P general motors supplier development general procedure

RUN @ RATE REVIEW CONTENT

The Run @ Rate will verify that the results of the supplier's actual manufacturing process meet customer requirements for on-going quality, as stated in PPAP, and quoted tooling capacity. Also, it will verify that the supplier's actual process is to plan, as documented in PPAP, GP-12 and the other documentation listed below.
During the Run @ Rate, the following will be reviewed: documentation; the manufacturing process and results; part quality requirements and results; sub-supplier requirements and Run @ Rate results; and packaging.

1. 
   DOCUMENTATION:At the time of the Run @ Rate, the following support documentation should be available for review:
   

1. 
   PPAP package including:
   

1. 
   Process flow diagram
   
2. 
   Process control plan, with reaction plan
   
3. 
   DFMEA/PFMEA
   
4. 
   Master part(s)
   

2. 
   GP-12 (Pre-launch) control plan
   
3. 
   Tool capacity information
   
4. 
   Operator/inspection instructions
   
5. 
   Prototype/pilot concerns (PR/R's)
   
6. 
   Sub-contractor control/capacity data
   
7. 
   Sub-contractor material schedules and transportation
   
8. 
   Packaging/labeling plan
   
9. 
   Acceleration plan.
   

Note: All documentation must be complete and correct.

B. MANUFACTURING PROCESS – ACTUAL TO PLAN

1. 
   The product is being manufactured at the production site using the production tooling, gaging, process, materials, operators, environment, and process settings.
   
2. 
   The actual process flow agrees with the process flow diagram, as documented in PPAP.
   
3. 
   Operator instructions/visual aids are available and adhered to at each work station.
   
4. 
   All in-process documents, such as process control charts, are in place at the time of the Run @ Rate. The documentation is utilized to drive a defined reaction plan and corrective action process.
   
5. 
   Production boundary samples, when required, are available at required work stations.
   
6. 
   Maintenance plans are in place; repair and maintenance parts are available; and there is planned downtime for preventative maintenance.
   

Note: All of the preceding requirements must be met to pass the Run @ Rate.

C. MANUFACTURING CAPACITY RESULTS

The following will be verified while the process is running.

1. 
   Net output from each operation can support quoted capacity.
   
2. 
   During the Run @ Rate, the tooling must meet the quoted up time requirements (net vs. gross quoted output). Any unexpected downtime must be documented and corrective action taken.
   
3. 
   All line changeovers, if any, can be performed within the quoted tooling capacity requirements.
   
4. 
   The net through-put of good pieces (scrap taken out, any allowable rework) meet daily quoted capacity.
   
5. 
   The acceleration plan is sufficient to meet requirements.
   

Note: All of the preceding five requirements must be met to pass the Run @ Rate.

D. PART QUALITY PLAN TO ACTUAL

1. 
   All production checking fixtures must be complete, with acceptable measurement system studies (i.e., gage R and R) performed, and operator instructions/visual aids available.
   
2. 
   All in process gaging and controls must be complete, functional and in place.
   
3. 
   The process control plan (normal and GP-12) must agree with the actual process. Production part checks and statistical monitoring must take place as outlined on the process control plan.
   
4. 
   Potential failure modes, as identified in the PFMEA, are addressed through error-proofing or the control plan.
   
5. 
   The process control plan reaction plan as well as the supplier's corrective action process to ensure containment and correction should be available for review.
   

Note: All of the preceding five requirements must be met to pass the Run @ Rate.

E. PART QUALITY RESULTS

1. 
   All parts produced off production tooling during the Run @ Rate meet GM's requirements for ongoing quality, as stated in PPAP.
   
2. 
   The manufacturing process is in control.
   
3. 
   The manufacturing process demonstrates the required capability.
   
4. 
   The process control plan is sufficient to effectively meet the design record requirements (i.e., control points, frequency of checks, etc.).
   
5. 
   Nonconformances
   

Note: The total number of parts produced, the pieces rejected and the pieces reworked need to be documented on the summary sheet.

1. 
   The non-conformances yielded by the process were identified by the normal PPAP control plan. If identified by the GP-12 Process Control Plan or an activity outside documented plans, corrective action is required.
   
2. 
   The PFMEA identified the potential failure modes. If not, the PFMEA needs to be updated and corrective action put in place.
   
3. 
   All rework and repairs effectively correct the nonconformance(s).
   
4. 
   All prototype and pilot concerns, if any, have been corrected and validated.
   

Note: All of the preceding five requirements must be met to pass the Run @ Rate.

F. SUBCONTRACTOR REQUIREMENTS

1. 
   Subcontractor(s)' abilities to meet the customer's quality and capacity requirements must be confirmed by the supplier prior to the Run @ Rate being conducted at the supplier's facility. Verification of the subcontractor(s)' manufacturing processes should be accomplished through a Run @ Rate or similar process conducted by the supplier.
   
2. 
   Controls must be in place to isolate incoming material until it has been approved.
   

Note: The preceding requirements must be met to pass the Run @ Rate.

7. 
   PACKAGING AND HANDLING
   

1. 
   In process and final shipment packaging will be reviewed for preservation of part quality and ease of use by supplier's operators loading and unloading parts. (Refer to GM 1738 for requirements.)
   
2. 
   The supplier's method for in process and final shipping packaging and handling must effectively eliminate the potential for process errors or mixed stock.