131025 GM 1927-30 QSB Audit

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Quality System B

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The QSB audit is a 'checklist' used to !o"ide o#$ecti"e e"ide%ce that satis&ies e%e(a%ual +

Sulie!s a!e !e,ui!ed to kee comleted coies o& the QSB audit- a%d accoma%yi%

#e uloaded i% QTS sulie! ce!t ta#+

Sulie! is !e,ui!ed to &o!0a!d a% udated sel& assessme%t e"e!y 12 mo%ths a&te! i%ima%a.e!- Quality (a%a.e! o! e!atio% (a%a.e!) o! !eeat Quality issue+

ot e"ie0ed is used 0he% immediate &ocus does %ot i%clude the st!ate.y+ la% to !eAlica#le is used i& a ,uestio% does %ot aly+ Questio% should #e .i"e% a sco!e o&

Sel&assessme%t audits ca% %ot a%d 0ill %ot #e ce!ti&ied 0ithout "e!i&icatio% #y a (( SQ ca% i%ut a &o!ecast date #y se%di%. sel& assessme%t to SQ e!t mail#o* 0i

"e!all sco!i%. o& 85 o! .!eate! 0ithout a%y ed st!ate.ies 0ill #e ce!ti&ied+ :i.h

ce!ti&icatio% 0ill o%ly occu! a&te! 6 day !e"ie0 e!iod o& !eductio% acti"ites se

A QSB ce!ti&icatio% is "alid &o! a 3 yea! e!iod+ The ce!ti&icatio% status 0ill #e made a%ote that this ce!ti&icatio% ca% #e !e"oked at a%y time du!i%. this e!iod i& it has #ee%0ill sot check se"e!al QSB eleme%ts at all ost ce!ti&icatio% "isits+

A /ist o& ( A!o"ed 3!d a!ty !o"ide!s is a"aila#le i% Suly o0e!

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;s the!e a system i% lace to catu!e i%&o!matio% that suo!ts co%ti%uous im!o"eme%ts to all oe!atio%s=!ocesses>

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*ast $esponse Process per#ormance istrac4ed7

Immediate revie% and timely responseo# all prolem resolution reports7.ig' P$$ duns locations (=@ SQ

related P$$Js in past 9= mont's) s'alle re2uired to per#orm P$$ reductionactivities (see itemKC in InstructionsS'eet)7 Score s'ould e E until P$$reduction activities are in place #or atleast CE days7

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T: S: C/Quality Q or ot'er met'od to trac4 *$ per#ormance is posted and up to date7Are P$$ assigned to a c'ampion #or immediate response and corrective actionsAre corrective actions roust enoug' to prevent #urt'er de#ectsL.ig' P$$ duns location s'all 'ave a special team created to %or4 on P$$ reductions -per#ormance s'all e trac4ed at *$ meeting on open issues list7

Quic4 pdatD&$!&7$evisar toda1esson 1ear*ormatos

A de#ined process #or Prolem Solvingincluding a standard #or documentingt'e tools used #or root causeidenti#ication7

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Standard process (PPS$8 :! or e2uivalent) used %it' a #ormat t'at #ollo%s t'e core HCStepsH o# prolem solving (97!e#ine8 =7ontain8 7$oot ause8 @7orrect8 ;7Dalidate8C7Institutionali5e)Prolem Solving #orms used across t'e plant #or internal8 customer and supplier issues7&vidence o# cross-#unctional team approac' and team memers got t'e necessarytrainingsools #or identi#ying root cause are applied (? diamonds8 !rill !eep " ; %'y to correct

systemic issues8 *is'one !iagram etc7)

AMA$I11, es N&&SA$A!A !,0Alertar a Provisita8 el docAudits y man

Prolem solving used e##iciently8all t'e core HC stepsH applied

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T: S: C/ ;& a (T Sulie!- +A+++ must #e imleme%ted+)

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Product removed #rom t'e approvedprocess #lo% #or repair or re%or46

- .as Approved 3or4 Instructions- Is re%or4ed y approved person

- Isreintroduced into t'e process at or prior to t'e point o# removal- Is traceale t'roug' an identi#ier- Is released using a de#ined process

and aut'ority7

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!ocumentation and evidence t'atindicates devices are veri#ied at least

once per day7

$eaction to #ailures and correctiveactions are documented7

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are easily accessile7$eaction plan includes %'o is noti#ied and actions to e ta4en7ontainment and corrective action documentation #or #ailures7

Auditorias de Missistema

&rror Proo#ing device locations s'all edocumented7

9) Master list o# all devices t'at prevent"detect t'e manu#acture or assemly o#noncon#orming product7

Por estacin7 $ev1uis Nieto7 Audito

Management revie%s results o#veri#ication7

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&ac' veri#ication #ailure needs to e escalated to *ast $esponse Meeting in order toavoid s'ipping out parts %it'out containment$evie% o# result o# veri#ications and 1ayered Audit in order to de#ine necessary step(increase #re2uency o# veri#ication or 1PA8 purc'ase reliale error detection device etc7)

CLA /ACA//A D (;STA

A de#ined 1ayered Process Audit (1PA)procedure t'at is o%ned ymanu#acturing7

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3ritten Procedure and 1ayered Audit 2uestionnaire templateAudit and %or4 instructions de#ine %'at to H1oo4 *orHounter measure process8 reaction plan %it' real target dates,%ned y Manu#acturing T: S: C/

.ig' ris4 items identi#ied and included in1PA Audit document8 #ocused c'ec4s onelo% sections63or4 Station - ;SPart"ProductProcessSystemDoice o# ustomerDeri#y *ast $esponse &xit riteria

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3or4 Station6 ;S8 3or4place organi5ation8 Sa#ety V list o# c'ec4s8 applicale to all %or4stationsPart-Product6 i7e7 *irst Piece Approval8 &rror Proo#ing veri#ication8 S,S"/&S 4ept8,perator raining Matrix8 Disual Aids8 *I*, etc7Process6 i7e7 Quality Alerts8 ool Set-up8 ontainment 1ogs8 ontrol Non on#orming8Gaging8 SP ompliance8 MM 1ogs8 etc7System6 i7e7 S'op *loor Management standards8 aliration ompliance8 PreventativeMaintenance8 ooling 1i#e Management8 etc7Doice o# ustomer6 i7e7 $unning containment due to 2uality prolem8 *ast $esponseMatrix8 Deri#ication Board8 Per#ormance Measurale8 Action Plans8 etc77 )Deri#y *ast $esponse &xit riteria6 i7e7 &xternal + Internal corrective action #or closure81essons 1earned etc7

Internal Process speci#ic audits areper#ormed (i7e7 Process"ommoditySpeci#ic Audit 8 QI audits etc7)

1ayered Process Audit under system speci#ic items8 %'ere applicale8 Audits #or specialprocesses are per#ormed and monitored7

All non con#orming issues are recorded

on t'e 1PA master document7

Non-con#ormances cannot e resolvedimmediately s'all e entered onountermeasure S'eet

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Sediment reduction strategy #or3as'ers"!eurProcedures #or maintaining integrity o#%as'er"deur process and control t'ea##ect o# sediment or contamination #orpart"product

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Procedures or %or4 instructions to selectand evaluate suppliers7

Supplier Quality Statement o# $e2uirement(SQ S,$) t'at contains all customerre2uirements8 expectations8 and processes

#or all potential suppliers7

9) Procedures t'at re2uire supplier audits (e7g76 Potential Supplier Assessment or PPA) tosupport sourcing decisions8 evaluation o# t'eir 2uality systems7

Approved supplier list (e7g76 Bidlist)SQ S,$ or e2uivalent signed y supplier&vidence o# SQ responsiility (SQ organi5ation c'art or SQ training records)

According#ollo%ed

Measurement and validation system #or 4eysuppliers per#ormance trac4ing

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Met'ods to determine ran4ing o# 0ey suppliers %it' revie%s o# supplier per#ormance tospeci#ied goals70ey Supplier list %it' de#ined metrics"goals$evie%s o# supplier per#ormance %it' a de#ined procedure and actions #or poorper#orming suppliers8 suc' as C panel7Met'od or process in place to communicate prolems and trac4 corrective action7

Su-Supplier APQP8 AIAG and customerspeci#ic re2uirement compliance

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&vidence o# tiered supplier compliance to AIAG PPAP8 APQP8 *M&As8 MSA8 and SPre2uirements7&vidence o# selection and designation o# 0Ps8 PQs 0s and Ps on engineeringdra%ings8 SP is applied #or 0P7Process speci#ic audits suc' as QI8 Sediment 7777etc are per#ormed per GMre2uirements

ustomer speci#ic re2uirements suc' as GM9R=?-E SQ S,$8 GP-R8 GP-9=8 1aellingetc7 implemented at tier supplier as %ell

Accordingre2uireme

Monitoring Su#Sulie! !ocess o%t!ol= ha%.esper#ormance

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ier I $evie% t'eir supply ase to ensure t'at6

&ngineering"process c'anges documented and communicated!emonstrate a systematic and disciplined approac' to prolem solving (tec'nical rootcause analysis and %'y t'e system #ailed (!! + 3ide)

A documented procedure #or monitoringand controlling all product8 process orsource c'anges7

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A c'ange #orm utili5ed to document all c'anges (engineering8 process and sourcec'anges)7 PP$ #orm is re#erence #or Po%ertrain suppliers'ange *orms are controlled t'roug' a !ocument ontrol Process7 (e7g7 trac4ing log

s'eet8 revision numering system8 approval process)Bot' planned and emergency c'anges covered y t'e c'ange procedure7All c'anges need to e !e"ie0ed a%d a!o"ed #y custome!7 In#orm GM SQ& in earlyp'ase to get approval e#ore 4ic4 o##7

Procedimi$evisar co

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=E o# :

QUALITY SYSTEMS BASICS AUDIT

Read through QSB Presentation (GM 1927-36) before !!ing audit for"

N E;D QF;D /H CO (

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$&DISA$ ,N /ADI&

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$&DISA$ ,N /ADI&

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$&DISA$ ,N /ADI&

N o!!ecti"e Actio% e,ui!ed @ S

ts leme%t Sco!i%.

leme%t is %ot i% lace a%d %o e"ide%ce o& la%s to imleme%t

1 leme%t is %ot i% lace #ut a la% to imleme%t is docume%ted

2 leme%t is i% lace #ut it is %ot #ei%. &ollo0ed

3 leme%t i% lace #ut %ot &ollo0ed at each $o# o! all the time

4 leme%t is i% lace a%d it is #ei%. &ollo0ed

Not $evie%ed6 0ey Strategy not audited at t'is time7 (raining $e2uired8 *ollo%-p $e2uired)

Note6 &nter appropriate score ased on $ > G score criteria and 'it enter7 orrect color %ill appear in $">"G cell7

Procedure to estalis' a de#inedProduction rial $un (P$) process7

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A standardi5ed communication procedure and #orm to control and monitor all Productionrial $uns t'at documents eac' step o# t'e process + records all approvals and results7Build readiness revie%s re2uired to aut'ori5e t'e start o# t'e trial run production process7Quality revie%s documented to release product #or P$ s'ipment and veri#icationprocess 'as returned to normal production7

A parts an4ing strategy"procedure #oridenti#ying8 protecting and retrieving longterm storage o# parts or materials7

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Procedure %it' responsiility #or t'e execution o# long term storage o# parts or materials84eep *I*, processustomer approval #or sa#ety stoc4 level&stalis'ed guidelines #or protective pac4aging #or parts and material7Quality revie%s to estalis'ed inspection criteria #or t'e aut'ori5ed release o# an4edparts and material prior to internal usage or s'ipment3ee4ly 1ayered Audit to ensure processes #ollo%ed

Procedure to aut'ori5e ypassingprocesses

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By-pass process approved y ,perations8 &ngineering and Quality manager8Standardi5ed 3or4 and training appliedA 3or4s'eet is used to trac4 eac' process t'at is in ypass7'e ypassed process is #re2uently audited #or compliance (Best Practice is 'ourly)Bypass processes are al%ays revie%ed y Quality Manager to ensure proper ac4-upinspections are in place and P*M&A and control plans updated7 ustomer to e noti#iedo# activites e#ore parts are s'ipped7

ot e"ie0ed is used %'en immediate #ocus does not include t'e strategy7 Plan to revie% in #uture7 Give #uture revie% date in comment ox

ot Alica#le6 is used i# a 2uestion does not apply7 Question s'ould e given a score o# @ and a note made in comment in ox7

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ess Performance QFA/;TM SMST(S BAS; AT; /A T

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plier Start !ate6 9="E"RR SQ&

ation $ev7 !ate6 SQ& P'one + *ax K6

ns Grad !ate6 12=3=99 Manager6

modity Program6 Group6

ed y6 reativity eam6

odesJ

Green - as4 ompleted on ime

M >ello% - as4 May Be 1ate

$ed - as4 is 1ate

I 3'ite - as4 $e-imed8 No Status

B Blue - as4 Status is Incorrect " Not pdated

No olor - as4 on rac4 ,A1 ,A1 SAS

&M AI,N I&M

SAS .IS,$>

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eso%se N o!!ecti"e Actio% e,ui!ed @

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!ol o%o%&o!mi%. !oduct N o!!ecti"e Actio% e,ui!ed @

catio% Statio%s N o!!ecti"e Actio% e,ui!ed @

da!died e!atio%s N o!!ecti"e Actio% e,ui!ed @

AI,N1&A!&$

!A&,P&N&!

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AA11,S& !A&

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red y6 reativity eam6

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ato! T!ai%i%. N o!!ecti"e Actio% e,ui!ed @

!oo& Ee!i&icatio% N o!!ecti"e Actio% e,ui!ed @

!ed !ocess Audits N o!!ecti"e Actio% e,ui!ed @

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eductio% N o!!ecti"e Actio% e,ui!ed @

ami%atio% o%t!ol N o!!ecti"e Actio% e,ui!ed @

ly hai% (a%a.eme%t N o!!ecti"e Actio% e,ui!ed @

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uns Grad !ate6 12=3=99 Manager6



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a.i%. ha%.e N o!!ecti"e Actio% e,ui!ed @

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ss Performance QFA/;TM SMST(S BAS; AT; /A T

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Person at supplier t'at prepared t'e #orm #or t'e GM SQ&7 (I# applicale)

AI,N I&M6 'e item t'at re2uires action to improve t'e process or 2uality o# t'e product eing produced7

Graduation !ate6'is !ate 3ill Be !etermined By GM SQ !irectors

*or P! SQ& ,nly6Identi#y %'ic' program your supplier is in HIQJ or HSQAH7

AI,N 1&A!&$6 'e person t'at leads t'e team to ma4e t'e improvements7 'is s'ould e t'e suppliers person ut may e a GM Management pe

*ormula6 !, N, >P& IN .IS &118 N1&SS >,$ A$& M,!I*>ING .& *,$M1A

SA$ !A&6 'e date t'e action item %as identi#ied and listed in t'e action item column

A$G& 1,S& !A&6 'e date t'e supplier %ill complete t'e action item7

'is date may c'ange7 I# t'e date c'anges8 you are re2uired to entry t'e correct color code in t'e pass status and present status columns7A comment on %'y t'e c'ange to e entered in t'e comment #ield

*ormula6 !, N, >P& IN .IS &118 N1&SS >,$ A$& M,!I*>ING .& *,$M1A

AA11,S& !A&6 'e date t'e action item %as closed , IN1!& DA1I!AI,N7

'e SQ& s'ould validate t'e action item as eing closed and $&S,1D&!7

1AS P!A&6 'e date t'e SQ& revie%ed t'e action item7

PAS SAS6 'e cell is #illed in %'en t'e status c'anges7 ,ldest status to t'e le#tI# status is 3.I& put a H3H in t'e cell7 !o not leave lan47opy t'e cell #or t'e correct color7

,1,$ ,!&6G$&&N6 as4 ompleted on ime>&11,36 Action item is in troule and may a##ect target date7$&!6 Action item 'as missed target date73.I&6 as4 $e-imed8 No StatusB1&6 as4 Status is incorrect " Not pdated

,N&$ M&AS$&S6

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QUALITY SYSTEMS BASI

Read through QSB Presentation (GM 1927-36)

N E;D QF;D 211 /H CO

1+ CAST SS< B/( S/E;- ((F;AT; a%d /SSS /AD;s the!e a system i% lace to immediately !eso%d to si.%i&ica%t i%te!%al a%d e*te!%al ,uality &ailu!es>

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;s the!e a de&i%ed !ocess &o! !o#lem Sol"i%. leadi%. to !oot cause ide%ti&icatio% a%d elimi%atio%>

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!aily leaders'ip meeting 'eld %it'cross-#unctional8 multilevel attendees toaddress signi#icantexternal and internalQuality concerns7

o eac' concern natural o%ner isdesignated8 next report out date isassigned

*ast $esponse (*$) meeting is o%nedy Manu#acturing

!aily leaders'ip meetingaddresses signi#icant Quality concerns7,%ned y Manu#acturing!esignates o%ners7

Assigns report out dates7ross-#unctional8 multilevel attendees7

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Prior to t'e audit c'ec4 last P$$s i# any7As4 i# t'ere are any signi#icant internal issues (e7g76 #Station8 doc4 audit or 1PA8 supplier issue etc)7 Prior tt'e oard i# t'ese issues addressed7 T: S: C/ ;& a (T Sulie!- +A+++ must #e imleme%ted+)

ontainment #orm or noncon#ormingmaterial #orm identi#ies expected

2uantity and locations o# suspectmaterial7Product in containment properlyidenti#ied7

ontainment #orm or noncon#ormingmaterial #orm identi#ies expected

2uantity and locations o# suspectmaterial7Product in containment properlyidenti#ied7

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Procedures or operator instructions #orsa#e8 clean8 and orderly arrangement o#

t'e %or4place environment t'ateliminate %aste8 provide a speci#iclocation #or everyt'ing8 contriute to'ig'er 2uality8 and t'e opportunity tostandardi5e and increase e##iciency7

Procedures or operator instructions #orsa#e8 clean8 and orderly arrangement o#

t'e %or4place environment t'ateliminate %aste8 provide a speci#iclocation #or everyt'ing8 contriute to'ig'er 2uality8 and t'e opportunity tostandardi5e and increase e##iciency7

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Systematic approac' #or 3or4place ,rgani5ation (li4implemented and maintained6

!e#ined in procedure level including standard mar4in,rgani5ation trained

Action plan %it' timing #or implementationAudit sc'edule and #eedac4 #or maintainA countermeasure s'eet or e2uivalent includes issueo%ner8 action and date #or correction7 T: S: C/

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N o!!ecti"e Actio% e,ui!ed @ 9+ TA(;AT; T/

;s the!e a system i% lace to co%t!ol co%tami%atio% 0he% a!o!iate>

sing 1PA #indings #or prolemprevention

Addition o# 1ayered Process Auditissues to t'e 1essons 1earned system7

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1PA results s'all e added to t'e 1essons 1earned appropriate

3'en appropriate noncon#ormance is added to *as7A7$7&7 process

P*M&As s'all e developed andmaintained y cross-#unctional teams#or all manu#acturing processes andsupport #unctions as re2uired y t'e

AIAG *M&A manual7

P*M&As s'all e developed andmaintained y cross-#unctional teams#or all manu#acturing processes andsupport #unctions as re2uired y t'e

AIAG manual7

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P*M&A is developed y cross-#unctional team7 'eteam7P*M&A availale #or all part numers and all operaScoring o# Severity",ccurrence"!etection are accor*M&A $e#erence Manual8 ratings are accurate7Potential cause o# #ailure de#ined speci#ically7 Amig(e7g78 operator error or mac'ine mal#unction8 etc7) sused7

Proactive approac' #or reduction o#'ig'estris4 items s'all e implemented7

Proactive approac' to reduction o#'ig'est $PN values 'as eenimplemented7 op $PN list %it' actionplans7

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3'en Severity is R or 9E8 P*M&A team ensures t'aaddressed t'roug' existing design controls or recomactionsPrioriti5ation ased on de#ined approac' (e7g76 com,ccurrence and !etection or $is4 Priority Numer e$ecommended actions documented %it' responsi$ecommended actions re-evaluated a#ter t'eir veri#

ross-#unctional teams 'ave periodicrevie%s o# P*M&A

ross-#unctional teams 'ave periodicrevie%s o# P*M&A and coordinate $PNreduction activitiesL

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ross-#unctional team agenda or ot'er evidence o# activities7!ocumentation t'at #re2uency and prioriti5ation o# rcustomer input8 process capaility8 process c'angeetcO$evie% c'ec4lists8 agendas or e2uivalent t'at assurevie% (all operations"processes (paint8 'eat treat8 laelling8 re%or4"repair8 etcO) are included and acc

All process controls are included7 !etection ratings are accurate7 ,ccurrence ratings are analy5ed using data (SP scrap data8 Deri#ication Station resultsetc7)

&vidence o# past 2uality issues andcorrective actions t'at 'ave eenimplemented7

&vidence o# past 2uality issues andcorrective actions t'at 'ave eenimplemented7

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'ec4 last P$$s or 2uality issues (example #rom po$evision date o# P*M&A lin4ed to past #ailures7$ecommended actionde#ined %it' actual target comeam validates t'e ne% ,ccurrence and !etection $PN7

Analysed %'y P*M&A did not predict #ailure (!rill !implemented to avoid in #uture

'ere is a $everse P*M&A-(Pro-active&rror Proo#ing) process in place veri#y

t'e $PN7

'ere is a $everse P*M&A-(Pro-active&rror Proo#ing) process in place veri#y

t'e $PN7

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ross-#unctional team conductson-station revie%7Sc'edule o# reverse P*M&A (timing #or revie% %it'

operation and its status "planned-done")7&vidence t'att'e #indings driven ac4 into Processontrol Plan8 3or4 Instructions as applicale7.ave ,ccurrence"!etection numers een revised7 T: S: C/'ose one station and per#orm a 2uic4 reverse P*Mcurrent controls rated properly and all potential #ailucreate ne% ones)

Managements support and revie% o# t'e$PN reduction process8 trainingre2uirements8 and trac4ing o# ris4reduction results7

Managements support and revie% o# t'e$PN reduction process8 trainingre2uirements8 and trac4ing o# $PNreduction results7

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Management revie% agenda"minutesNecessary resources allocated #or P*M&A develop%ell as recommended action implementation on timross-#unctional team training and individual 2uali#iveri#ied annually7

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QUALITY SYSTEMS BASI

Read through QSB Presentation (GM 1927-36)

N E;D QF;D 211 /H CO

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N o!!ecti"e Actio% e,ui!ed @

1+SF/M :A; (AA(T

;s the!e a systematic !ocess i% lace to co%t!ol sulie!s>

1+1

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!irt in Paint or PartProcedure #or maintaining t'e

processes to control and prevent dirtcontamination7

Process and Procedures #or Part.andling and Storage6

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Procedure or instruction descries dirt control and pareas6 People8 Process8 *acility and Material7

!irt a%areness training are 'eldApplication o# statistical met'od to monitor and contsuc' us dirt count (SP8 -c'art)8 dirt identi#ication 'ere is an active dirt reduction team and action pla T: S: C/

Documents

131025 GM 1927-30 QSB Audit