GM 1927-57 CS2 Entry Letter

By Joshua Morgan,2014-09-10 00:47
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GM 1927-57 CS2 Entry Letter




    Supplier Co Name

    Mfg Location Duns:

    Pres/CEO’s Corp Address (Street)

    Pres/CEO’s Corp Address (City, ST ZIP)

Subject: Entry into Controlled Shipping-Level 2

Dear Mr. /Mrs./Ms. (last name only):

    Controlled Shipping is part of General Motors Supplier Processes and Measurements Procedure, GP-5, and is part of the Supplier Quality Improvement Process. Controlled Shipping is a containment and problem solving

    process. General Motors has determined that current controls by your organization are insufficient to insulate initiating GM (list affected GM plant name/s and state/s) Plant from the receipt of non-conforming parts/material

    produced by your facility. This letter is formal notification and confirms discussions held with your organization that effective (date), your (manuf’g location City, ST) facility has been placed into Controlled Shipping-Level 2

    (CS2). CS2 includes compliance to GP-5 as evaluated by a third party Provider assessment, for the following non-conformances. See table below:

Part Number*** (List all affected part numbers)

    Part Name*** (List all affected part names)

    Non-conformance(s) (List defects as noted on the exit request and entry letter)

    PRR Number (List all current and recent PRR’s related to the non-conformity)

    Plants Affected*** (List all affected GM operations or plants)

    (List all affected GM vehicle lines) (The Initiating SQE should complete either the Vehicle Lines Affected***

    vehicle platforms

    (List all affected GM product lines) or the non-vehicle product lines affected) Product Lines Affected***

     SQE has not recommended or required the use of any specified provider from GM’s No Providers Recommended (double click on box to edit) approved provider list.

    Other Special Instructions

    ***This Controlled Shipping-Level 2 process may be completed on ALL similar part numbers or similar manufacturing processes for these listed non-conformances for ALL possibly affected General

    Motors vehicles or product lines at the discretion of General Motors.

Therefore, you must immediately:

    1. Implement CS2 containment and pay the costs of the approved third-party CS2 Containment and

    Assessment Provider. The GM-defined Controlled Shipping-Level 2 Process activities are in addition to any

    existing controls and containment activities. The list of GM-approved containment and assessment providers is


    2. Controlled Shipping-Level 1 containment must remain in effect. If Controlled Shipping-Level 1 is not in

    place, consider this CS2 Entry letter as formal notification to immediately implement CS1 for the specified

    defect(s) in accordance with GM General Procedure 5 (GP-5).

    3. Pay the costs of the GM-approved CS2 Provider assessments, plus any spill prevention activities as

    required and follow up activities associated with any PRR action items. Follow up activities will continue

    and will be monitored until supplier compliance to GP-5 is validated.

    4. Implement and pay the costs of GM defined containment activities over and above your current process

    controls and containment activities. The supplier must enter into a contract with a GM-approved CS2

    Provider within 24 hours.

    ; The CS2 Provider must establish the CS2 containment and conduct a CS2 Kickoff Meeting within 24 hours

    of receiving a Purchase Order.

    ; The first assessment shall be initiated within 3 business days and submitted to GM within 5 business days

    after receiving the Purchase Order.

    ; Follow up assessments shall be conducted on the 15th working day, and every 30 working days thereafter,

    until a passing assessment is achieved.

    698839992.doc GM 1927-57 Page 1 of 7

    ; The required documentation includes the CS2 Assessment, Matrix, Masterdot Action Plan, 5Y Analysis


    ; The Training Needs Verification must be completed within 5 days and updated after 45 days unless the

    supplier has exited CS2.

    5. Return the attached “Controlled Shipping Confirmation Reply” within 24 hours of the receipt of this letter.

    6. Clearly identify the qualified shipments to indicate that the authorized Controlled Shipping Provider has

    completed the containment process.

    7. GM requires that your Irreversible Corrective Action plans for CS2 issues be submitted to the GM and

    CS2 Provider representatives for review.

    8. Submit your Irreversible Corrective Action plans to your TS16949 registrar for review and/or

    assessment. Please authorize your registrar to submit the review and/or assessment findings to

    General Motors.

    Note: Failure to comply with this process or the inability to implement successful CS2 action plans or containment activities will result in the implementation of New Business Hold-Quality. Reference the GM Supplier Quality Processes and Measurements Procedure GP-5 at for additional details concerning

    Controlled Shipping.

    The attached CS2 Confirmation Reply form must be completed and returned within 24 hours to the GM contacts noted below.

If you have any questions, your GM contacts are:

(Initiating SQE’s name) - SQE @ (phone number), fax: (fax number), & e-mail: (address), who, along with the CS2

    Provider Quality Engineer, will be monitoring and defining your Controlled Shipping activities, and

    Note to TS16949 Registrar: pursuant to this CS2 notification letter, General Motors requests your assessment findings be submitted to the individuals noted above.




    Group Manager


General Motors Corporation



698839992.doc GM 1927-57 Page 2 of 6

Attachment: Entry into CS2 letter,

Supplier Responsibilities During Controlled Shipping-Level 2:

    ; Maintain Controlled Shipping-Level 1 inspections and communications.

    ; Contain all non-conforming parts at the supplier, warehouses, in transit, and at any General Motors locations

    immediately upon notification of Controlled Shipping status.

    ; Participate in all Controlled Shipping-Level 2 meetings as required.

    ; Establish an CS2 containment area that is separated from the normal production and from the Controlled

    Shipping-Level 1areas. This containment area may be located within the normal production area if the General

    Motors representatives approve the location based on material flow, possible damage due to excessive

    handling, or product design considerations.

    ; Provide gaging, tooling, or equipment, if required, for product or process inspections. ; Validate data-supported Corrective Actions. Outline your plans for reviewing your CS2 data.

    ; Track and report your progress by using the GM-approved report formats as specified by the GM

    representatives and the TS16949 Registrar monitoring these activities.

    ; Participate and pay the costs of GM approved Supplier Assessment process as required by GM. ; Meet the defined CS2 exit criteria.

Exit Criteria:

; No PRRs issued for the listed defects and inspection data showing no rejects into the inspection area for a

    minimum of 20 working days AFTER implementation of Irreversible Corrective Actions. If deemed

    appropriate by Supplier Quality, the duration of the Controlled Shipping activities may be adjusted. ; Implement Error Proofing as appropriate within your process for the defect(s) noted above. ; Supplier corrective actions that are classified as Error Proofing solutions require only 5-days’

    inspection data for validation. Criteria are as follows :

    1. The corrective action is classified with a detection score of 1, 2, or 3 as per the AIAG PFMEA manual.

    2. “Master rejects” have been made to validate the error proofing on a regular basis in production. The CS2

    PQE must verify that the “master rejects” work correctly and are used to validate error proofing in

    production. This must be added to the supplier’s process control plan.

    3. The GM SQE and CS2 Provider PQE agree to the above.

    ; Evidence that a thorough problem-solving process was used, the true root causes of the problems were

    discovered, and effective Irreversible Corrective Actions were implemented and validated. ; Statistical Process Control used when appropriate to confirm stable and capable processes during the 20