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1、GP-12Early Production Containment Procedure 早期生产件遏制程序GP-12 - Early Production Containment Procedure GP-12早期生产件遏制程序Key GP-12 Process and Procedure Questions 关于关于GP12程序和过程的普遍问题程序和过程的普遍问题What is GP-12?什么是GP12?Why do we perform GP-12?为什么我们要执行GP12?Who will perform GP-12?谁来执行GP12程序？When do we perform GP-1
2、2?什么时候执行GP12?How do we perform GP-12?如何执行GP12?Purpose目的目的 Validate the suppliers production control plan.验证供应商生产控制计划 Protect assembly, manufacturing centers, and service part warehouses from quality non-conformances during critical periods.保护在特定阶段总装，制造和售后不会接收到不合格品 Ensure that any quality issues that
3、 may arise are quickly identified, contained, and corrected at the suppliers location.保证可能发生的质量问题在生产过程中被识别，修正GP-12 - Early Production Containment Procedure GP-12早期生产件遏制程序Definition and Necessary Input定义及必要输入定义及必要输入Pre-Launch Production Control Plan 批量生产前控制计划 Is a significant enhancement to the suppl
4、iers production control plan and raises the confidence level to ensure that all products shipped will meet GMs requirements. The pre-launch control plan will also serve to validate the production control plan.GP-12 AuditGP-12评审GP-12 - Early Production Containment Procedure GP-12早期生产件遏制程序Entrance Cri
5、teria进入程序标准进入程序标准GP-12 is to be used for all pre-production, production, service, and accessory parts at the time of PPAP.GP12程序是适用于PPAP阶段所有的试生产，生产，服务及附件产品This procedure applies to all new and changed parts that require PPAP for start-up, acceleration, or revisions to the manufacturing process. Also
6、, when manufacturing runs are separated by 3 months or more.GP12程序适用于所有新变更的需要PPAP启动，产能提升，或者生产程序变更，或者生产间断3个月以上GP-12 - Early Production Containment Procedure GP-12早期生产件遏制程序Identification 标签识别标签识别Compliance to identify GP-12 was performed on parts that are being shipped to the customer is执行GP12程序过程中应使用
7、的标签 Attach to each shipping label a 25mm (approx.) green, circular sticker. 标签为直径25mm的绿色圆形标签，贴附于每个独体发送包装上面 Signed by a designated senior management representative accountable to insure proper implementation of GP-12. 由指定的有资质的管理层代表签字（如质保部长）保证GP12执行的有效性GP-12 - Early Production Containment Procedure GP
8、-12早期生产件遏制程序Frequency of Inspection检查频次检查频次GP-12 inspection is mandatory for 100% of all parts required through the GP-12 period. GP12执行阶段强制对所有零件进行100%GP12检查After manufacturing validation builds by the customer, based on documented acceptable performance, (no issues identified at GP-12 or by the cus
9、tomer), the Customer/SQE may approve a reduction of the 100% inspection requirements.主机厂进行生产验证后，基于产品评估报告（在GP12记录中没有问题报告，或主机厂没有问题报告发布），主机厂的供应商质量工程师可以批准进行降低检查比例。Any additional inspection or testing must also be approved by the Customer/SQE.所有附属检查试验必须经过SQE批准GP-12 - Early Production Containment Procedur
10、e GP-12早期生产件遏制程序DurationGP12执行周期执行周期GP-12 must be implemented for a period of time or quantity of parts as specified by the Customer or until the Production Control Plan has been validated, whichever is longer. GP12执行周期或者执行数量由主机厂制定（SQE),或者在生产控制计划验证后自然结束If time or quantity is not specified, GP-12 wil
11、l remain in effect through acceleration or a minimum of 2 weeks, whichever is longer.如果时间和周期没有指定，GP12将持续到产能爬坡结束或则至少2周时间GP-12 - Early Production Containment Procedure GP-12早期生产件遏制程序Exit Criteria退出条件退出条件Supplier will be eligible to exit GP-12 after validating the effectiveness of the Process Control P
12、lan and供应商在验证过程控制计划后可以申请退出GP12A.No problems identified, at supplier or customer, within the GP-12 period established.在GP12执行阶段，没有问题报告发生，包括供应商端及客户端B. If a problem is identified during the GP-12 period at the supplier or customer, GP-12 will remain in effect for a minimum of 2 weeks after implementati
13、on of corrective action or through the original GP-12 period, which ever is longer.如果在GP12执行过程中，有问题报告发生，无论在供应商端还是在客户端，GP12将继续执行，至少在改进措施执行后两周没有问题报告再次发生后，可申请退出GP12 If the GP-12 plan continues to identify non-conformances, the GP-12 plan must be kept in place until process controls and capabilities hav
14、e proven effective.如果仍然有不合格件发生，GP12将继续执行，直到过程控制和过程能力得到验证GP-12 - Early Production Containment Procedure GP-12早期生产件遏制程序Supplier Responsibility供应商责任供应商责任Develop an early production containment plan as specified in GP-12. Ensure that plan is in compliance with 1927-33 (GP-12 Audit)开发早期遏制程序，确保计划与GP12 审核相
15、一致.Root cause any non-conformances and implement additional checking provisions to the pre-launch checklist.在量产前的检查清单中包含所有的根本原因分析及不合格品控制，并应用Require compliance to GP-12 from all subcontractors, as well as monitor and maintain their records. 所有的GP12的程序需在二级供应商处执行，并监控和维护相关记录(This will require that subco
16、ntractors pull ahead their GP-12 to allow the Tier 1 GP-12 timing compliance.)Identify and communicate any changes to SQE.与SQE 识别，沟通所有的变更GP-12 - Early Production Containment Procedure GP-12早期生产件遏制程序SQE ResponsibilitySQE 责任责任Ensure GP-12 plan is available (timing and exit criteria has been defined) a
17、t Gate Review #3. 在Gate Review 3 的时间确保GP12 建立执行Verify the following are addressed by the pre-launch control plan:验证在量产前控制计划中包含所有以下信息High RPNsKCDS DesignatorsPRRPilot IssuesWarrantyPlant DisruptionsVerify that the supplier used the PFMEA and statistical data to determine what additional controls are
18、necessary.验证供应商使用PFMEA 和统计数据决定是否需要特殊的控制方式Ensure that 1927-33 (GP-12 Audit) is completed and assessed by Gate Review #4.确保在GATE 4 阶段GP12 评审评估完成Validate that the physical and systemic corrective actions for the root cause have been implemented and documented.验证系统的针对根本原因的整改方案被执行并记录GP-12 - Early Product
19、ion Containment Procedure GP-12早期生产件遏制程序GP-12 - Early Production Containment Procedure Red Flags!Below are a few things to look for when assessing a suppliers GP-12 process:以下几个方面需要在GP12 过程中对供应商进行评估Verify the location of the GP-12 area is separate from the manufacturing process, clearly defined, and
20、 has robust work and gauge instructions.验证GP12 程序执行地点-与生产过程分开，清晰的定义，并确定了工装的使用说明Verify that identification (green dot) stickers are signed by an senior management representative at the time of inspection. “Pre-signed” stickers are not acceptable. 验证在GP12过程中，绿色标签是被管理人员在检查现场帖附，在之前贴的不被认可Ensure that the
21、supplier is implementing GP-12 on all Tier 1 PTCs (Pass Through Characteristics) at their sub-contractors. 确保所有的免检特性也被GP12覆盖 GP-12 - Early Production Containment Procedure GP-12早期生产件遏制程序POST TESTtIs GP-12 required?vSensor is at Non-Saleable Status for a PPV Build vHousing Asm that has been in produc
22、tion since MY2007 has a PRR written for missing bushing vIntake Manifold that has been in production since MY2006 changes locations from Ohio to Hawaii vWhat about if location is across the streetvCamshaft has a process change to the tier 2-seal component YES, part is at a PPAP status and in pre-lau
23、nchNO, it is current part with no change, Controlled Shipping Process should be used, not GP-12.YES, the mfg process location is changing therefore changing the process. YES, the mfg process location is still changing.YES, the mfg process is changing but the tier 1 should push the GP-12 to be done a
24、t the Tier 2 location .GP-12 - Early Production Containment Procedure GP-12早期生产件遏制程序GP-12 AuditGP12 评审评审Audits the following elements for GP-12 compliance (30 questions total)GP12评审将关注以下几个方面的问题（共有30个问题）A.Technical Information Availability技术信息的获得B.Quality System Documentation质量系统文件C.Quality System Im
25、plementation Plan质量系统执行计划D. Quality System Implementation by ManagementC.质量系统管理层监管GP-12 - Early Production Containment Procedure GP-12早期生产件遏制程序GP-12 - Early Production Containment Procedure Key Reference Documents主要支持文件主要支持文件GM1920 (GP-12 Procedure)GP12程序说明1927-33 (GP-12 Audit)GP12评审GP-12 - Early Production Containment Procedure GP-12早期生产件遏制程序演讲完毕，谢谢观看！