RYGW

1927 31b PDCA Job Aid Reference Guide

Purpose:
This guide is intended to serve as a standardized reference for both Suppliers and SQE’s in
regard to the GM 1927 31a PDCA Wall Scorecard. The information provided in this guide
serves as best practices and examples of expectations outlined for Greenfield / Brownfield
Facilities globally.

Suppliers may utilize organization-specific formats as long as it meets the criteria as

outlined in the GM 1927 31a PDCA Wall Scorecard.
Important:
Please contact your Greenfield / Brownfield representative or regional SQE if you have any
questions and / or require additional job aid examples or assistance with the proper
execution of the GM 1927 31a PDCA Wall Scorecard.

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GM 1927 31b PDCA Elements

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Job Aid Reference Document
GM CONFIDENTIAL
 Table of Contents RYGW

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GM 1927 31b PDCA Elements

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Job Aid Reference Document
GM CONFIDENTIAL
 List of GM 1927 Documents RYGW
Element: Document Name:
GM 1927 31a
All Supplier Quality GM Documents are posted within GM 1927 31b
GM Supplypower EN-3 GM 1927 29
GM 1927 10
EN-7 GM 1927 04
PC-3 GM 1927 35
GM 1927 25
PC-4 GM 1927 16
QS-2 GM 1927 21
QS-3 GM 1927 09
QS-4 GM 1927 28
QS-5 GM 1927 16
QS-6 GM 1927 19
QS-10 GM 1927 35
GM 1927 25
QS-11 GM 1927 22
NOTE: Suppliers shall reference the latest GM documents as posted within GM SupplyPower
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GM CONFIDENTIAL
 RYGW

Suppliers
Log In / Federate
within
SupplyPower

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Job Aid Reference Document
GM CONFIDENTIAL
 RYGW

Select
Collaborate Tab

Select
Document Library

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GM CONFIDENTIAL
 RYGW

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GM CONFIDENTIAL
 RYGW

GM Document Name Example GM 1927 21

Select
Supplier Quality

Type
GM Document
Name

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GM CONFIDENTIAL
 RYGW

General Motors
Model Year
Program Name

PDCA REVIEW

Name of Commodity
Supplier Name
Supplier Program Mgr. Name
Date

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Job Aid Reference Document
GM CONFIDENTIAL
 Human Resources

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GM CONFIDENTIAL
HR - 1 Human Resources RYGW
Company Organizational Chart – Director Level
General Manager
Add names of personnel with all contact information

QS Systems IT Corp Purchase Divisional Plant Controller HR Manager/ Health

Manager Assistant & Safety
Controller
General Manager

Assistant
Quality Maintenance Press Shop & Tool Assembly Manager Materials Manager
Engineering Engineering
Manager Manager Room Manager
Manager Manager

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Job Aid Reference Document
GM CONFIDENTIAL
HR - 2 Human Resources RYGW
Launch Team Organizational Chart – Plant Name and Location
Plant Manager

Add names of personnel with all contact information

Quality Lead Manufacturing HR/ Payroll/ Safety Materials/ IT Production Production Quality Lab
Production
Engineer Engineer Production Supervisor Supervisor Supervisor Technician
Planner

Current Staff
Receptionist/Office Robotic Technician 2nd Robotic Weld Robotic Weld Robotic Technician Maintenance
1st Shift – 6 Operators Clerk Shift Technician 2nd Shift Technician

1st Shift – 2 Weld Repair Operators

1st Shift – 1 Material Handler

2nd Shift – 3 Operators

2nd Shift – 1 Weld Repair Operator
2nd Shift – 1 Material Handler

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Job Aid Reference Document
GM CONFIDENTIAL
HR - 3 Human Resources RYGW
Hiring Plan for All Personnel
Embedded file for formatting reference

Show names of all personnel assigned to the GM program along with job responsibility.
Show Hire date(s)
Include absenteeism and attrition rates per quarter
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Job Aid Reference Document
GM CONFIDENTIAL
HR - 3 Human Resources RYGW
Hiring Plan for All Personnel
Embedded file for formatting reference

Show names of all personnel assigned to the GM program along with job responsibility.
Show Hire date(s)
Include absenteeism and attrition rates per quarter
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Job Aid Reference Document
GM CONFIDENTIAL
HR - 4 Human Resources RYGW
Safety, Quality & Capacity Plan for:
Salary, Skilled Trades, and Operators

Workforce
Include names of personnel, job description and classification.
Include core training and job specific training for respective job classification.
Supplier shall have trained operator back up in the event of absenteeism, and or daily operational shortfalls. Trained back
up operators must be identified in the overall Training Plan.
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GM CONFIDENTIAL
 Facilities

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GM CONFIDENTIAL
F-1 Facilities RYGW
Construction Guidelines Check List
Embedded File for Formatting Reference

Construction Layout to encompass Lean Manufacturing Principles.

Layout shall provide adequate floor space for WIP and finished goods.
Need evidence that floor space assigned, meets overall plant capacity requirements.

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GM CONFIDENTIAL
F-2 Facilities RYGW
Facility Construction Progress Report
Embedded file for formatting reference

Update Progress Report per PDCA meeting cadence

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Job Aid Reference Document
GM CONFIDENTIAL
F-3 Facilities RYGW
Floorplan Layout with all Equipment
Power on date
Power on date

Power on date

Power on date

Layout shall provide adequate floor space for

WIP and finished goods.
Need evidence that floor space assigned, meets
overall plant capacity requirements.

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Job Aid Reference Document
GM CONFIDENTIAL
F-4 Facilities RYGW
EDI / IT Equipment Installation Plan

EDI setup between XXX & GM

We are now receiving EDI from GM (862 & 830)
Vendor EDI has now been setup between XX plant
sites
Week of month/ date training completed
More training schedule for month, year

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Job Aid Reference Document
GM CONFIDENTIAL
 Engineering

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GM CONFIDENTIAL
EN - 1 Engineering RYGW
Design Failure Mode and Effects Analysis Readiness
P/N xxxxxxxxx Part Name Program P/N xxxxxxxxx Part Name Program P/N xxxxxxxxx Part Name Program
CAD Level geo_fin001.001999 CAD Level geo_fin001.001999 CAD Level geo_fin001.001999

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GM CONFIDENTIAL
EN - 2 Engineering RYGW
Product Quality Characteristics / Key Product Characteristics Requirements
P/N xxxxxxxxx Part Name Program P/N xxxxxxxxx Part Name Program P/N xxxxxxxxx Part Name Program
CAD Level geo_fin001.001999 CAD Level geo_fin001.001999 CAD Level geo_fin001.001999

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GM CONFIDENTIAL
EN - 3 Engineering RYGW
Gage Readiness
Topics to illustrate but not limited to:
• Includes both Final End of Line Fixtures & any In-process and / or
Attribute type Check Fixtures
• Timing & Status of Gage(s) to meet Initial Part Tool Completion to
enable Gage R and Gage R & R for Part PPAP requirements.
• PO Kickoff, Chips Flying, Final Approvals.
• Must Follow GM 1927 29 Gauge Concept Design and Build review.
• Must Follow GM 1927 10 Gauge Fixture Standards.

NOTE: Always reference the latest GM 1927 29 Gauge Concept Design and Build review
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Job Aid Reference Document
GM CONFIDENTIAL
EN - 4 Engineering RYGW
Release Readiness

-Part list and WO tracking by PN with release number

Part List with Engineering Levels
-PDT minute /mail from DRE should be included to confirm list is upto date

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Job Aid Reference Document
GM CONFIDENTIAL
EN - 5 Engineering RYGW
Validation Status (ADVP&R)

-ADVP&R Format including start and completion dates approved by GM validation Engineer
ADVP&R Planning
-5 phases for testing that is late or in risk of being late

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GM CONFIDENTIAL
EN - 6 Engineering RYGW
Engineering Changes Summary
• anr70254, anr70300,
anr92815 Box Mounts
• ANR67669/ANR70096 – LH/RH FESM
• ANR94248 – FESM Lwr Reinf Bracket
PPV Status : Hard tool, no home line PPV Status : Full PPAP
Target Full PPAP Date Mar 15, 2018 Target PPAP Date Jan 26 2018

• ANS62480 – Jounce Cup • ANR84805 – Spare Tire Heat Shield bkt

PPV Status : Full PPAP PPV Status : Full PPAP
Target PPAP Date Feb 23 2018 Target PPAP Date Feb 26 2018

• ANR80751, ANR80752 - BRKT

COMPATIBILITY LH/RH • UCA 5mm Up Gauge • Rear Rail Patch
PPV Status : Hard tool, no home line PPV Status : Hard tool, special means PPV Status : Hard tool, no home line
Target PPAP Date Feb 26 2018 Target PPAP Date Apr 1, 2018 Target PPAP Date March 15, 2018

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Job Aid Reference Document
GM CONFIDENTIAL
EN - 7 Engineering RYGW
Manufacturing Change Request Plan (MCRs)
Follow GM 1927 04 Manufacturing Change Request
• Includes MCR Process Flow Chart
• MCR Rasic
• Part Data
• GD&T requested relief information
• PPAP approval after MCR is approved

NOTE: Always reference the latest GM 1927 04 MCR

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Job Aid Reference Document
GM CONFIDENTIAL
 Manufacturing Readiness

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GM CONFIDENTIAL
MR - 1 Manufacturing Readiness RYGW
MFG. Equipment Commissions Plan / Spare Parts
Lists / PMs
P/N xxxxxxxxx Part Name Program
CAD Level geo_fin001.001999

Supplier provide tracking documents for:

• Mfg. Equipment Commission Plan; Power on Date
• Spare Parts Activities
• Preventative Maintenance Activities.

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Job Aid Reference Document
GM CONFIDENTIAL
MR - 2 Manufacturing Readiness RYGW
Measuring and Test Equipment Readiness

• Process Optimization and Equipment Readiness (Status)

• Include laboratory Equipment and Personnel
• Process Capability Results, List by Equipment, Plan for Completion of Equipment
• Personnel Training and staffing Plan
• Must enable adequate timing to achieve Full PPAP
• Facilitize for Steady State Process Control Monitoring
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GM CONFIDENTIAL
MR - 3 Manufacturing Readiness RYGW
First Time Quality (FTQ) Glide Path
**** for APPV supplier to verify Target % with respective SQ SMT

MRD Matching APPV PPV1 NS1 S1 R @R SORP

Start of Production
(Min Req'd (Min Req'd
(Min Req'd 80%) (Min Req'd 100%) PPAP Gate
100%) 100%)
(Min Req'd
Part Vi sual Part # PART NAME **** (Min Req'd 100 %) (Min Req'd 100%)
100 %

New p/n
12345678 Ref. New p/n 84222565
EWO 12345
Actual
Actual 65.7% Actual 86.0 % Actual 87.7%
70.58%
EWO 2526578
Actual
Actual 75.8 %
62.72%
Actual 73.46% N/A Actual 88 % Actual 88.5 % Actual 89.4% Actual 94.0%

Actual 81.6% N/A Actual 99% Actual 99% Actual 99% Actual 100%

Actual
Actual 86.44% N/A Actual 91.5% Actual 92.8% Actual 93.7%
91.51%

N/A N/A N/A Actual 100% Actual 100% Actual 100%

Actual 100%
N/A Actual 100% Actual 100% Actual 100% Actual 100%
@ 5 May 2016

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Job Aid Reference Document
GM CONFIDENTIAL
MR - 4 Manufacturing Readiness RYGW
SDC
Number
Assemblies
xx LH=/xxx
xxofRH
SDC = xxx
hours
per hour
= xx= xxx pc/hr
Workstation Readiness
Number of hours = xx
Assemblies per hour = xxx pc/hr
xx LH / xx RH
Supplier Location

• Layout shall provide adequate floor space for WIP and finished goods, and
presence on manf. floor
• Need evidence that floor space assigned, meets overall plant capacity
requirements and operator instructions at workstations
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Job Aid Reference Document
GM CONFIDENTIAL
MR - 5 Manufacturing Readiness RYGW
Scrap Percentage Glide Path

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Job Aid Reference Document
GM CONFIDENTIAL
MR - 6 Manufacturing Readiness RYGW
Overall Equipment Effectiveness / Utilization Glide Path

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Job Aid Reference Document
GM CONFIDENTIAL
MR - 7 Manufacturing Readiness RYGW
Downtimes Glide Path

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Job Aid Reference Document
GM CONFIDENTIAL
MR - 8 Manufacturing Readiness RYGW
Stock Outs Report

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GM CONFIDENTIAL
 Materials Management

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GM CONFIDENTIAL
MM - 1 Materials Management RYGW
Tier II Value Stream Map

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GM CONFIDENTIAL
MM - 2 Materials Management RYGW
Bill of Material Process (BOM)

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Job Aid Reference Document
GM CONFIDENTIAL
MM - 3 Materials Management RYGW
Final Containerization Plan
Program - Component Name:
Note: Container ID:
Container Delivery Schedule:
Embedded excel file is
the GM 1738
Container Form for
your reference.
Supplier to check with
GM container group to
assure form is to latest
revision

This schedule will satisfy the rack needs for upcoming EDI releases and Run at Rate Build Event.
List of Open Issues, Owner and expected closure date.
Supplier to complete GM 1738 Container Form and submit to GM for approval .

NOTE: Always reference the latest GM 1738 Form

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Job Aid Reference Document
GM CONFIDENTIAL
 Purchasing and Supply Chain

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GM CONFIDENTIAL
PC - 1 Purchasing & Supply Chain RYGW
Commercial Issues Summary
Purchasing GM Contract
Supply Chain (Tier II) Contracts
Direct Buy Letters
Ensure if Stage Contracts match Run at Rate Manufacturing Plan

Current Contract -> xx Hrs.

Confirm SDC Requirements

List of Commercial Issues

1. Commercial issue
2. Commercial Issue
3. Commercial Issue

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Job Aid Reference Document
GM CONFIDENTIAL
PC - 2 Purchasing & Supply Chain RYGW
Tier II Full PPAP Approval Plan

Embedded File is GM SQ Elements PPAP Check List.

Supplier is encouraged to use similar process for their TIER II Supply Base
• Show summary of TIER II PPAP Approval Plan
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Job Aid Reference Document
GM CONFIDENTIAL
PC - 3 Purchasing and Supply Chain RYGW
Tier II Run at Rate Plan
Suppliers may use GM 1927 35 and GM 1927 25 and / or organization equivalent.
Run At Rate forms for Tier II Supply Base (Rasic A)
Supplier should download from GM Supply Power
• Show summary of Tier II Run at Rate Plan and expected completion date(s)

NOTE: Always reference the latest GM 1927 35 and GM 1927 25 Forms

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Job Aid Reference Document
GM CONFIDENTIAL
PC - 4 Purchasing & Supply Chain RYGW
Tier II Process Control Plan Assessment

Suppliers may use GM 1927 16 or Organizational equivalent for their TIER II

Process Control Plan Assessment (Rasic A) GM 1927 16
Supplier may download from GM Supply Power
• Show TIER II control plans with scheduled and actual completion dates

NOTE: Always reference the latest GM 1927 16 Process Control Plan Audit
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Job Aid Reference Document
GM CONFIDENTIAL
 Program Management
Summary

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GM CONFIDENTIAL
PM - 1 Program Management Summary RYGW
Program Timing

= Check
GM PDCA WALL PLAN
Product Design & Development Verification
AIAG APQP Latest Edition to be Process Design & Development Verification
followed Product & Process Validation
18Aug17 Production
29Jul16 18Nov16 15Feb17 Feedback Assessment & Corrective Action 12Mar18 03Jul18 03Sep18

CSO PQRR IVR PQRR IVS PQRR IVE PQRR PPV PQRR M VBns M VBs
-123 -107 -95 -68 -39 PQRR -23 PQRR -14
15Jul16 07Oct16 06Jan17 06Feb17 22Jan18 25May18 24Ago18
CVER / SVER LL IVER / IVER 02Oct17 / BiW CVER / SVER / IVER PPV BiW M VBns BiW M VBs BiW
P Re le as e -125/-113 P Re le as e -100/-96 M atcing MRD -62/-56/-47 M RD -46 M RD -28 M RD -15
19Feb16 01Feb17 / 22Feb17 2Mar17 29Jun18 31Ago18
4Dec17
M ULE BiW / GA IV BiW / GA M 1 GA M 2 & PPV GA M 3 & M VBns GA M 4 & M VBs GA
M RD -146 M RD -97/-94 M RD -53 M RD -40 M RD -23 M RD -14
Laun 04Dec17 15Dec17 25Jun18
26Jan18 20Ago18
PPAP PPAP ns PPAP ns VTC PPAP
GM GLOBAL GVDP follow specific M atching -53 BiW -51 GA 100% -45 -24 Gate -16
program timing SRV 2 SRV 3 20Ago18
APQP Kick Off SRV 1 (deadline -36) (deadline -25) PPAP
Within 30 days of nomination (deadline -76) -1 w k PPV -1 w k MVBns Approved
PQRR PQRR -16

PDCA WALL REVIEW Kick Off WR WR WR WR WR WR WR WR WR WR

Within 45 days of APQP KO -84 -76 -68 -60 -52 -44 -36 -28 -20 -12

-165 -104 -100 -96 -92 -88 -84 -80 -76 -72 -68 -64 -60 -56 -52 -48 -44 -40 -36 -32 -28 -24 -20 -16 -12

* PDCA wall review should start no later 30 days after APQP or Contract/Project KO Frecuency should be from 4-6 weeks
GM SQ to help supplier prep for Wall Review
Supplier is responsible to continously update wall content.
Onsite reviews preferred;display information contingent on regional prefernce.
Supplier to submit electronic copy to SQ upon completion of days review event
* Supplier is responsible to provide solution for Issues discovered Supplier Participants required

Mandatory: Support Team Minimum Mandatory Areas representation

Program Leadership, Engineering, Quality, Purchasing, Containerization, SQ

Responsible SQ Launch Rep Program Manager HR Facilities
Cross-functional teams Quality Manufacturing Purchasing

* Supplier to submit electronic copy to SQ upon completion of days review event

* Supplier is responsible to provide solution for Issues discovered

Example of PDCA wall review filled

NOTE: Suppliers must use Appendix B Program Description SOR

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Job Aid Reference Document
GM CONFIDENTIAL
PM - 2 Program Management Summary RYGW
Lessons Learned: include SPPS, Warranty, PALs, SWAs from current process / previous programs

PRR – Problem Reporting and Resolution / PAL – Preventive Action Letter / SWA – Supplier Warranty Analysis
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Job Aid Reference Document
GM CONFIDENTIAL
PM - 3 Program Management Summary RYGW
Executive Summary
Supplier Location: Detroit, US Current Status:
Current Part Numbers: 843 / 844
1)
Volume/GM Plants: Direct Ship to plants 2)

GM Plant
Volume
SORP Key Issues under review:
( LCR/Hrs.)
1)
2)
Lead Program Timing: Identify issues “GM HELP NEEDED”

PROGRAM
R@R date
MILESTONES

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Job Aid Reference Document
GM CONFIDENTIAL
PM - 4 Program Management Summary RYGW
Visual Bill Of Materials
Manufactured at XXX Manufactured at XXX – shipped from XXXX
P/N) P/N P/N
CAD Level geo_fin001.001999 CAD Level geo_fin001.001999 CAD Level geo_fin001.003999

P/N P/N P/N

CAD Level geo_fin001.001999 (MRD2 84166145) CAD Level geo_fin001.002999 CAD Level geo_fin001.001999

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Job Aid Reference Document
GM CONFIDENTIAL
PM - 5 Program Management Summary RYGW
Plan for Every Part

Complete work sheet

Embedded File for Formatting Reference
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Job Aid Reference Document
GM CONFIDENTIAL
PM - 6 Program Management Summary RYGW
Plan for Every M E (Manufacturing Equipment)

Identify all
equipment related
to manufacturing
process
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Job Aid Reference Document
GM CONFIDENTIAL
PM - 7 Program Management Summary RYGW
Component Readiness Valve (CRV)

Supplier to identify RED elements in CRV with action plan and recovery date
Scorecard Ratings RED if CRV rating elements are RED; and Green if all elements are Green
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GM CONFIDENTIAL
 Quality Systems

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GM CONFIDENTIAL
QS - 1 Quality Systems RYGW
PFMEA Assessment
Supplier to provide a confirmation of completed PFMEA documentation signed by Responsible Supplier and GM Personnel

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Job Aid Reference Document
GM CONFIDENTIAL
QS - 2 Quality Systems RYGW
DFMEA to PFMEA Gap Analysis Process and Transition Form
GM 1927 21
Supplier shall complete the GM 1927 21
• Complete GAP Assessment
• Identify deviations and corrective actions
• Where deviations are noted –
• use deviation form and obtain electronic approvals

NOTE: Always reference the latest GM 1927 21 Form

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GM CONFIDENTIAL
QS - 3 Quality Systems RYGW
S upplier Quality M S Action Plan
anagement ystem

GM 1927 09

• List matrix summary of action plans and status

NOTE: Always reference the latest GM 1927 09 Form

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GM CONFIDENTIAL
QS - 4 Quality Systems RYGW
GM 1927 28 Early Production Containment

List matrix status summary and show eye chart from collected data

NOTE: Always reference the latest GM 1927 28 Form

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Job Aid Reference Document
GM CONFIDENTIAL
QS - 5 Quality Systems RYGW
GM 1927 16 Process Control Plan Assessment
(PCPA)

NOTE: Always reference the latest GM 1927 16 Form

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GM CONFIDENTIAL
QS - 6 Quality Systems RYGW
GM 1927 19 PPAP Checklist

Supplier Shall Provide:

Non-Saleable Forecast Date(s)
Saleable Forecast Date(s)
Full Approval Date(s)

NOTE: Always reference the latest GM 1927 19 Form

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GM CONFIDENTIAL
QS - 7 Quality Systems RYGW
Critical Component Inspection Standard (CCIS)
Perceived Quality Alignment / Master Sample
• Identify and list all parts meeting the CCIS Standard / Master Sample

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GM CONFIDENTIAL
QS - 8 Quality Systems RYGW
Product and Process Capability Review
30-piece Capability Study MCR Form
GM 1927 04 Manufacturing Change Request

Supplier may use any Organization-Specific formatting.

MCR Form required when measuring points that are Out of Specification and Supplier requests dimensional relief.
• List all parts which completed Capability Study, and MCR request (if required) with acceptance dates
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Job Aid Reference Document
GM CONFIDENTIAL
QS - 9 Quality Systems RYGW
Lot Acceptance / Batch-Hold Traceability
Plan How to Measure Product Characteristics after PPAP
GMW Requirements by Commodity
Manufacturing day considered as a “lot” of material
• Safety Compliance Validation (Laser Score, Vibe Weld, Sonic Welds)
• Functionality Checks (Electrical)
• Raw Material Certifications
• Adhesion Validation (Wrapping)
• Dimensional Compliance Data
• Appearance Criteria to Established CCIS and / or Boundary Standards
• Welding (Metal or Sonic) Validation Process controls
• Verify correct shipping label is being used (reference BIQS Shipping Approved Packaging element)
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Job Aid Reference Document
GM CONFIDENTIAL
QS - 10 Quality Systems RYGW
Run at Rate Plan
Suppliers shall use GM 1927 35 and GM 1927 25.

Supplier shall download from GM Supply Power

• Show Glide Path Plan and status summary for incremental burst build plan
• Show summary Run at Rate Plan and expected completion date(s)
• Supplier to complete the Run at Rate Activity

NOTE: Always reference the latest GM 1927 35 and GM 1927 25 Forms

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GM CONFIDENTIAL
QS - 11 Quality Systems RYGW
MQRRs or GM 1927 30, and IATF 16949 Certification
GM 1927 22

Supplier shall demonstrate overall Glide Path for attainment of metrics

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GM CONFIDENTIAL
 Sharepoint RYGW
Access to Documents for GM Employees
https://share.gm.com/sites/GSQD/SitePages/Home.aspx
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GM CONFIDENTIAL