GENERAL MOTORS SUPPLIER QUALITY GENERAL PROCEDURE (GP-9) RUN at RATE
THIS GP9 PROCEDURE APPLIES TO:
? TIER-1 SUPPLIERS
? RASIC B “DIRECTED BUY” SUPPLIERS ? TIER-1 VAA/SEQUENCERS
1. Purpose
The purpose of GP-9 is to verify that a supplier’s manufacturing or sequencing system (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 Supplier Daily Capacity (SDC) 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 Manager’s 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 customers.)
2. Scope
This procedure applies to all manufacturers, 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: Any exemption from this process must be approved by the GM SMT Supplier Quality Manager from the supplier manufacturing region. Exemptions will be reviewed in Supplier Quality Program Launch Readiness regional meetings for concurrence.
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GENERAL MOTORS SUPPLIER QUALITY GENERAL PROCEDURE (GP-9) RUN at RATE
3. Type of Run at Rate
The GM Representative will confirm the type of Run at Rate based upon the GM 1927- 07 APQP Supplier Assessment. The supplier will be notified of the need to perform a \Product Quality Planning Process as possible.
A. Customer Monitored
The supplier conducts the Run at Rate with the presence of a GM representative and submits a copy of the completed GM 1927-35 form(s) to that person. The Supplier also uploads all applicable 1927-35 forms to the Run at Rate Module of GQTS (Global Quality Tracking System) after approval of the GM representative.
B. Supplier Monitored
The supplier conducts the Run at Rate without the presence of a GM representative and submits a copy of the completed GM 1927-35 form(s) to the designated GM SQE. The Supplier also uploads all applicable 1927-35 forms to the Run at Rate Module of GQTS (Global Quality Tracking System) after approval of the GM representative.
Note: Equipment suppliers and/or subcontractors may be asked to participate in either customer or supplier monitored Run at Rates.
4. Preparation for Run at Rate
To ensure readiness for the Run at Rate evaluation and the Supplier’s (and Tiered Supply Chain’s) ability to meet GM’s contracted daily capacities, Vehicle and
Powertrain launch and acceleration plans, LCR and MCR rates, capacity planning and analysis is performed throughout the APQP timeline as part of the Supplier Readiness Valves (APQP Kick Off and SRV1, 2 and 3).
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GENERAL MOTORS SUPPLIER QUALITY GENERAL PROCEDURE (GP-9) RUN at RATE CAPACITY PLANNING AND ANALYSIS TASKS 1) Confirm with GM Purchasing Buyer that contract SDC is TIER 1 S S R R R R R I R R GM SQE R R S S S I A R I A APQP SRV1 SRV2 K/OFF X X X X SRV3 X X X X X X X X X X accurate and is greater than or equal to GM’s daily requirement (LCR). 2) Confirm with GM Purchasing Buyer if Staged Capacity is allowed in the contract? 3) Provide/update and evaluate Plant Layout 4) Provide/update and evaluate Manufacturing Block Diagram (include all processes, tools, banks, buffers, manpower, planning gross and net rates, first time quality assumptions and change over times, if applicable.) 5) Complete Sub-Tier Supplier Risk Assessment 6) Confirm SDC, LCR and MCR volumes been communicated to Sub-Tier Suppliers. 7) Provide/update and evaluate Sections 1 & 2 of GM 1927-35 Work Book including Shared Capacity and Build at Rate sheets when applicable. 8) Determine and communicate customer or supplier monitored Run @ Rate requirements to Tier 1. 9) Determine and communicate customer or supplier monitored Run @ Rate requirements to Tiered Suppliers. 10) Schedule R@R date with GM SQE or designee
X X X X X X X X X X X X X X X X z R = Responsible; A = Approve; S = Support; I = R = Responsible; A = Approve; S = Support; I = Inform; N/A = Not Applicable X = Required by Event
Practice Run at Rates or “Burst Builds” (short production runs) shall be conducted and documented prior to the actual scheduled Run at Rate.
The use of practice run at rates or burst builds should be utilized to the maximum
extent possible during the pre-production build events including PPAP runs, in order to validate the capability of the manufacturing system and/or to develop countermeasures as may be required to meet the SDC.
These practice production runs shall be performed under normal production operating conditions including planned production, maintenance, and support staffing levels and production rates.
Production and quality performance data is to be collected, documented and analyzed for capability at all potential system constraint operations, as well as the final assembly operation. This data is to include hourly production counts, scrap and/or first time quality (FTQ) data, scheduled and unscheduled downtimes, operational cycle times, and changeover times.
The Supplier may use their standard production and quality performance tracking systems to document the results of these practice runs provided it meets the above minimum requirements. The supplier may also adapt GM provided reference
production documentation (GM 1927-24) or the GM 1927-35 Run @ Rate form for these practice runs. All final Run at Rate documentation must be provided on the GM 1927-35 Run at Rate form and Shared Capacity Worksheets.
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GENERAL MOTORS SUPPLIER QUALITY GENERAL PROCEDURE (GP-9) RUN at RATE
5. Timing of Run at Rate
All Run at Rates must be conducted and initially statused no later than eight weeks prior to start of regular production (SORP). The Run at Rate should be performed after the supplier has attained a PPAP status of “Approved” or “Saleable”. Run at Rates conducted on “Non-Saleable” parts must be approved by the GM SQ Manager.
Whenever the contracted Supplier Daily Capacity increases on a part that already has a Run at Rate status, an additional Run at Rate is required. GQTS is required to be updated (prior to the effective date of the SDC change) with either the new Run at Rate result, or an exemption if the existing run at Rate is confirmed to meet the higher SDC.
Whenever an approved Engineering Change (EWO) requires new tooling and/or a manufacturing process change to a part that already has a Run at Rate status, an additional Run at Rate is required to confirm the part continues to meet the SDC.
GQTS is required to be updated (prior to the implementation date of the EWO) with the appropriate Run at Rate result.
6. 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, including impact of pending EWO’s ? Storage & Packaging ? Cost
? Production Day Length
? The cumulative documented production history from practice run at rates or burst builds
Any deviated Run at Rate plan must be sufficient to verify that the manufacturing
system can meet the contracted daily capacity while operating under normal operating conditions and under total customer requirements. Multiple Run at Rates or Burst Builds, each with a recommended minimum duration of four (4) hours, may be conducted during pre-production build events to accumulate adequate production
history to evaluate and status Run at Rate capability. The Run at Rate evaluation must also verify part, tool and equipment changeover times wherever appropriate.
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.
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GENERAL MOTORS SUPPLIER QUALITY GENERAL PROCEDURE (GP-9) RUN at RATE
7. Subcontractor Requirement
Tier 1 suppliers are required to ensure the ability of all of their sub-tier suppliers to meet their capacity, quality, and delivery requirements. The use of this GP9 Run at Rate Procedure is recommended for capacity planning and verification with the sub-tier suppliers throughout the APQP process.
On-site capacity verification is required for all suppliers identified as “Critical” in the Sub-Tier Supplier Risk Assessment (GM1927-07a Risk Assessment or equivalent) conducted by the Tier 1.
Tier 1 suppliers must have all of their sub-tier suppliers confirm in writing and provide documented evidence (GM 1927-35 or equivalent) to demonstrate their ability to meet capacity requirements.
Sub-tier suppliers may be exempt from Run @ Rate verification (non-critical
components like simple discrete electronic components or stock fasteners), however, they must confirm in writing that ample capacity is available to meet GM requirements. Rationale for exempting Run @ Rate verification of sub-tiers should be reviewed with the responsible GM SQE.
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 (including CC&A system fill requirements). This inventory may be considered part of the suppliers’ required safety stock/bank of parts to support GM’s launch. 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 Supplier Daily Capacity in one production day. In addition, the Tier 1 subcontractors’ abilities to meet the capacity, quality and delivery requirements has been confirmed by the supplier and are supported by documented evidence (GM1927-35 or comparable document).
B. Fail
A status of “Fail” indicates that the Tier 1 Supplier / VAA / Sequencer has NOT met the contracted Supplier Daily Capacity in one production day, OR the Tier 1 subcontractors’ abilities to meet the capacity, quality and delivery
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