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GM 1927-14-2 Powertrain


POWERTRAIN APQP Kick-off/Pre-Production Checklist
The purpose of this meeting is to develop a common understanding concerning the total requirements of the part/material by assuring that

proper communication and buy-in occurs between our companies. This form encompasses questions from the AIAG Advanced Product Quality Planning and GM APQP Manual GM-1927. Its intent is to ensure advanced product quality planning activities occur at the appropriate time and establish customer requirements for part qualification, part availability, quality, packaging, scheduling, terms & conditions, unit cost information, and tooling information. This document should be completed and provided to the Buyer prior to the meeting date. DATE: PROJECT/PROGRAM: SUPPLIER:

AP BUYER: PROD. BUYER ASQE REL. ENGR. PPM/Asst. PC&L REP. PROTO BUYER SPO SVC REP GM RECVG PLANT(S) ACTION PLAN #
PART NO:

MANUFACTURING
LOCATION:

SUPPLIER CONTACTS: - ACCT MGR - QUALITY REP. - SCHEDULING

PART DESCRIPTION:

CHANGE LEVEL CHANGE DATE

SECTION 1. CUSTOMER REQUIREMENTS
1. 2. Does the supplier understand all the applications and intended end uses of the parts/materials for all customers? Yes No Explain:

Does the supplier have the latest information about program timing (example: Drawing release, Prototype – series, Matching, Pilots, SOP)? Yes No Explain: Review Program Milestones with supplier. Key Project Milestones Dates Key Project Milestones Dates SOURCING PLAN MILESTONES – SPELLED OUT AS PER PPM SUPPLIED TIMING CHARTS

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3.

Does the supplier have and understand the QS-9000 Manual or TS16949 Manual, FMEA Manual, SPC Manual, Measurement Systems Analysis Manual, Quality System Analysis Manual, PPAP Manual and the Advanced Product Quality Planning (APQP) and Control Plan Manual? (Refer to GM Supply Power web site for the latest revision date of each manual.) Yes No Explain: Has the supplier provided all information listed in the Required Quality Information letter as outlined in the RFQ package? Yes No Explain: Does the supplier have and understand all the requirements listed in the Supplier Quality Statement of Requirements and has page 5 (and page 6 for Powertrain specific requirements) been signed and returned with the quote response to the Buyer? Yes No Explain: Does the supplier have and understand the requirements listed in the GM North America Operating Guide for Suppliers of Prototype Materials Yes No Explain:

4. 5.

6

7. Has the GM 1703 Container Assumption Form been provided and returned to the Buyer? Yes No Explain: 8. Are returnable containers required? Yes No Explain: 9. Are there any packaging issues to be resolved? Yes No Explain: 10. Does supplier agree to provide product in clean dunnage/containers? Yes No Explain: 11. Does supplier have electronic communications capability and required systems testing complete for scheduling and shipping? Yes No Explain: 12. Part Weight Net: Gross: __________ __________

13. Does supplier understand and agree to GM1700 GMNA Production Control & Logistics Requirements? Yes No Explain: 14. Does supplier understand premium freight policy? Yes No Explain:

SECTION 2. Product Design / Development
15. Does the supplier have and understand ALL of the latest drawings and specifications (SOR, SSTS, CTS, STD)? Yes No Explain plans to obtain: 16. Has an Advanced Development Validation (ADV) plan been provided, if specified in the SOR? Yes No Specify planned date: 17. If communication link for math data exchange is needed have appropriate contacts been taken? Yes No Explain: 18. If GM is design responsible, has a Design-FMEA review been done between supplier and the GM Engineer? Yes No Specify planned date: 19. If Supplier is design responsible, has a Design-FMEA been done? Are actions in place to reduce high RPNs? Has a review with the GM engineer been completed? Yes No Specify planned dates: Note: Design responsible supplier to complete AIAG A-1 Design FMEA Checklist; specify completion date:

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20. If supplier is responsible for system, has a system FMEA been completed and been reviewed? Yes No Specify planned dates: 21. Has a design review been done by the supplier and reviewed with the GM product engineer? Yes No If No, explain: If yes, has design review been approved by engineering and drawings/specifications revised as appropriate? Yes No If No, specify plans 22. Have KPCs and PQCs been identified and included in drawings/specifications? Is the supplier aware of the KPCs and PQCs? Is the supplier’s intended process able to meet the capability requirements of the KPCs and PQCs? Yes No Explain: 23. Does the supplier understand the critical nature of dimensions that interface with the customer’s application of their mating parts? Yes No List all known interfaces: 24. Are there any Mule/Alpha/Beta/Gamma/Prototype requirements? Yes No List them in the space below: MRD Type & Date (Alpha, Beta, etc.) Quantity Supplier Promised Date Comments – Is GP-11 required?

25. Does the supplier understand the requirements of GP-11 procedure? Yes No Explain: 26. Will the appropriate control plan be developed for use during each build i.e. Prototype, Pre-Launch, and Production? Yes No Explain: 27. Are controls for KPCs, PQCs and KCCs clearly identified? Yes No Explain: If no explain the process to control Critical Features (KPCs, PQCs and KCCs) 28. Is supplier’s version of Unigraphics compatible with GM’s current version? Yes No Explain: 29. Does supplier understand and accept responsibility for translation errors if current version of Unigraphics is not utilized? Yes No Explain: 30. Per SOR, what amount of design and or test is required by supplier?

31. When and how are Design deliverables required? 32. Does the supplier understand ISO14001 demands, GM environmental demands for product and process and made plans to fulfill them? Yes No Explain:

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SECTION 3. PROCESS DESIGN/DEVELOPMENT
Key Activities from the APQP Project Plan and Timing Chart (Ref. GM APQP 1927-1 & GM APQP 1927-2). 33. Does the supplier understand ALL items listed on the APQP Project Plan? Yes No Explain: 34. Has the supplier filled in the APQP Timing Chart for these parts? Yes No Explain: 35. GM Global APQP requires 4 Supplier Gate Reviews. In addition to the 4 reviews, specify your planned reporting frequency: _ 36. Have the following preliminary documents been completed? Process Flow Chart If No: Yes No Specify completion date: Process FMEA Yes No Specify completion date Control Plan Yes No Specify completion date 37. Has error proofing been considered during PFMEA creation and included in quoted price? Yes No If No, explain plans to achieve quality requirements

38. When will the Production Control Plan be ready? Planned date: _ Note: Specify the date each of the following AIAG checklists will be completed: A-6 Process Flow Chart Checklist: _ A-7 Process FMEA Checklist: _ A-8 Control Plan Checklist: _ 39. Is any new equipment, tooling, gages, special fixtures or test equipment needed to produce this part? Yes No Comment Review the tooling and gage breakdown .as submitted in the RFQ. 40. General Motors minimum required acceptance criteria for the PPAP initial study is a Cpk or Ppk of 1.67 (ref. AIAG PPAP Manual). Are any print, material specifications or process control plan changes needed to meet these requirements? Yes No Explain: 41. Has the supplier confirmed that their suppliers will do the following: 42. APQP Yes 43. PPAP Yes No No Explain: Explain: Explain:

44. Run @ Rate Yes No

SECTION 4.0 PPAP (Production Part Approval Process)
45. Lead-time for tooling ____________________

46. After tool completion, first parts off tools, lead-time for PPAP submission ____________________ 47. Is additional lead time required after PPAP approval to meet the QTC? Yes No Explain:

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48. Does the supplier understand the requirements for Full PPAP? Yes No Explain: 49. Does the supplier know where to obtain the required forms for PPAP? Yes No Explain: 50. Does the supplier understand the GM 1411 Interim PPAP form? Yes No Explain: 51. Have preliminary characteristics (KPCs/PQCs/KCCs) for capability studies for PPAP been defined? Yes No Explain: 52. Level of PPAP Submission required_____ 53. Define the number of samples to be submitted along with PPAP documentation. Total # of Samples: ________ Samples per Cavity: ________ Total # of Cavities: ________ 54. Name the GM person that you will send PPAP documentation and samples to: 55. Lead-time for production quantities after PPAP approval 56. Is a production trial run required? Yes No Explain: 57. Will Pilot/MVB (and pre-pilot, if applicable) parts be produced from 100% production tools? Yes No Explain: 58. Does supplier understand/agree that all pilot (and pre-pilot, if applicable) activity must be in accordance with GP4 requirements?. Yes No Explain: 59. GP-12 Early Production Containment – In effect from PPAP approval through 6-8 weeks after Start of System Fill (SSF) or other date to be specified by GM. Does the supplier understand the GP-12 procedure? Yes No Explain: 60. Does the supplier understand the GP-12 exit criteria? Yes No Explain: _______________________ _

Run @ Rate & Capacity Related
61. Fill in the following capacity information: A. What is the daily contracted capacity? B. Daily Max Capacity Rate (MCR) C. Number of tool sets required for LCR D. Number of machines/lines/cells required for LCR E. Capacity per tool set F. Net capacity per day G. Number of work hours per day H. Number of shifts per day I. Number of days per week J. Maximum sustainable tooling capacity 1) Hours per day 2) Days per week 62. Will LCR be met in 5 days, in 20hr/day Yes No Explain: 63. ____________________ ____________________ ____________________ ____________________ ____________________ ____________________ ____________________ ____________________ ____________________ ____________________ ____________________ ____________________

Run @ Rate GP-9 – Normally 8 Weeks Prior to SOP

Does the supplier understand the requirements for Run @ Rate? Yes No Explain:

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64. Does the supplier have all of the documentation needed to perform the Run @ Rate process? Yes No Explain: 65. Run-at-Rate Decision (Exempt, Customer/GM Monitored, Supplier Monitored) 66. Run-at-Rate Scheduled Date 67. Will staged R@R be planned? Yes No Explain: 68. State length of time the Run @ Rate must be performed: _ _______________________ _______________________

69. Fill in the following material status information for parts from serial/production tooling, if applicable: Material Status Parts for Matching (scribed) (GP6) Material from serial/production tooling/serial material with dimension/function OK Run @ Rate approved parts Required Date Promised Date Comments

70. Does the supplier understand the procedures that apply when problems occur at a GM plant?(GP-5, Containment Controlled Shipping level 1 & 2, New Business Hold, Global Sourcing) Yes No Explain:

SECTION 5.0 – SUPPLIER QUALITY PERFORMANCE
71. What is supplier’s PPM rating? ________________________________________________ 72. Does supplier have any parts currently in controlled shipping environment? Yes No Explain: 73. Does supplier have any PR/R’s that are not resolved? Yes No Explain: 74. Was a Business Case required? Yes No Explain: 75. Sourcing Risk Assessment (H,M,L) ____________ 76. Is supplier’s manufacturing location QS9000 certified? Yes Expiration Date No If no: GM waiver issued? Planned certification date: Name of Registrar:

SECTION 6.0 COMMERCIAL INFORMATION
77. Is piece price finalized? Yes No 78. Did supplier provide cost breakdown data sheet using form GM-1804? Yes No 79. Was delivered pricing provided? Yes No

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80.Has the cost for prototype parts been established? Yes No Piece Price $_____________ Tooling $_____________ 81. Does supplier agree to provide service requirements at production price levels for 3-5 years beyond last year in production? Yes No Number of years agreed to: 82. Are there any exceptions to the Statement Of Requirements (SOR)? Yes No Explain: 83. Is the supply location non-North American? Yes No 84. Has supplier quoted alternate F.O.B.’s? Yes No Yes Yes Yes No 1) F.O.B. – Supplier manufacturing location No 2) F.O.B. – Delivered price (includes all duties, taxes, etc.) No 3) F.O.B. – Warehouse a) Quantity to be held in warehouse: ______ 85. Is tooling cost finalized? Yes No Explain: 86. Did supplier provide cost breakdown data sheet using form GM-1810? Yes No 87. Does GM own tooling? Yes No 88. Is Tooling maintenance, refurbishment and replacement included in supplier’s price? Yes No Explain: 89. TIER II SUPPLIERS – Note the following information: Supplier Name Duns #

Location

90. Have potential cost savings on this or other programs been identified or recommended to GM? Yes No Explain: 91. Please provide the following duns numbers for contractual purposes: Header Manufacturing Remit To Schedule To Ship From Mail To 92. Does supplier have 4 digit Z code? If Yes, Z-Code = If not, please fill out the Supplier Information Form and make it available to your production buyer at the time of APQP Kick-Off Meeting. 93. Will this award be covered by an (A) Annual, (G) Long-term or (L) Life-time agreement? 94. If long-term or life-time agreement, has cost reduction/sharing formula been established? Yes No Explain: ___________ (A, G or L)

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95. Pricing each year of the agreement is as follows: 1st YR % ___________ 2nd YR % ___________ 3rd YR % ___________ 4th YR % ___________ 5th YR %___________ 96. Are there any patent issues? Yes No Explain: 97. Are there any exceptions to GM Standard Terms and Conditions? Yes No Explain:

SECTION 7 - OTHER ISSUES
98. Are employees at supplier’s location unionized? Yes No 99. If “yes”, UNION LOCAL EXPIRATION DATE _______________ _______________ _______________

100. Is the supplier participating in a Tier 1/Tier 2 Supplier Diversity Program? Yes No Explain: 101. Is supplier’s SPO rating satisfactory (SPDI of 1 or 2)? Yes No SPDI Rating: If “no”, has Action Plan been completed and submitted to SPO? Yes No Explain: 102. Has the supplier completed a “Declaration of Conformance / Restricted and Reportable Substances for Parts” form (GMW 3059) as required? Yes No Explain: 103. Are there any additional issues to be resolved? Supplier to list these issues and above concerns on the APQP Open Issues form (GM-1927-5) and provide to meeting attendees listed below. Warranty/IPTV commitments provided?

-

Risk and Reward Program

Yes

No

Date:

GM Attendees:

Supplier Attendees:

Advanced Supplier Quality Engineer (ASQE) Product/Design Release Engineer (DRE) AP Buyer: Production Buyer PPM/Asst. Materials Rep. SPO Rep./After Sales Manufacturing Engineer

Quality Manager Program Manager Manufacturing Engineer Quality Engineer

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