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Elements 13. Product Quality Standards 14. Manufacturing Process Validation 15. In-Process Control & Verification 16. Quality Feedback/Feedforward 17. Quality System Management

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Built-In Quality

GMS Element: Product Quality Standards Definition: Measurable requirements for product characteristics, which when satisfied, ensure our products meet internal/external customer requirements. Purpose: To provide cross functional groups with criteria for product evaluation. Core Requirements: 1. A documented process is in place to develop, approve, and revise the product

quality standards. 2. Product quality standards must satisfy customer (as determined from external

data such as surveys, clinics, etc.), engineering, and regulatory requirements. 3. Product quality standards are clearly communicated to the user/team member

at the work place. 4. Product quality standards are incorporated in standardized work. 5. Product quality standards are common within the facility (e.g. multiple lines)

as well as between facilities building the same platform/product line (vehicle, powertrain, panel).

6. Product quality standards are not tighter than those applied in upstream

processes. 7. Product quality standards are defined & applied at each stage of the process. 8. Product quality standards are measurable and/or comparable with

established criteria. 9. A formal process exists between engineering and the Plant to

feedback/feedforward the capability to meet quality standards.

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Built-In Quality

GMS Element: Manufacturing Process Validation Definition: The method by which processes are prepared and validated before starting full volume production on new products and post-SOP on current products. Purpose: To ensure that each manufacturing process is capable of meeting defined product quality standards, while achieving schedule. Core Requirements: In compliance with Global Vehicle Development Process: 1. Risk analysis methods (e.g. Failure Mode and Effects Analysis, Quality

Control Operation System, etc.) are used in the development of processes - minimum requirement: critical processes.

2. Error Proofing is incorporated in process/product design activity and

applications are reviewed as part of on-going problem prevention. 3. Process controls are identified and implemented to comply with engineering

and/or risk assessment requirements. 4. Primary and back-up tools, equipment, containers, gauges, material and

methods are validated prior to use (e.g. Conduct Operation Readiness). 5. Manufacturing Validation is conducted under production conditions. 6. Countermeasures (plans/actions) for identified problems are implemented

before next build event. 7. Processes are validated relative to changes to Man, Machine, Material,

Method, and Environment. 8. Inspection verification is increased in case of high quality risks such as (e.g.

model launch, and major changes, etc.).

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Built-In Quality

GMS Element: In-Process Control & Verification Definition: The system of building quality in station through prevention, detection, and containment of abnormalities. Purpose: To minimize process variation to ensure that all products are OK in station and are confirmed as soon as possible following manufacture and to reduce waste associated with defects. Core Requirements: PREVENTION 1. Standardized work is performed in cyclic and non-cyclic quality jobs. 2. Processes are controlled through the implementation of a TPM plan (e.g.

tooling and equipment). 3. Documented process controls are followed (e.g. QCOS, Process Control

Plans, Tooling and Equipment Bulletins). 4. Only parts that meet defined standards are delivered to the line. 5. Reviews of process equipment with high risk/impact (e.g. “critical

processes”, KPCs, Safety Regulations, etc.) are held to identify process capability and required corrective actions.

6. Lessons learned and error proofing process controls are applied to all lines.

Processes within similar models and the same plant use similar gauging, test equipment and methods.

7. Function and use of error proofing devices are verified on a scheduled basis

to maintain, consistent required functionality.

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Built-In Quality

GMS Element: In-Process Control & Verification (cont.) DETECTION 8. Required quality checks are included in all standardized work. 9. Quality check items and frequency are based on defined criteria/risk,

regulations, appearance, internal/external audits, customer feedback/survey, etc.

10. Sufficient resources are allocated in accordance with the quality plan (e.g.

space, time, people, equipment) to assure required “as shipped” quality levels.

11. Quality check systems are updated to reflect changes in risk levels and

process/product changes. Inspection verification is diminished to a auditing/confirmation role if/when capability reaches targeted levels over a specified time.

12. Inspection frequencies are established to prevent defects from leaving the

department/shop control.

13. The repair of documented discrepancies is verified utilizing standard tasks by independent inspection (man and/or machine).

14. Inspection verification is located, as a minimum, at end of each main

assembly shop/department (body, paint, GA) and is 100% for vehicle assembly operations; an audit check accompanied by part retention may be used in other applications (e.g. Powertrain, Press/Metal Fabrication, etc.)

15. Point, touch, listen, and count inspection methods are incorporated in

standardized work. 16. An alarm and escalation procedure is implemented to create an urgent

response to abnormal conditions.

17. Audio/visual signals and the ability to manage abnormal conditions exist at production and inspection stations.

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Built-In Quality

GMS Element: In-Process Control & Verification (cont.) CONTAINMENT 18. An Andon system when activated will stop the process at a fixed

location/position when discrepancies that impact downstream activities must be controlled in station.

19. A documented containment procedure is followed and the containment is

verified as being effective. 20. A problem solving process is initiated to identify permanent corrective

actions which are verified as being effective.

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Built-In Quality

GMS Element: Quality Feedback/Feedforward Definition: The communication of quality expectations and results between customers and suppliers through standardized communication pathways. Purpose: To ensure that information on quality reaches those who need it. Core Requirements: 1. Internal and external customers and suppliers of each process are identified

and a communication process is established. 2. Timing, content, and form of information required by customer/supplier at all

organizational levels is defined and applied. 3. In-process measurements are established and tracked for communication to

upstream/ downstream processes. 4. Information is fed forward in cases of escaped defects, backup

tool/equipment use, problem resolution and changes in process/product (man, machine, material or method).

5. Information is fed back in cases of identified defects and to communicate the

results of problem resolution. 6. A tracking element for follow-up of containment and countermeasures is

established.

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Built-In Quality

GMS Element: Quality System Management Definition: Common documentation, practices, procedures, and organizational structure that support managing the quality system. Purpose: To define and regulate the intended operation of the quality activities. Core Requirements: 1. Head of quality department reports to Manager/Director of the plant. 2. A strategic quality plan is developed for the organization and is followed. 3. An appropriate organizational structure is in place for quality related

functions that includes current model, and new model planning. 4. Documentation, procedures, practices, and management assessments are

compliant with the appropriate quality system standard(s). 5. The Business Plan Deployment process is used to manage measurements

and track progress to goals.