Global Pre-Production Part Quality Process Global Pre-Production Process Owner: Bob Warner Global Pre-Production Process SME: Chris Fellin Global Materials and Program Management SME: BJ Lee Supplier Training Module Release Date: November 2008Version: V1.0 Global Engineering Process Champion: Jay Reidsma Engineer Standard Work Project Manager: Linda Anthony
Purpose • The Pre-Production Part Quality Process (PPQP) is a General Motors global process that aims to: • Assure that all parts meet dimensional and functional requirements as specified by General Motors. • Commonize associated processes across Product Development, PPO and Suppliers globally • Establish methods to assure that all parts are approved before shipment and installation
Scope • PPQP is a GM global process. • PPQP applies to all internal and external Suppliers of Pre-Production parts to PPO Build shops. This includes, but is not limited to, GM Parts Fabrication, GM Metal Fabrication, GM Powertrain, and all non-GM Suppliers • PPQP certification does not apply to PPAP approved parts. • PPQP supersedes all previous processes governing inspection, certification and delivery of Pre-Production parts. • PPQP replaces GP-11 (General Procedure #1820) for Pre-Production / Prototype parts supplied to the PPO Build Shops. • PPQP does not replace GP11 for parts supplied to GM Powertrain Facilities globally nor Pre-Production parts supplied to GM Assembly Plants.
Overview • PPQP describes the requirements for inspection, certification and delivery of parts for use in Pre-Production builds. • The PPQP classifies parts that are being used in Pre-Production builds into three categories: • Prototype/Pre-production Critical parts • Prototype/Pre-production Non-Critical parts • PPAP Approved parts • The category of the part and conformance to GM specifications determine approval requirements.
Critical Parts • The process begins with the Dimensional Program Manager (DPM) leading development of the Program-Specific Critical Parts List. • The DPM begins with a generic list and adapts the list for the specific program taking into consideration: new unique designs or technologies, past history, and other appropriate criteria. • Parts not on this list will be classified as Non-Critical • The Requisition, Request for Quote and Purchase Order will identify Critical Parts based on the Program-Specific Critical Parts list from the DPM. • GM must approve the checking strategy (checking fixtures, holding fixtures, etc.) • GM must approve the 1st batch of Critical parts before it is shipped to PPO • The Release Engineer and Program Sub-system Validation Engineer will support PPO providing technical expertise when required by PPO. • Subsequent shipments of Critical Parts will be inspected and certified by the supplier. • In order for non-conforming parts to be shipped by the supplier to PPO, the Release Engineer and the Program Subsystem Validation Engineer must approve the Corrective Action Plan. • Non-conforming critical part data must be transmitted by the supplier to GM for posting to CDIS or GDIS. Approval to deliver paper copies of data must be approved by GM
Non-Critical Parts Non-Critical parts are all other parts that are not on the Program Specific Critical Parts list. These parts are to be inspected and self-certified by the supplier. Conforming parts do not require GM approval prior to shipment to the build site. A Non-Critical part that is found to have a quality issue may be changed to a Critical part by GM. PPO will spot-check Non-Critical parts on a sampling basis In order for non-conforming parts to be shipped by the supplier to PPO, the Release Engineer and the Program Subsystem Validation Engineer must approve the Corrective Action Plan. PPAP Approved Parts PPAP Approved Parts require no additional checking and do not require PPQP Quality Warrants. For parts that are in the PPAP process, but not yet approved, the PPQP process must be followed and all PPAP information provided with the shipment.
Other Requirements and Information All shipments to PPO sites must include quality warrants, corrective action plans (when required), and any other data required by the procedure. For parts supplied to GMNA PPO shops, the Quality Warrant Electronic System will not be used. The Supplier is responsible for retaining all original PPQP documentation for a specified model year for two (2) months after the start of regular production for that model year. The Supplier is obligated to provide copies quickly to GM on request. Part shipments received without proper documentation will be quarantined pending resolution and payment will be withheld until necessary documentation is received by GM PRRs will be issued to suppliers by GM for non-compliance to this process New Quality Warrants and Corrective Action Plans will be available on GM SupplyPower in the Quality Document Center, Procedures & Forms folder. New Labels and Tags are available on GM SupplyPower in the Quality Document Center, Procedures & Forms folder or they will be available for purchase from CMS Print Solutions via the "CMS/Supplier Portal" link on the GM SupplyPower Website home page. PPQP Training will be available on GM SupplyPower in Quality Document Center Training and Education Folder
Timing • Effective January 1, 2009 new requirements that are independent of program starts shall be implemented. • Materials/shipment labeling and tagging • All shipments to include new Quality Warrant and Corrective Action Plan (when required) • Quality warrants and Corrective Action Plan original documents to be retained by Supplier and be made available to GM as required.
Timing • The new process shall be followed in its entirety beginning with the following lead programs: • GMDAT - - This process is already in use. • GMH - - VE/WM Integration build • GMNA Warren - - 651 & D1JCI • GMB - - G1LC • GME - - 3401 • PATAC - - G1JD • Key features to be implemented with these programs include: • GM PPO Quality must approve Critical Parts Checking Strategy • GM PPO Quality must approve Critical Parts 1st batch prior to shipment to GM • Release Engineer and Program Subsystem Validation Engineer approvals required in order to ship non-conforming parts (both critical and non-critical) • Non-conforming critical part data to be transmitted by supplier to GM for CDIS or GDIS. Approval to deliver paper copies of data must be approved by GM.
Key Contacts If additional information is required please contact your appropriate key contacts