communicates the requirements necessary to develop a product quality plan • Top Management support by the supplier is key to the success of the any APQP process • Requires an environment of trust and cooperation between all parties

5. Background • QS- 9000 APQP Direction • Establishment of an Advanced Product Quality Plan • QS-9000 section 4.2.3.1 requires the establishment of an advanced product quality plan • AIAG APQP Manual is referenced as the document that should be used • Detail of specific deliverables was not clearly defined • Separate “unique” Regional & Divisional requirements developed

6. Global APQP Development GM General Motors Corporation Advanced Product Quality Planning Worldwide Purchasing November 2000 GM Global APQP • GM-1927 is the General Motors Common Global APQP Manual • GM’s common direction for the development and implementation of an APQP plan

7. Global APQP Development Common Global APQP Process for GM Worldwide • GM-1927 replaces all regional and divisional APQP reference manuals • GM-1927 harmonized and standardized the multiple regional and divisional APQP manuals • Aligns with the 5 phases within the AIAG APQP manual and provides the detail required to implement an APQP plan • Aligns with GM’s 4 Phase Program Timing and Deliverables

8. Global APQP Development GM 1927 Documents and Forms • Ordering: Ordering information for all documents and manuals listed or referenced throughout this manual (GM 1927) is contained on page II • Electronic Copies: This manual and all documents that are part of this manual (this includes any document with a GM 1927 number) can be found through the internet at the GMSupplyPower website The address is www.gmsupplypower.com, then follow these steps: • Log in • Select Quality Power • Select Library • Select Supplier Quality • Select APQP Manual & Documents

9. Combination of the Best Processes WWP SUPPLIER QUALITY IMPROVEMENT PROCESS GLOBAL SOURCING IMPROVEMENT MEETING PROBLEM RESOLUTION QUALITY WORKSHOP LEVEL II CONTROLLED SHIPPING LEVEL I CONTROLLED SHIPPING SUPPLIER QUALITY PROCESSES & MEASURES (GP-5) PERFORMANCE MONITORING TIME LINE CONTINUOUS IMPROVEMENT (GP-8) EARLY PRODUCTION CONTAINMENT (GP-12) LIFE OF PART RUN @ RATE (GP-9) GM Global APQP PRODUCTION PART APPROVAL (PPAP) PROTOTYPE SAMPLE APPROVAL (GP-11) SQ Global APQP ADVANCE PLANNING & PREVENTION Experience PRE-PRODUCTION MEETING ADVANCED PRODUCT QUALITY PLANNING (APQP) SOURCING DECISION POTENTIAL SUPPLIER ASSESSMENT START OF PRODUCTION

10. Global APQP GM General Motors Corporation Advanced Product Quality Planning Worldwide Purchasing November 2000 Manual Contents • Preface • Table of Contents • RASIC • Explanation of PMI’s (Process Model Integration) • PMI’s for 17 Tasks / Deliverables • Appendices • Glossary The 17 Tasks are the Key for Success!

11. SQ Global APQP APQP Project Plan APQP “At a Glance” • Shows the linkage of the 17 deliverables to: • GM’s 4 phase timing • GM’s Sourcing Process • AIAG APQP 5 phases within the APQP planning process • The focus of the APQP Project Plan is on timing of each deliverable • Levels of completeness for specific deliverables is clearly identified • The required completion of items is tied to the specific GM build event

12. APQP Project Plan

13. Supplier Program Reviews APQP Project Plan Start Here Task 4 Supplier Activities

14. Purpose: • Ensure Supplier’s Quality Plan is Progressing to Meet • GM Program Timing • Provide a Formal Process to Raise Issues for Resolution Four Major Program Reviews: TODAY • Pre-Production Meeting (APQP Kickoff) • Beta Prototype Build Review • Gamma Prototype Build Review • Pilot (Final PPAP Submission) Review Meeting Responsibility: • Pre-Production Meeting is Scheduled by SQE • Meetings 2, 3, 4 are Scheduled by Supplier Overview Task 4) Supplier Program Reviews

15. Meeting Subjects Include: 4) Supplier Program Reviews Supplier Program Reviews 2,3,4 • APQP Major/Open Issues List • APQP Timing Chart Updates • Progress of Tooling/Fixtures/Gages • Supplier Manufacturing Assessment Letters (3 letters) • Lessons Learned • Design Issues • RPN Reduction Plans • AIAG New Equipment Checklist (A-3) • AIAG Process Flow Checklist (A-6) • AIAG PFMEA Checklist (A-7) • AIAG Control Plan Checklist (A-8) • GP-12 Plan Task 6 Suppliers need to be prepared for each meeting with supporting documents SQEs will Review Documents at Meetings

16. Purpose: • Ensure Program Deliverables are Executed on Schedule SQE Responsibility: • Review the APQP Timing Chart and APQP Issues List • Identify and Communicate Key Timing and Program Issues with GM • Management Supplier Responsibility: • Create and maintain an APQP Timing Chart and Open Issues List • Maintain Detail behind Each High Level APQP Chart • Review Timing Chart and Issues List at All Program Reviews • Identify and Communicate Any Changes to SQE • Identify and Communicate Key Timing and Program Issues with SQE 5) Timing Charts / Open Issues

17. 6) Manufacturing Assessment Letters Purpose: Supplier Evaluates Manufacturability of the Part Manufacturing Assessments: Design -- can the Design be Manufactured to Conform to all GM Performance Requirements? Prototype -- using the Intended Production Process, will all Parts Conform to GM Requirements? Process Capability -- will the Production Process Provide Parts that Conform to GM Requirements? Supplier Responsibility: • Evaluate Feasibility during 3 stages of program development • Submit Letters Signed by the Manufacturing Plant Manager

18. Design Is Manufacturable to GM Required Quality Levels… Manufacturing is making a commitment to achieve zero defects.. Minor concerns about the design .. Confident that design will be modified..manufacturable to Required Quality Levels… commitment to achieve zero defects.. Major concerns about design, not confident part can be produced at GM Required Quality Levels… 6) Manufacturing Assessment Letters

19. Purpose: • Provide a Logical Pictorial Representation of the Process Flow that can • be used as the Foundation for PFMEA’s. Control Plans, Work Station • Layouts, etc. SQE Responsibility: • Review Process Flow Charts at Sourcing (if available), at Prototype, at • Production Part Approval and Regular Production • Ensure that the Production Version is linked to the PFMEA and Control Plan • Ensure that the Flow Chart Includes Inspection and Rework Supplier Responsibility: • Create Preliminary Process Flow Chart using a Similar Process • Create and Maintain the Flow Chart through Prototype and into Production • Ensure the Flow Chart is Linked to the PFMEA and Control Plan • Communicate any Changes to the SQE 7) Flow Chart

20. Purpose: • Support the Design Process in Reducing the Risk of Failure • SQE Responsibility: • Confirm that a DFMEA has been Completed • Ensure that Supplier has a DFMEA for input to PFMEA • Lessons Learned Checklist to Design Owner • Supplier Responsibility: • GM Design Responsible • Suppliers must participate in DFMEA Reviews with Product Engineer • Share Knowledge and Experience on Similar Designs • Recommend Action Plans for Severity, Occurrence, Detection Targets • Supplier Design Responsible • Lead Cross-functional Team to Develop and Improve FMEA • Schedule Review Meetings with GM Product Engineer • Develop Action Plans for Severity, Occurrence, Detection Targets • Maintain DFMEA for PPAP Submission 8) Design Failure Mode and Effects Analysis

21. Purpose: • Ensure that the Design has been adequately Defined to Build Tools and Gauges • SQE Responsibility: • Participate in KCDS Workshop and GD& T Reviews • Participate in Design Reviews addressing changes in Manufacturing Process/ • Quality/Timing/ Risk • Supplier Responsibility: • Participate in KCDS Workshop and GD& T & Design Reviews • Participate in Defining Measurable KPC’s • Participate in Defining Appearance Specifications • Satisfy all Performance and Material Testing Requirements • Ensure that the Manufacturing Process can achieve Tolerances on a • Continuing Basis • Quality of the Design Directly Impacts Process Design and Process Quality 9) Design Reviews

22. Purpose: • Ensure that the Manufacturing process is being designed, built and certified to • produce parts with quality at rate according to GM program requirements • SQE Responsibility: • Confirm that Gage, Tooling and Equipment Timing is on Schedule to Support • Program Requirements • Confirm that the Gauge Agrees with the Functional Part Usage, Complies with • GD&T, Includes Measurement of KPCs and is at the Correct Change Level • Ensure Gage is Used as Indicated in Process Flow Chart and Control Plan • Supplier Responsibility: • Design, Build and Obtain Certification of Gages • Participate in Reviews with General Motors Relative to Design, Build and • Certification of the Gage 10) Gage, Tooling & Equipment Reviews

23. Purpose: • Ensure Part Problems are Identified and Corrected in order to • Minimize the Impact of Part Variation upon Design Evaluation, • Manufacturing, and Assembly. • Supplier Responsibility: • Adhere to Requirements Specified in GP-11. • Ship Parts and Documentation as Specified in GP-11 and the • Prototype Purchase Order. • Respond to and Resolve Issues Identified in Prototype Build. • Revise the Flow Chart, PFMEA, and Control Plan as Problems • are Identified throughout GP-11 and the Prototype Build. • Update the APQP Open Issues List and APQP Timing Chart as • Problems and Changes Occur. • Prototype will act as a Mirror for Problems that will • Appear at Pilot = Address Issues Early in Program! 11) GP 11 Prototype

24. Purpose: • Assure Potential Failure Modes of the Process have been Considered and Addressed • SQE Responsibility: • Attend initial PFMEA Development Team Meeting • Monitor Progress and Review PFMEA with Supplier • Supplier Responsibility: • Initiate PFMEA prior to Sourcing as part of the Quotation to GM • Drive Error Prevention and Detectionthroughout the Process • Prepare PFMEA - Multi-disciplinary team • Insure that PFMEA results have been incorporated into Control Plan • Revise PFMEA if Process / Material / Manufacturing Location Changes • Develop and Implement RPN Reduction Plans 12) PFMEA Strategy

25. Purpose: • Define the Method being used to Control all KPCs and • KCCs for Parts being Manufactured for Vehicle Builds. • SQE Responsibility: • Verify use of PFMEA & Statistical Data to determine Necessary Controls • Verify Update of Control Plan with Solutions from PFMEA • Verify Pre-Launch Issues have been Incorporated into Production Plan • Supplier Responsibility: • Develop Pre-sourcing Control Plan • Ensure Control Plan Flows from PFMEA & Process Flow Chart • Use Pre-Launch Control Plan to Validate Production Control Plan • Update Control Plan • Process Control Plan Audits will be Conducted at Run@ Rate 13) Control Plans

26. 14) GP 12 Early Production Containment • Purpose: • Establish a Containment Plan during Start-up and Acceleration that will • Quickly Identify Quality Issues at the Supplier’s Facility; i.e., a Pre-Launch • Control Plan. • SQE Responsibility: • Provide GP-12 Timing to the Supplier • Review the Supplier’s Process and Pre-Launch Control Plan • Verify that any PR&R, Prototype or Pilot Issues are in Control • Verify that the Supplier used PFMEA & Statistical Data to Set Controls • Supplier Responsibility: • Develop the Pre-Launch Control Plan Based on Experience from Prior Issues • Implement the Pre-Launch Control Plan • Monitor GP 12 Data and Modify Internal Process to Eliminate Issues • Monitor Customer Issues and PR&Rs, Update Control Plans

27. 15) Production Part Approval Process • Purpose: • Determine if All Customer Engineering Design Records & Specifications • Requirements are properly understood by the Supplier and that the Process has • the Potential to Produce Product Meeting these Requirements during Production • at the Quoted Rate. • SQE Responsibility: • Review PPAP Documentation Prior to Submission • - Verify Completion of all 19 Required Items • - Many Documents Can be Reviewed in Advance of PPAP Submission • Follow-up on PPAP Rejections • Supplier Responsibility: • Produce Parts in the Production Environment • Complete all Documents and Test Requirements in Advance of PPAP Date • Target for Full PPAP on First Submission

28. 16) Run at Rate • Purpose: • Verify that the Supplier’s Actual Manufacturing Process is Capable • of Producing Parts that Meet: • - GM’s On-going Quality Requirements • - Quoted Tool Capacity • - GM’s Daily Volume Requirements • SQE Responsibility: • Evaluate the Supplier’s Run at Rate Plan • Determine if the Run at Rate should be Customer or Supplier Monitored • Participate in Customer Monitored, or Review the Results of Supplier Monitored • Confirm Actual Capacity Exceeds Quoted Capacity and GM Daily Requirements • Status Run at Rate According to Results • Supplier Responsibility: • Develop Run at Rate Plan and Review with SQE • Confirm Quoted Tool Capacity and Duration of Run at Rate • Conduct Run at Rate, Complete Worksheets and Forward to SQE

29. 17) Lessons Learned • Purpose: • Review Experience from Previous Programs and Consider Opportunities to • Improve Performance on New Programs. • SQE Responsibility: • Acquire Information about Previous Experiences with Similar Commodities • - Other SQEs, Local or in Other Regions • - Product Engineers • Share Personal Knowledge and Experience • Verify that the Supplier Applies Lessons Learned in New Process • Supplier Responsibility: • Share Lessons Learned from Similar Commodities • Evaluate Lessons Learned from External Sources • Incorporate All Applicable Items into Production Process and Tool Designs

30. GM General Motors Corporation Advanced Product Quality Planning Worldwide Purchasing November 2000 APQP Kick-off Meeting Agenda • SQ Requirements • Program Timing • Review 1927-14 Checklist • Open Issues • Summary

31. Signature of Supplier Representative Supplier Quality SOR • Supplier Quality has a Global Statement of Requirements that applies to all suppliers. • SOR Included in the GM RFQ. • Supplier Quotations to GM must include a signed copy of the SOR, indicating compliance to these requirements.

32. Required Quality Information Letter • (GM1927-4 is Included in all GM RFQs. • Supplier submits as part of Quote to GM, includes requested documents. • Review Supplier Quality Information provided and discuss exceptions. • Update APQP Open Issues List for exceptions.

33. Lessons Learned • Review Lessons Learned in GM SupplyPower website • - Obtain worksheet on major components • - Evaluate Lessons for application to new part • Discuss other Lessons Learned from similar parts • Objective of this activity is --- Avoid Repeat Issues

34. Program Timing Information • Define Program Timing Elements • -Major Program Benchmark Dates are provided by the SQE • - GM 1927-2 provides the Minimum list of activities that must be tracked by the supplier • Suppliers complete the form and return it to the SQE • - Updates showing progress are forwarded to the SQE • - Detailed evaluations are conducted as part of future Program Reviews.

35. Program Contacts Who to Contact? GM1927-17 List the Key Positions needed to Manage New Programs

36. APQP Open Issues APQP Kick-Off Meeting Checklist • Review 1927-14 Checklist • Identify Open Issues • - GM responsibility • - Supplier Responsibility • Add Items to APQP Open Issue List (GM1927-5) • Drive all Issues to Closure!

37. Requirements from Suppliers • Proactive Conformance to AIAG APQP Requirements • and GM Global APQP Tasks • Develop Detail Plans for Each Part / System • - Robust Part Designs • - Robust Processes with Error-proofing ZERO DEFECTS • Maintain Program Timing • - Design Completion • - Prototype Part Delivery • - Accurate Sample Submissions and Part Delivery • Identify Issues Early in Program and Drive Correction • Document on APQP Open Issues List • Maintain Communication with GM on Program Status • and Issues-- Manufacturing Assessment Letters • Expect these Same Requirements from Sub-Suppliers

38. Summary • Proactive Conformance to AIAG APQP Requirements • and GM APQP Tasks • Supplier Drives Tasks 4 through 17 to Completion • Identify Issues Early in Program and Drive Correction • Maintain Communication with GM on Program Status • and Issues • -- Manufacturing Assessment Letters • -- Schedule Program Review 2,3,4 with the SQE • Expect these Same Requirements from Sub-Suppliers Let’s Get Going!!