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• Audit- this audit MUST be completed above and beyond the QSB &
QSB+ to ensure this Systemic Material Handling issue has been
addressed at all Suppliers
IDENTIFYING
“GOOD” STOCK
QUARANTINE “BAD”
STOCK Conforming parts need to be identified
Quarantine Suspect/Nonconforming with a Green tag if it’s a fully finished
Non-
parts from good parts in all areas of part that is GOOD. Parts that are not
conforming the Plant or Warehouse to prevent FINISHED also must be identified
material mishandling of parts. Place parts in with a IN-PROCESS tag stating
a locked area or wrap parts with where in the process the part was
handling/
caution tape, again so they are removed (example: Removed
Containment CLEARLY IDENTIFIED. Operations 10, Ready for Operations
20).
Nonconforming Material Handling
All Suppliers are responsible for ensuring non-conforming material does not reach the customer.
This helps maximize manufacturing efficiency, and helps ensure end customer satisfaction,
strengthening vehicle sales performance
COMMUNICATE
ROBUST CONTAINMENT
If ANY GM facility is at IDENTIFYING STOCK
Non- risk of being presented Identify robust
conforming with non-conforming See Material containment process,
material, inform all key Identification slide and obtain appropriate
material GM contacts (SQE,SQA) approvals from GM SQ
identified immediately, at ALL and Engineering.
potentially affected
facilities globally
PERMANENT FIX Ensure compliance with the Initiate containment with the Work with key
Complete following material control assistance of the following GM customer
root cause process Audit (Slide 4) and checklists contacts to initiate
and Break containment worksheet. containment at
solution -Point
their facility(s) if
activities. potentially
affected.
Once audit is completed upload results into a SharePoint Survey by June 30th. If any Gaps
are found the supplier has until August 30th to fix those Gaps, on August 30th all SQE’s will
need to fill out a second SharePoint Survey to address Gap closure (see examples both survey’s
on the next slide).
Current Revise
Struc Supplier Original
Item QSB+ PCPA NSA Requirement Look for Comment audit d
ture score QSB+
score QSB+
Nonconforming Material / Material Sample audit to verify that team members understand what to do with nonconforming / suspect material.
Identification
Confirm that conforming material is handled, stored and identified appropriately.
Team members have standardized
work and understand what to do with Confirm that nonconforming / suspect material is clearly identified and/or segregated. Red, Yellow, Green
non conforming / suspect material. stoplight approach is adhered to for foot printing, containerization, table marking and tagging.
Conforming material is handled, stored Audit that all parts removed from the process are identified, accounted for (FTQ), and reconciled to
and identified appropriately. eliminate mishandling of material.
Non conforming / suspect material is Verify use of Department Containment Worksheets, with potential parts locations by operation identified to
clearly identified and/or segregated for ensure no parts are missed during a containment and all parts are reconciled.
review/disposition (i.e. appropriate
CNC-1 X color coding for foot printing – red, Looks for:
yellow, green). Parts should be physically tagged (no stickers), painted or locked-out upon identification to
ensure a conscious act is required to remove a part from quarantine (i.e. something must be
A containment method is in place to removed from each part before it can be mixed in with production material).
ensure that an effective breakpoint has All quarantined or rejected parts must then reconciled with total shift or daily production quantity
been established. Containment to ensure no parts are misplaced back into system.
activities and results are documented. Any lost parts must be traced immediately and include a reaction process to notify downstream
customers of any risk of loss of control of NC material.
These requirements should be common to parts quarantined or rejected line side as well as
larger quantities or pallets of parts quarantined or rejected in other parts of the plant.
Example of Audit Survey 1 & 2. Both must be
completed by the SQE on SharePoint.
*NOTE: Both audits are located in SharePoint, in the same
location as the current QSB survey.
4) Audit that all parts removed from the process are identified, accounted for
(FTQ), and reconciled to eliminate mishandling of material.
6) How many Gaps did you find during the Audit (0-5)?
1) Are all the Gaps found during the Audit in June closed (Yes or No)
a) If NO how many still OPEN (0-5).
b) Does Supplier have action Items on Open issue (Yes or NO)
c) Do you think Supplier should be given an extension to complete the
open items? (Yes or No).
Real Examples of Nonconforming Material
handling issues that have impacted GM
Example 1:
Issue Description
A GM Vehicle Assembly Plant found two failed Axel shafts in two different vehicles, prior to shipping to customers.
Root Cause
Both Axel shafts were setup parts off the Suppliers induction hardeners, both parts were intended for the Metrology Lab to
verify part hardness. The parts were not identified and became mishandled which allowed them to ship to the customer.
Result
Both Axel Shafts exceeded the hardness print spec. and resulted in two failed vehicle at the Assembly Plant.
Example 2:
Issue Description
Partially inserted Transmission Oil Cooling (TOC) line becomes disconnected and causes a fluid leak. This failure could
result in a thermal event.
Root Cause
Part was rejected from the Suppliers process by the Error Proofing and was no clearly identified as a nonconforming or
suspect part. The part was then mishandled and shipped to the Assembly Plant.
Result
Because the part was not identified it was mishandled and shipped, which resulted in a RECALL.
Example 3:
Issue Description
A GM Vehicle Assembly Plant received a halfshaft with a loose boot clamp.
Root Cause
The Suppliers error proofing camera rejected the halfshaft due to incorrect housing. The area Team Leader did an
unapproved repair/rework by installing the correct housing onto the halfshaft and then reintroduced the halfshaft back into
the process at the wrong operation, skipping the Boot Clamp operation.
Result
Two failures: 1) Once the part was rejected from the process it was not identified. 2) A unapproved repair/rework was
performed. The part was reintroduced back into the process at the wrong operation because an out of process unapproved
repair was performed with no controls to prevent this failure, which caused the vehicle assembly plant to receive the
defect.