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GM 1960 - GP9 Procedure

By Clyde Scott,2014-11-25 22:21
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GM 1960 - GP9 Procedure

    GENERAL MOTORS SUPPLIER QUALITY GENERAL PROCEDURE

     RUN at RATE GP-9

     THIS GP-9 PROCEDURE APPLIES TO

    ; RUN AT RATE AT TIER-1 SUPPLIERS

    ; BUILD AT RATE AT TIER-1 SEQUENCERS

1. Purpose

    The purpose of the Run at Rate/Build at Rate activity is to verify that a supplier’s actual

    manufacturing/sequencing process, while operating under normal operating conditions,

    and under Total Customer Requirement, is:

    A. Capable of producing/sequencing quality components/systems/modules, as stated in

    the Production Part Approval Process (PPAP) (reference Attachment B - Process

    Control Audit), and…

    B. Capable of meeting or exceeding the "daily contracted capacity within one production

    day," on a sustained basis (reference Capacity Analysis Worksheets - Attachments C,

    C-1, C-2, C-3, S-1, S-2)

    Note: It is expected that the daily contracted capacity is equal to or greater than

    the daily LCR.

    Note: “Total Customer Requirement” Includes All customer requirements (other GM

    Service Parts/After-Sales and other OEM’s.)

2. Scope

    This procedure applies to all manufacturing, assembly and sequencing processes

    contracted to General Motors to:

    A. Produce/sequence new components/systems or modules

    B. Increase existing capacity on previously contracted volume

    C. Tool and equipment moves to new manufacturing/sequencing locations

    The application of this procedure may be required for changes to existing processes where

    it is deemed that the capability and/or capacity of the system have been altered.

    Note: An exemption from this process can only be granted with the written approval of the

    Quality and Purchasing Directors of the procuring division.

General Motors Corp. Page 1 Published by GPSC GM 1960 March 2005

GENERAL MOTORS SUPPLIER QUALITY GENERAL PROCEDURE

     RUN at RATE GP-9

     3. Type Of Run at Rate / Build at Rate

    GM Supplier Quality will confirm the type of Run at Rate / Build at Rate. The supplier will be notified of the need to perform a "Customer Monitored" or "Supplier Monitored" Run at Rate / Build at Rate as early in the Advanced Product Quality Planning Process as possible.

General Motors Corp. Page 2 Published by GPSC GM 1960 March 2005

    GENERAL MOTORS SUPPLIER QUALITY GENERAL PROCEDURE

     RUN at RATE GP-9

     SECTION .1. TIER-1 SUPPLIER RUN AT RATE PROCESS

    1. General Information

A. Duration Of Run at Rate

    The duration of the Run at Rate will be sufficient to verify that the process can meet the contracted capacity while producing the Total Customer Requirement. The default length of the Run at Rate will be equal to the daily contracted hours. However, the authorized Customer Representative (SQE) may deviate from the default duration (upon approval from their manager) after taking into consideration the following factors:

    ; Product Complexity

    ; Shelf Life

    ; Storage & Packaging

    ; Cost

    ; Production Day Length

B. Timing Of Run at Rate

    The Run at Rate should be performed after the supplier has attained a PPAP status of “Full”, “Saleable”, or “Non-Saleable” (when pre-approved by GM Supplier Quality

    Manager or above), and no later than eight weeks prior to start of regular production.

    C. Supplier Preparation For A Customer Monitored Run at Rate

    1. To ensure readiness before the Run at Rate is performed, the supplier will

    conduct a practice Run at Rate and/or production simulations, as well as

    complete the following Run at Rate worksheet attachments:

    ; Attachment B (GM1927-16) Process Control Plan Audit

    ; Attachments C, C-1, C-2, and C-3 Capacity Analysis Worksheets

    2. Requests for changes to the Run at Rate schedule must be submitted to the

    authorized Customer Representative (SQE) at least two (2) weeks prior to the

    Run at Rate.

    Note: Supplier will not be deemed ready for a Run at Rate until all required documentation has been properly filled out and forwarded in advance to the procuring division authorized Customer Representative (SQE).

    General Motors Corp. Page 3 Published by GPSC GM 1960 March 2005

    GENERAL MOTORS SUPPLIER QUALITY GENERAL PROCEDURE

     RUN at RATE GP-9

D. Required Participation And Coverage

    1. Customer Monitored

    A representative from the procuring division is to be present for the entire Run at

    Rate. No portion of the Run at Rate should be performed without representation

    from the procuring division. If, however, it is clearly evident that the systems

    capacity is well above the contracted requirement, the authorized Customer

    Representative (SQE) may accept the results of a portion of the Run at Rate

    without being present. The lead Customer Representative typically will be the

    Supplier Quality Engineer, with participation from the Buyer and/or Release

    Engineer upon request.

    2. Supplier Monitored

    The lead supplier representative is responsible for ensuring that the Run at Rate

    is performed as detailed in this GP-9 Procedure. The lead supplier

    representative (Project Manager) or their designate must be present during the

    entire Run at Rate.

    Note: Within 24 hours of completing the formal Run at Rate, the

    Supplier must complete the Run at Rate Summary sheet

    (Attachment A) and the Quality and Capacity worksheets

    (Attachments B, C, C-1, C-2 and/or C-3) and forward them to the

    Procuring Division SQE.

    Note: Equipment suppliers and/or subcontractors may be asked to participate in

    either customer or supplier monitored Run at Rates.

E. Subcontractor Requirement

    Suppliers are required to ensure the reliability of their suppliers. Written

    confirmation of daily contracted requirements, as well as actual systems

    performance for Quality, Capacity and Delivery, must be provided to the customer

    procuring division authorized Customer Representative (SQE) prior to the Run at

    Rate.

    Where an on-site study is conducted at a subcontractor, it is recommended that this

    GP-9 Run at Rate process be utilized.

F. Inventory

    General Motors Corp. Page 4 Published by GPSC GM 1960 March 2005

    GENERAL MOTORS SUPPLIER QUALITY GENERAL PROCEDURE

     RUN at RATE GP-9

     Finished parts inventory resulting from production runs to prepare for or complete a

     Run at Rate, will be the responsibility of the supplier. This inventory will be held

    until scheduled for shipment by General Motors. The contracting division must

    approve exceptions to the above.

2. Run at Rate Content Review

    1. During the Run at Rate the Suppliers actual manufacturing process will be

    assessed to verify its ability to meet the quality and capacity requirements as

    contracted and detailed in Attachments B (Quality) and C (Capacity), C-1, C-2

    and/or C-3.

3. Approval

    Upon completion of the Run at Rate study, and a formal review of the completed Process

    Control Plan audit and Capacity Analysis worksheets (Attachments B, C, C-1, C-2, C-3),

    the Run at Rate will be assessed with one of the following five results:

    A. Pass

    A Status of “Pass indicates that all Run at Rate requirements have been met. The

    Process Control Plan Audit (Attachment B) and Capacity Analysis (Attachments C,

    C-1, C-2 and/or C-3) have passed. Subcontractors’ abilities to meet the capacity

    and quality requirements have been confirmed in writing by the supplier, and all

    parts produced meet GM’s quality requirements as stated in the requirements.

    B. Staged

    A Status of “Staged” implies that the supplier is meeting the approved Plan for the

    gradual introduction of tooling, machinery, and/or shifts required to meet the full

    contracted capacity.

    C. Customer Fail

    A Status of “Customer Fail” indicates that the Supplier passed all Run at Rate

    requirements based on the contracted capacity, or agreed to staged implementation

    plan; however, customer requirements (LCR) exceed contracted capacity.

    D. Pending PPAP

    A Status of “Pending PPAP indicates that all capacity related elements have been

    met and the status “Pass” is pending due to:

    i. PPAP status is “Non-Saleable”, or…

General Motors Corp. Page 5 Published by GPSC GM 1960 March 2005

    GENERAL MOTORS SUPPLIER QUALITY GENERAL PROCEDURE

     RUN at RATE GP-9

     ii. In the judgment of the customer’s SQE or supplier there are incomplete

     PPAP issues which may impact the capacity of the production system.

    (Example: Low volume or temporary tools being used.)

    Upon satisfactory correction of the above conditions and assurance the capacity

     has not been affected, the status can be changed to “Pass”.

    E. Fail

    A Status of “Fail indicates that a serious nonconformance exists in the Process

    Control Plan Audit (Attachment B) or Capacity Analysis (Attachment C) that requires

    significant action by the supplier to correct, or if supplier fails to provide written

    confirmation of the subcontractor’s abilities to meet the Quality, Capacity, and

    Delivery requirements.

4. Corrective Actions

    Should the Run at Rate results fail to meet the requirements of this procedure for quality

    and/or capacity a corrective action plan (as outlined in the attachments) must be submitted

    to and approved by the authorized Customer Representative (SQE) within two days

    following the completion of the Run at Rate.

    Upon full implementation of the corrective action plan, the Customer Supplier

    Representative will determine the method of verification, which may require an on-site

    review and/or a new Run at Rate study.

    Following verification of successful implementation, the Run at Rate status will be changed

    to a Pass, or other appropriate level.

    Required Levels of GP-9 Documentation for Submission and Retention

    Document Customer Supplier

    Document Type Attachment Number Monitored Monitored

    S S Run at Rate Summary Attachment A GM 1960-A

    S S Process Control Plan Audit Worksheet Attachment B GM 1927-16

    S S Capacity Analysis Worksheet Attachment C GM 1960-C

    S S Run at Rate Manufacturing Flow Diagram Attachment C1 GM 1960-C1

    S S Manufacturing System Capacity Estimate Attachment C2 GM 1960-C2

    S S Constraint Capacity Estimate Attachment C3 GM 1960-C3

    Customer "on-site" verification Yes No

    General Motors Corp. Page 6 Published by GPSC GM 1960 March 2005

GENERAL MOTORS SUPPLIER QUALITY GENERAL PROCEDURE

     RUN at RATE GP-9

     S Submit document to Customer / SQE

    General Motors Corp. Page 7 Published by GPSC GM 1960 March 2005

    GENERAL MOTORS SUPPLIER QUALITY GENERAL PROCEDURE

     RUN at RATE GP-9

     SECTION .2. TIER-1 SEQUENCER BUILD AT RATE PROCESS

    1. General Information

    A. Duration Of Build at Rate

    The duration of the Build at Rate will be sufficient to verify that the process can meet

    the contracted capacity while producing the Total Customer Requirement. The default

    length of the Run at Rate will be equal to the daily contracted hours. However, the

    authorized Customer Representative (SQE) may deviate from the default duration upon

    approval from the GM Materials Launch Manager.

    B. Timing Of Build at Rate

    The Build at Rate should be performed after the sequencer has attained a PPAP status

    of “Full”, “Saleable”, or “Non-Saleable” (when pre-approved by GM Supplier Quality

    Manager or above). The build at rate can take place before or after start of production

    ; Before start of production the timing of the build at rate should coincide

    with the Manufacturing Validation Build event

    ; After start of production the build at rate should take place after the GM

    plant has reached steady state.

    C. Sequencer Preparation For A Customer Monitored Build at Rate

    1. To ensure readiness before the Build at Rate is performed, the sequencer will

    conduct a practice Build at Rate and/or simulations, as well as complete the

    following Build at Rate worksheet attachments:

    ; Attachment B Process Control Plan Audit

    ; Attachments S-1, S-2 Capacity Analysis Summary & Worksheet

    2. Requests for changes to the Build at Rate schedule must be submitted to the

    authorized Customer Representative (SQE) at least two (2) weeks prior to the

    Build at Rate.

    Note: Sequencer will not be deemed ready for a Build at Rate until all required

    documentation has been properly filled out and forwarded in advance to the procuring

    division authorized Customer Representative (SQE).

    General Motors Corp. Page 8 Published by GPSC GM 1960 March 2005

    GENERAL MOTORS SUPPLIER QUALITY GENERAL PROCEDURE

     RUN at RATE GP-9

     D. Required Participation And Coverage

    1. Customer Monitored

    A representative from the procuring division is to be present for the entire Build

    at Rate. No portion of the Build at Rate should be performed without

    representation from the procuring division. If, however, it is clearly evident that

    the systems capacity is well above the contracted requirement, the authorized

    Customer Representative (SQE) may accept the results of a portion of the Build

    at Rate without being present. The lead Customer Representative typically will

    be the Supplier Quality Engineer, with participation from the Sequencer and the

    GM Materials Launch Manager.

    2. Sequencer Monitored

    The lead sequencer representative is responsible for ensuring that the Build at

    Rate is performed as detailed in this GP-9 Procedure. The lead sequencer

    representative (Project Manager) or their designate must be present during the

    entire Build at Rate.

    Note: Within 24 hours of completing the formal Build at Rate, the

    Sequencer must complete the Build at Rate Summary sheet

    (Attachment S-1) and the Quality and Capacity worksheets

    (Attachments B, and S-2) and forward them to the Procuring

    Division SQE and the GM Materials Launch Manager.

    E. Subcontractor Requirement

    Sequencers are required to ensure the reliability of their suppliers. Written confirmation of daily contracted requirements, as well as actual systems performance for Quality, Capacity and Delivery, must be provided to the customer procuring division authorized Customer Representative (SQE) prior to the Build at Rate.

    Where an on-site study is conducted at a subcontractor, it is recommended that this GP-9 Build at Rate process be utilized.

    F. Inventory

    Finished parts inventory resulting from sequencing runs to prepare for or complete a Build at Rate, will be the responsibility of the sequencer. This inventory will be held until scheduled for shipment by General Motors. The contracting division & GM Materials Launch Manager must approve exceptions to the above.

    General Motors Corp. Page 9 Published by GPSC GM 1960 March 2005

    GENERAL MOTORS SUPPLIER QUALITY GENERAL PROCEDURE

     RUN at RATE GP-9

    2. Build at Rate Content Review

    2. During the Build at Rate the Sequencer’s actual manufacturing/sequencing process

    will be assessed to verify its ability to meet the quality and capacity requirements as

    contracted and detailed in Attachments B (Quality), and S-2 (Capacity).

    3. Approval

    Upon completion of the Build at Rate study, and a formal review of the completed Process Control Plan audit and Capacity Analysis worksheets (Attachments B, S-1, and S-2), the Build at Rate will be assessed with one of the following six results:

    A. Pass

    A Status of “Pass indicates that all Build at Rate requirements have been met

    under GM Plant steady state condition. The Process Control Plan Audit (Attachment

    B) and Capacity Analysis (Attachments S-1 & S-2) have passed. Subcontractors’

    abilities to meet the capacity and quality requirements have been confirmed in

    writing by the sequencer, and all parts produced meet GM’s quality requirements as

    stated in the requirements.

    B. ManVal Pass

    A Status of “ManVal Pass indicates that all Build at Rate requirements have been

    met during the Manufacturing Validation Build event. The Process Control Plan

    Audit (Attachment B) and Capacity Analysis (Attachments S-1& S-2) have passed.

    Subcontractors’ abilities to meet the capacity and quality requirements have been

    confirmed in writing by the sequencer, and all parts produced meet GM’s quality

    requirements as stated in the requirements

    C. Customer Fail

    A Status of “Customer Fail” indicates that the Supplier passed all Build at Rate

    requirements based on the contracted capacity, or agreed to staged implementation

    plan; however, customer requirements (LCR) exceed contracted capacity.

    D. Pending PPAP

    A Status of “Pending PPAP indicates that all capacity related elements have been

    met and the status “Pass” is pending due to:

    i. PPAP status is “Non-Saleable” or…

    General Motors Corp. Page 10 Published by GPSC GM 1960 March 2005

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