Drill Deep Worksheet

Revision Date: Name and Title: Supplier Team Lead: Provide a complete member list with contact information on Contact List Worksheet GM SQE: Supplier Duns: Supplier Name and Location: Supplier is Tier 1 to GM Issue Category: PRR PRTS Other , Specify : CDP Issue Number: Phone: RPN Severity Occurance Detection Original Final

Failure Mode: Effects of Failure Mode: Cause of Failure Mode: Point of Manufacture Tier 1

Drill Deep Why did the Manufacturing System not prevent this Failure Mode M2
**************** **************** ** **************** **************** **Manufacturing System Error Proofing & **************** Standardized Work **************** **

Corrective Action

Verification

Owner

Due Date

M1

Cause of Failure Mode

M3

Prevent

M4

M5

Quality Assurance
Why did the Quality System not Protect GM from this Failure Mode

M-RC

Q1

Q2
**************** **************** ** **************** **************** Quality System ** Error Detection & ****************Containment **************** **

Protect

Q3

Q4

Q5

Quality Control
Why did the Planning System not Predict this Failure Mode

Q-RC

P1

P2
**************** **************** ** **************** **************** Planning System ** informational content **************** documentation in all **************** **

Predict

P3

P4

P5

Quality Planning
What are the key findings based on this quality issue?

P-RC

B
**************** **************** ** **************** **************** ** **************** **************** **

REV: 10 05/15/06

Page 1 of 9

Print Date:5/4/2012

Drill Deep Worksheet

Revision Date: Name and Title: Supplier Team Lead: Provide a complete member list with contact information on Contact List Worksheet GM SQE: Supplier Duns: Supplier Name and Location: Supplier is Tier 2 to GM Issue Category: PRR PRTS Other , Specify : CDP Issue Number: Phone: RPN Severity Occurance Detection Original Final

Failure Mode: Effects of Failure Mode: Cause of Failure Mode: Point of Manufacture Tier 2

Drill Deep Why did the Manufacturing System not prevent this Failure Mode M2
**************** **************** ** **************** **************** **Manufacturing System Error Proofing & **************** Standardized Work **************** **

Corrective Action

Verification

Owner

Due Date

M1

Cause of Failure Mode

M3

Prevent

M4

M5

Quality Assurance
Why did the Quality System not Protect GM from this Failure Mode

M-RC

Q1

Q2
**************** **************** ** **************** **************** Quality System ** Error Detection & ****************Containment **************** **

Protect

Q3

Q4

Q5

Quality Control
Why did the Planning System not Predict this Failure Mode

Q-RC

P1

P2
**************** **************** ** **************** **************** Planning System ** informational content **************** documentation in all **************** **

Predict

P3

P4

P5

Quality Planning
What are the key findings based on this quality issue?

P-RC

B
**************** **************** ** **************** **************** ** **************** **************** **

REV: 10 05/15/06

Page 2 of 9

Print Date:5/4/2012

Drill Deep Worksheet

Revision Date: Name and Title: Supplier Team Lead: Provide a complete member list with contact information on Contact List Worksheet GM SQE: Supplier Duns: Supplier Name and Location: Supplier is Tier 3 to GM Issue Category: PRR PRTS Other , Specify : CDP Issue Number: Phone: RPN Severity Occurance Detection Original Final

Failure Mode: Effects of Failure Mode: Cause of Failure Mode: Point of Manufacture Tier 3

Drill Deep Why did the Manufacturing System not prevent this Failure Mode M2
**************** **************** ** **************** **************** **Manufacturing System Error Proofing & **************** Standardized Work **************** **

Corrective Action

Verification

Owner

Due Date

M1

Cause of Failure Mode

M3

Prevent

M4

M5

Quality Assurance
Why did the Quality System not Protect GM from this Failure Mode

M-RC

Q1

Q2
**************** **************** ** **************** **************** Quality System ** Error Detection & ****************Containment **************** **

Protect

Q3

Q4

Q5

Quality Control
Why did the Planning System not Predict this Failure Mode

Q-RC

P1

P2
**************** **************** ** **************** **************** Planning System ** informational content **************** documentation in all **************** **

Predict

P3

P4

P5

Quality Planning
What are the key findings based on this quality issue?

P-RC

B
**************** **************** ** **************** **************** ** **************** **************** **

REV: 10 05/15/06

Page 3 of 9

Print Date:5/4/2012

Supplier Contact List

Tier 1 Supplier Team Leader: Team Member: Team Member: Team Member: Team Member: Team Member: Tier 2 Supplier Team Leader: Team Member: Team Member: Team Member: Team Member: Team Member: Tier 3 Supplier Team Leader: Team Member: Team Member: Team Member: Team Member: Team Member: Tier 4 Supplier Team Leader: Team Member: Team Member: Team Member: Team Member: Team Member:

Supplier Name:
Name Title Phone E-mail

Supplier Name:

Supplier Name:

Supplier Name:

Tier 1 Tier 2 Tier 3 Tier 4

Formulrio Drill Deep(escavao profunda)

Data da Reviso: 07/23/08 Nome e Ttulo: RPN Severidade Ocorrncia Deteco Telefone: Lider do Time do Fornecedor: Rafael Abuhab 55 11 45476700 Prover a lista completa dos membros com informaes de Contato na Contact List (T) GM SQE (representante da GM): Cherubin Schwartz Duns do Fornecedor: 902300896 Nome do Fornecedor e Localizao: Forjafrio Industria de Peas Ltda. / Brazil Fornecedor srie 1 para a GM
CDP

Original 126 54 6 3 7

Final 6 3 3

Categoria da emisso(assunto):

PRR PRTS Other , Specify :

Nmero da emisso(assunto):

380033

Modo de Falha: Rebarba no vertice do chanfro interno Efeitos do Modo de Falha: Danos e parada da linha de produo da GM Causa do Modo de Falha: Uso da ferramenta de acabamento das faces at seu completo desgaste Ponto de Manufatura Tier 1

Drill Deep(escavao profunda) Por que o Sistema de Manufatura no fez a preveno desta Rebarba no vertice do chanfro interno M2
************************ **********

M1

Uso da ferramenta de acabamento das faces at seu completo desgaste No existencia de instruo que previsse reao para desgaste de ferramentas Plano decontrole no previa verificao da existencia de rebalba atravs de calibrador PNP

Ao Corretiva estudar vida util das arestas, fazendo trocas preventivas das ferramentas Criao de instruo baseada no estudo citado acima Incluso da verificao 100% da existencia de rebarbas/desvios do furo atravz de calibrador PNP

Verificao Fase de testes

Responsvel Rodrigo Rocha

Prazo 08/01/08

Aguardando teste (anual)

Rodrigo Rocha

08/01/08

M3

100%

M. Contiero

08/23/08

Preveno
M4 M5

************************ ********** de Manufatura - A Sistema

prova de erro & ************************ do Trabalho Padronizao

**********

M-RC

Qualidade Assegurada
Por que o Sistema de Qualidade no protegeu a GM de Rebarba no vertice do chanfro interno Q2
************************ **********

Q1

Planos de controle das operaes subsequentes no previam verificao especifica de rebarba/desvios no furo.

Verificao 100% com calibrador PNP ser feita proxima aos processos finais de produo

100%

Diogo Fontenele

08/04/08

Proteger

Q3

************************ Sistema de Qualidade ********** ************************ **********

Q4

- Deteco de erro & Conteno

Q5

Q-RC

Controle de Qualidade
Por que o Sistema de Planejamento no Preveu isto Rebarba no vertice do chanfro interno P2
************************ **********

P1

Tipo de defeito nunca antes presenciado

Incluso da falha no PFMEA para gerar historico

N/A

Robson Romero

08/04/08

Prever

P3

************************ Sistema de **********

P4

PLanejamentoContedo informacional em todos os ************************ documentos

**********

P5

Planejamento de Qualidade
Quais so as evidncias(encontradas) chaves baseada nessa assunto de qualidade?

P-RC

************************ ********** ************************ ********** ************************ **********

REV: 10 05/15/06

Page 6 of 9

Print Date:5/4/2012

Lista de Contato do Fornecedor

Srie 1 Fornecedor

Nome do Fornecedor:
Nome do Fornecedor: Lder do Time: Membro do Time: Membro do Time: Membro do Time: Membro do Time: Membro do Time: Rafael Abuhab Silvio Martins Robson Romero Diogo Fontenele Diretor Qualidade Gesto Qualidade Processos Ttulo Telefone 45476700 38366233 45476700 38366233 E-mail rafael.abuhab@forjaf rio.com.br silvio.martins@forjafri o.com.br robson.romero@forja frio.com.br diogo.fontenele@forj afrio.com.br

Srie 2 Fornecedor Lder do Time: Membro do Time: Membro do Time: Membro do Time: Membro do Time: Membro do Time:

Nome do Fornecedor:

Srie 3 Fornecedor Lder do Time: Membro do Time: Membro do Time: Membro do Time: Membro do Time: Membro do Time:

Nome do Fornecedor:

Srie 4 Fornecedor Lder do Time: Team Member: Team Member: Team Member: Team Member: Team Member:

Nome do Fornecedor:

Srie 1 Srie 2 Srie 3 Srie 4