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GM 1927-35 Run at Rate Procedure (GP9)

By Dennis Parker,2014-09-23 00:52
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    GENERAL MOTORS SUPPLIER QUALITY GENERAL PROCEDURE

     (GP-9) RUN at RATE

     THIS GP9 PROCEDURE APPLIES TO

    ; RUN AT RATE AT TIER-1 SUPPLIERS

    ; BUILD AT RATE AT TIER-1 VAA/SEQUENCERS

1. Purpose

    The purpose of GP-9 is to verify that a supplier’s manufacturing or sequencing

    process (while operating under normal operating conditions and under total

    customer requirement) is capable of producing or sequencing the contracted daily

    capacity of PPAP (Production Part Approval Process) approved (full or interim)

    components, systems, or modules.

    Note: It is expected that the Contracted Daily Capacity is equal to or greater than

    the daily Lean Capacity Rate (LCR). If not the GM SQE or designee is required to

    contact the buyer for resolution. A SQ Managers Approval is required to status a

    Run@Rate as Pass if any part within the Run@Rate group has a Contracted Daily

    Capacity < LCR.

    Note: total customer requirement” includes All customer requirements (i.e. other

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

2. Scope

    This procedure applies to all manufactures, Value Added Assemblers (VAA), and

    sequencers contracted to General Motors that:

    A. Produce new components, systems or modules

    B. Increase existing capacity on previously contracted volume

    C. Produce components due to a business transfer (BTAB Business Transfer

    Approval Board)

    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 has

    been altered.

    Note: An exemption from this process can only be granted by the GM SQ Manager

    of the procuring division.

3. Type of Run at Rate

    The GM Representative will confirm the type of Run at Rate. The supplier will be notified of the need to perform a "Customer Monitored" or "Supplier Monitored" Run at Rate as early in the Advanced Product Quality Planning Process as possible. January 2010 Page 1

    GENERAL MOTORS SUPPLIER QUALITY GENERAL PROCEDURE

     (GP-9) RUN at RATE

    A. Customer Monitored

    The supplier conducts the Run at Rate with the presence of a GM

    Representative and submits the completed GM 1927-35 Run at Rate form to

    that person.

     B. Supplier Monitored

    The supplier conducts the Run at Rate without the presence of a GM

    Representative and submits the completed GM 1927-35 Run at Rate form within

    24 hours to the GM Representative or designee.

    Note: Equipment suppliers and/or subcontractors may be asked to participate in either customer or supplier monitored Run at Rates.

4. Timing of Run at Rate

    All Run at Rates must be conducted no later than eight weeks prior to start of regular production (S.O.R.P.). The Run at Rate should be performed after the supplier has attained a PPAP status of “Full” or “Saleable”. Run at Rates conducted on Non-

    Saleable parts must be approved by the GM SQ Manager.

5. Duration of Run at Rate

    The default duration of the Run at Rate will be equal to the contracted daily hours. However, upon approval from the GM SQ Manager, the GM Representative may deviate from the default duration after taking into consideration the following factors:

    ; Product Complexity

    ; Shelf Life

    ; Storage & Packaging

    ; Cost

    ; Production Day Length

    The duration of the Run at Rate should be sufficient to verify that the manufacturing process can meet the contracted daily capacity while producing under total customer requirements. If the contracted daily capacity is achieved prior to the end of the Run at Rate duration, the Run at Rate can be stopped and evaluated for a Pass or Fail.

6. Preparation for Run at Rate

No later than -23 weeks prior to SORP the supplier should:

    1. Complete Section 1 & 2 of the GM1927-35

    2. Confirm the scheduled Run @ Rate date with the GM SQE or designee. January 2010 Page 2

    GENERAL MOTORS SUPPLIER QUALITY GENERAL PROCEDURE

     (GP-9) RUN at RATE

     3. Confirm that the Daily contracted Capacity is accurate and is greater than or

     equal to GM’s daily requirement (LCR).

    The supplier shall submit the GM 1927-35 to the GM SQE or designee upon request. Run at Rates cannot be rescheduled without authorization from the GM

     Representative. Practice Run at Rates should be done prior to the actual Run at Rate.

7. Subcontractor Requirement

    Tier 1 suppliers are required to ensure the reliability of their suppliers. Tier 1 suppliers must have their subcontractors confirm in writing their ability to meet capacity, quality and delivery requirements.

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

8. Inventory

    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 by the supplier until scheduled for shipment by General Motors. The contracting division must approve exceptions to the above.

9. Run at Rate Status

    Upon completion of the Run at Rate and review of the GM 1927-35 form the GM

    Representative will status the Run @ Rate in GQTS with one of the following

    results:

    A. Pass

    A status of “Pass” indicates that the Tier 1 Supplier / VAA / Sequencer has

    met the Contracted Daily Capacity in one production day under GM Plant

    steady state condition.

    B. Fail

    A status of “Fail” indicates that the Tier 1 Supplier / VAA / Sequencer has

    NOT meet the Contracted Daily Capacity in one production day under GM

    Plant steady state condition

    C. Conditional Pass

    A status of “Conditional Pass” indicates that the Tier 1 Supplier / VAA /

    Sequencer has met GM’s fixed (steady-state) production volume

    requirements as indicated by the Program Team but did NOT meet the

    contracted capacity and the plan (including re-scheduled date) to meet the

    contracted capacity was approved by the GM SQ Manager.

January 2010 Page 3

    GENERAL MOTORS SUPPLIER QUALITY GENERAL PROCEDURE

     (GP-9) RUN at RATE

     10. Corrective Actions

    All Run at Rates that have a Fail or Conditional Pass status require a Reschedule

    or Follow up Date. The GM Representative is to ensure that proper corrective

    action plans are in place that resolves the issue prior to 8 weeks before S.O.R.P.

11. Retention

    The GM Representative shall ensure that the GM 1927-35 form is stored in the Global Quality Tracking System (GQTS).

12. Flow Chart

    January 2010 Page 4

    GENERAL MOTORS SUPPLIER QUALITY GENERAL PROCEDURE

     (GP-9) RUN at RATE

     Supplier conducts By -23 weeks prior to SORP the practice R@R supplier during PPAP build 1. Completes Section 1 & 2 of the and/or simulations.Yes GM1927-35 Is 2. Confirms the scheduled Run @ R@R Rate date with the GM SQE or Required? designee. Customer 3. Confirms that the Daily Supplier Customer Or contracted Capacity is accurate Supplier and is greater than or equal to Monitored GM’s daily requirement (LCR). No The supplier shall submit the GM 1927-35 to the GM SQE or designee upon request. Supplier completes Supplier conducts Section 1 of the GM1927-Supplier conducts R@R with GM SQE 35 and submits it to the GM R@R and completes present. SQE or designee the GM1927-35 form

    Supplier submits GM SQE ensures GM SQE completed GM1927-35 to the GM 1927-35 is acquires GM SQ the GM SQE or designee completed Managers written approval

    GM SQE or designee statuses the R@R SQE statuses R@R as exempt

    Is Yes R@R END Status “Pass”?

    No END No

    Yes

    SQE SQE ensures issue Is a R @ R required? reschedules resolution January 2010 Page 5

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