GM-Customer-Specifics-Requirements-ISO-TS-16949-26Oct2016-1
GM Customer Specifics – ISO/TS 16949
Posted Date: October, 2016
Effective Date: December, 2016
Including GM Specific Instructions for PPAP 4th
Ed. (see Section 5)
Preface
General Motors Customer Specific Requirements - ISO/TS16949 Including GM Specific Instructions for PPAP 4th Ed. (see Section 5) NOTE: A revision history to the November 2014 Edition is also provided. However, it is the organization’s responsibility to review and apply the requirements of this document.
Table of Contents
Revision History (7)
1.0 Scope (12)
2.0 References (12)
3.0 Definitions (13)
Accredited Laboratory - 3.1 (13)
Active Part – 3 (13)
Aftermarket Part(s) – 3.3 (13)
Consulting – 3.4 ............................................................................. (13)
Customer – 3.5 .....................................................,.,. (13)
Ergonomics – 3.6 (13)
Initial Process Study –3.7 (14)
PPM (Parts Per Million –3.8 (14)
S-IpB (Severtiy Incidents per Billion –3.9 (14)
Quality Indices – 3.10 (14)
Organization – 3.11 (15)
Service Parts – 3.12 (15)
Suppliers – 3.13 (15)
Value-added Production Parts – 3.14 (15)
4. 0 Requirements.................................................................................. (16)
ISO TS 16949:2009 (Third Edition) June 2009 -Related Requirements - 4.1 (16)
Management of production tooling – 4.1.1 (16)
Records Retention – 4.1.2 (16)
Electronic Communication – 4.1.3 (16)
Shipment Notification System –4.1.4 (16)
Special Characteristics – 4.1.5 (16)
Design Changes – 4.1.6 (16)
Official Language Version –4.1.7 (17)
Part Approval Process –4.1.8 (17)
Customer Satisfaction –4.1.9 (17)
Internal Auditor Qualifications –4.1.10 (17)
Supplier Quality Management System Development –4.1.11 (17)
Customer Acceptance of 2nd Party Audits and Criteria for Approval
4.1.11.1 (18)
Supplier Development of Specially Designated Small Suppliers
4.1.11.2 (18)
Heat Treating Processes –4.1.12 (19)
Plating Processes –4.1.13 (19)
Coating Processes –4.1.14 (19)
Plastic Molding Processes –4.1.15 (20)
Solder Processes –4.1.16 (20)
BIQS Essential Requirements – 4.1.17 thru 4.1.28 …………………………21-25
Verification Station/Final Inspection /CARE / GP12 –4.1.29 (25)
General Motors – Specific Requirements –4.2 (25)
Third Party Registration Requirements – 4.2.1 (25)
General Procedures and Other Requirements –4.2.2 (26)
IS0/TS 16949:2009 Applicability – 4.2.3 (26)
UPC Labeling for Commercial Service Applications –4.2.4 (27)
Layout Inspection and Functional Test –4.2.5 (27)
Customer Signature on Control Plan –4.2.6 (27)
Certification Body Notification and Certification Status –“New Business Hold –
Quality” –4.2.7 (27)
Controlled Shipping Level II (CSII) – Notice to Certification Body –4.2.8 (28)
Management Review 4.2.9 (28)
5.0 PPAP – GM Specific Instructions (29)
Applicability – 5.1 (including Service Parts note) (29)
Requirements for Approval –5.2 ................................................, (29)
PSW Form –5.2.1 (29)
Acceptance Approval Report –5.2.2 (29)
Sample Production Parts –5.2.3 (30)
Control Plans – 5.2.4 (30)
Design Records –5.2.5 (30)
Design Failure Mode and Effects Analysis - 5.2.6 (31)
Material/Performance Test Results – 5.2.7 .............................. .. (31)
International Material Data System (IMDS) 5.2.7.1 (31)
Customer Notification of Supplier - Initiated Changes –5.2.8 (32)
Submission Levels –5.2.9 (32)
Part Submission Status –5.3 (32)
Approved 5.3.1................................................................ .. (32)
Saleable PPAP –5.3.2 (32)
Examples of Saleable PPAP - 5.3.2.1 (33)
Non-Saleable PPAP –5.3.3 (33)
Examples of Non-Saleable PPAP –5.3.3.1 (33)
Rejected PPAP - 5.3.4 (34)
SQMS Action Plan - 5.5 (34)
Revision History - March 2006 to current edition
1. Scope
ISO/TS 16949:2009, Second Edition, June 15, 2009, “Quality management systems – Particular requirements for the application of ISO 9001:2008 for automotive production and relevant service part organizations,” and this document define General Motors fundamental quality system requirements for organizations where automotive customer-specified parts, for production and/or service are manufactured. Third party certification to ISO/TS 16949 shall meet the following conditions: ?The certification scope must include both ISO/TS 16949 and the accompanying ISO/TS 16949 GM-Customer Specific Requirements,
?The certification must be conducted in compliance with the IATF recognized automotive certification scheme by a certification body currently contracted and recognized by an IATF
Oversight office.
All ISO/TS 16949:2009 requirements including the requirements of this document shall be addressed in the organization’s quality management system.
2. References
2.1 Chrysler, Ford Motor, General Motors Production Part Approval Process PPAP, Fourth
Edition, March 2006.
2.2 Chrysler, Ford Motor, General Motors Statistical Process Control (SPC),
Second Edition, July 2005.
2.3 Chrysler, Ford Motor, General Motors Advanced Product Quality Planning and Control Plan,
APQP Second Edition July 2008. Chrysler, Ford Motor, General Motors Measurement
Systems Analysis, MSA Fourth Edition, June 2010
2.4 Chrysler, Ford Motor, General Motors Potential Failure Mode and Effects Analysis, FMEA
Fourth Edition, July 2008.
2.6 Automotive Certification Scheme for ISO/TS 16949:, Rules for Achieving IATF
Recognition, Fourth Edition for ISO/TS 16949: November 2013
2.7 ISO/TS 16949:2009, 3rd Edition, June 2009
2.8 Minimum Automotive Quality Management System Requirements for Sub-tier
Suppliers, April 2013
The list above contains the most current editions. However, the latest edition or most current version of the reference documents listed applies unless otherwise specified by the GM Procuring Division. Copies of PPAP, APQP, FMEA, MSA, SPC, ISO/TS 16949 Rules, , and ISO/TS 16949:2009 and other related manuals are available from AIAG at https://www.wendangku.net/doc/dc1752822.html,. Copies of ISO documents are available from the American National Standards Institute (ANSI) at https://www.wendangku.net/doc/dc1752822.html,.
Certain documents listed above are requirements documents and are described as such in section 4 of this document. Section 5 of this document contains the GM PPAP Specific Instructions. PPAP is a requirements document.
3. Definitions
Where inconsistent terminology exists between ISO/TS 16949:2009 and this document, this document shall take precedence. Otherwise the definitions from ISO/TS 16949:2009 apply to this document.
3.1 Accredited Laboratory
An accredited laboratory is one that has been independently evaluated for technical competence. The criteria for evaluation are based on ISO/IEC 17025, or national equivalent. Accreditation is performed by qualified agencies (public or private) operating in accordance with ISO/IEC 17011.
NOTE: The above definition also applies to the reference manuals in Section 2 of this document and currently in effect.
3.2 Active Part
An active part is one currently being supplied to the customer for original equipment or service applications. The part remains active until tooling scrap authorization is given by the appropriate customer activity. For parts with no customer-owned tooling or situations where multiple parts are made from the same tool, written confirmation from the customer Purchasing activity is required to deactivate a part.
NOTE: For bulk material, “active part” refers to the bulk material contracted, not the parts that
are subsequently produced from that material.
3.3 Aftermarket Parts
Aftermarket parts are replacement parts not procured or released by OEM for service part applications which may or may not be produced to original equipment specifications.
3.4 Consulting
For the purposes of TS16949:2009, consulting is the provision of training, documentation development, or assistance with implementation of quality systems to a specific customer. If these activities are open to the public, advertised, and not customer specific, they are considered training rather than consulting. Other products, processes or services may be offered directly or indirectly, provided they do not compromise confidentiality or the objectivity or impartiality of its certification process or decisions. Refer to the most current version of Automotive Certification Scheme for ISO/TS 16949 Rules, (Currently in the 4th Edition). Also see ISO/IEC 17021.
3.5 Customer
References to “customer” in ISO/TS 16949:2009 and this document shall be interpreted as the Procuring Division of General Motors for suppliers pursuing third party registration to ISO/TS 16949:2009 to satisfy General Motors sourcing requirements third party quality system assessment registration.
3.6 Ergonomics
Ergonomics is the evaluation of the design of a product or process to assure compatibility with the capabilities of human beings. Analysis of motion refers to capabilities of people with respect to tasks (e.g. lifting, twisting, reaching) to prevent or relieve problems of strain, stress, excessive fatigue, etc. Factors involved include anatomical dimensions of the worker, placement of products to be worked upon, placement of buttons/switches, physical loads imposed on the worker, and environmental effects such as noise, vibration, lighting and space.
3.7 Initial Process Study
Initial Process Studies are short-term studies conducted to obtain early information on the performance
of new or revised processes relative to internal or customer requirements. In many cases, preliminary studies should be conducted at several points in the evolution of new processes (e.g. at the equipment
or tooling subcontractor’s plant, after installation at the supplier’s plant). These studies should be based on as many measures as possible. When utilizing X-Bar and R charts, at least twenty-five subgroups (minimum of four pieces per sub-group) are required to obtain sufficient data for decision-making.
When this amount of data is not available, control charts should be started with whatever data is available, or contact the authorized customer representative to develop a suitable plan. See also the Production Part Approval Process (PPAP) in Section 5.
NOTE: Initial Process Studies. The purpose of the initial process study is to understand the process variation, not just to achieve a specific index value. When historical data are available or enough initial data exist to plot a control chart (at least 100 individual samples), C pk can be calculated when the process is stable. Otherwise, for processes with known and predictable special causes and output meeting specifications, P pk should be used. When not enough data are available (< 100 samples) or there are unknown sources of variation, contact the authorized customer representative to develop a suitable plan.
3.8 PPM (Parts per Million)
PPM for a GM supply organization is impacted when both of the following conditions exist: ?Quality PRR is written with quantity discrepant and
?There are receipts for referenced part and duns number within the previous twelve months.
PPM for a supplier manufacturing duns is calculated monthly using the following formula:
1 Total all the “estimated quantity nonconforming” for all part numbers for that location
Note: Actual quantity nonconforming is used for supplier initiated PRR’s.
2 Divide by total receipts for that location
3 Multiply by 1,000,000.
3.9 S-IpB (Severity Incidents per Billion)
S-IpB for a GM supply organization is impacted when both of the following conditions exist: ?Quality PRR is written with a documented impact towards the GM final customer, GM manufacturing plant and GM product (vehicle, powertrain or component).
?There are receipts for referenced part and duns number within the previous six months.
S-IpB for a supplier manufacturing duns is calculated monthly using the following formula:
1. Each Quality PRR receives a weight factor based on the documented impact towards the
GM final customer, manufacturing plant and product
2. Total all the weight factors of all the Quality PRR’s received in the last 6 months for that
location
Note: Supplier initiated PRR’s and Supplier alerts are not included.
3. Divide by total receipts in the last 6 months for that location
4. Multiply by 1,000,000,000.
3.10 Quality Indices
See current edition of the DaimlerChrysler, Ford, and General Motors Statistical Process Control reference manual.
3.11 Organization
Organizations are defined as providers of: a) production materials, b) production or service parts, or c) heat treating, plating, painting or other finishing services, directly to General Motors or other customers subscribing to this document.
NOTE: See ISO/TS 16949:2009, Section 3, Terms and definitions.
3.12 Service parts
Replacement parts manufactured to OEM specifications, which are procured or released by the OEM for service part application.
3.13 Suppliers
Suppliers are defined as organizations that are providers of production materials, or production or service parts, directly to an organization who is a provider of General Motors or other customers subscribing to this document. Also included are organizations who are providers of heat-treating, painting, plating or other finishing services.
NOTE: The term “tier supplier(s)” refers to suppliers at any tier level in the automotive supply
chain.
3.14 Value-Added Production Processes
Refers to activities or operations that improve the product for which a customer is willing to
pay, where given the option.
See also ISO/TS 16949:2009, 3rd Edition (June 2009), definition of “manufacturing” 3.1.6, “site” 3.1.11, and “remote location” 3.1.10.
4. Requirements
4.1 ISO TS 16949:2009 (Third Edition), June 2009 - Related Requirements
All references to clauses in this section pertain to ISO/TS 16949:2009, unless otherwise stated.
4.1.1 Management of production tooling
Where warehouses or distribution centers (distributors) are remote sites, the requirements for management of production tooling (cl.7.5.1.5) may not be applicable.
4.1.2 Records Retention
Supplier Business records shall be retained as specified in GMW15920:
4.1.2.1 Production part approvals, tooling records, Advanced Product Quality Planning (APQP) records, purchase orders and amendments shall be maintained for the length of time that the part (or family of parts) is active for production and service requirements plus one calendar year unless otherwise specified by the customer.(See 6.1).
Note: Customer purchase orders/amendments are included in this requirement. Organization purchase orders/amendments for customer-owned tooling are included in this requirement.
4.1.2.2 Quality performance records (e.g., control charts, inspection and test results) shall be retained for one calendar year after the year in which they were created.
4.1.2.3 Records of internal quality system audits and management review shall be retained for three years. Note: Retention periods longer than those specified above may be specified by an organization in their procedures. The organization shall eventually dispose of records.
Note: These requirements do not supercede any regulatory requirements. All specified retention periods shall be considered "minimums".
4.1.2.4 As a reference, the following is a list of the 18 requirements from Production Part Approval Process (PPAP).See Retention/Submission Requirements and the GM Information Lifecycle Management (ILM) retention period for each item:
4.1.2.4.1 Design Record. For proprietary components/details, Production Run +50 years with review. For all other components/details Production Run +50 years with review.
4.1.2.4.2 Engineering Change Documents, if any. Production Run +50 years with review
4.1.2.4.3 Customer Engineering Approval, if required. Production Run +50 years with review.
4.1.2.4.4 Design Failure Mode and Effects Analysis (DFMEA). Production Run +50 years with review.
4.1.2.4.5 Process Flow Diagram. Production Run +50 years with review.
4.1.2.4.6 Process Failure Mode and Effects Analysis (FMEA). Production Run +50 years with review.
4.1.2.4.7 Control Plan. Production Run +15 years.
4.1.2.4.8 Measurement System Analysis Studies. Maximum three years.
4.1.2.4.9 Dimensional Results. Production Run +50 years with review.
4.1.2.4.10 Material and Performance Test Results. Production Run +15 years.
4.1.2.4.11 Initial Process Studies. Production Run +15 years.
4.1.2.4.12 Qualified Laboratory Documentation. Production Run +50 years with
review.
4.1.2.4.13 Appearance Approval Reports (AAR), if applicable. Production Run +15
4.1.2.4.14 Sample Products. Production Run +50 years with review.
4.1.2.4.15 Master Sample. Maximum three years.
4.1.2.4.16 Checking Aids. Production Run +15 years.
4.1.2.4.17 Records of Compliance with Customer Specific Requirements. Production Run +50 years with review, including sub-suppliers.
4.1.2.4.18Part Submission Warrant (PSW) (including GM3660 - the supplier obtains GM3660
from Automotive Industry Action Group/Supplier Quality (AIAG/SQ) team – the documents are part of PPAP
– those documents are not handled by IHS but by Purchasing directly) and related documentation). Production Run +50 years with review.
4.1.3 Electronic Communication
Reference cl.7.2.3.1
NOTE: Examples of such systems for suppliers to GM’s North American Operations are: 1)
requirement planning information such as the Electronic Data Interchange (EDI) ANSI ASC X12 830 transaction set or the EDIFACT DELFOR message, and 2) shipping schedules such as the ANSI ASC X12 862 or 866 transaction sets or the EDIFACT DELJIT message.
4.1.4 Shipment Notification System
Reference cl. 7.2.3.1
NOTE: Examples of such systems for suppliers to GM’s North American Operations are: 1) the ANSI ASC X12 856 transaction set, or 2) the EDIFACT DESADV message.
4.1.5 Special Characteristics
The supplier shall use General Motors Key Characteristic Designation System definitions and symbols to comply with ISO/TS 16949:2009 special characteristics requirements
(e.g. cl. 7.2.1.1), and as provided in 4.2.2, General Procedures and Other Requirements, and 4.2.2.11, Key Characteristic Designation System (KCDS), (GM 1805 QN) which defines GM’s approach to “special”characteristics.
NOTE: GMW 15049 replaces GM 1805 QN for all global programs beginning with 2009 MY and all other programs beginning in 2010.
4.1.6 Design Changes
All design changes, including those proposed by suppliers, shall have written approval by the authorized customer representative, or waiver of such approval, prior to production implementation. See cl. 7.3.7 and 7.1.4. See also the Production Part Approval Process (PPAP) manual.
For proprietary designs, impact on form, fit, function, performance, and/or durability shall be determined in conjunction with the authorized customer representative so that all effects can be properly evaluated.
4.1.7 Official Language Version
The English language version of ISO/TS 16949:2009 or related reference documents shall be the official version for purposes of third party registration.
Sanctioned translations shall:
?be for reference only,
?reference the English language as the official version,
?not contain ISO 9001:2008 text verbatim, and
?include an appropriate copyright statement.
Any other language translations are not authorized.
4.1.8 Part Approval Process
The organization shall comply with the Chrysler, Ford, and GM Production Part Approval Process (PPAP) manual to comply with cl. 7.3.6.3
NOTE: PPAP-Vehicle Assembly Centers (Assembly Plants)
Unless otherwise specified by the Customer, PPAP requirements for vehicle assembly centers
shall be taken from a specified production run of saleable pilot vehicles.
4.1.9 Customer Satisfaction
Trends in quality system performance and customer satisfaction (see Cl. 5.2, 5.6.1.1, 7.4.3.2, and
8.2.1.1) should be compared to those of competitors, or appropriate benchmarks, and reviewed by top management.
4.1.10 Internal Auditor Qualifications
Internal auditors should be qualified as recommended in ISO 19011:2011 – Sections 7, Competence and Evaluation of Auditors, In addition internal auditors should be competent in understanding and applying the Process Approach of Auditing (See “Process Approach”, Section 0.2 of ISO/TS
16949:2009), Core Tools including PPAP and other reference manuals including APQP, MSA, SPC, and FMEA and GM Customer Specifics, as applicable.
NOTE: A process and plan with implementation monitoring for assurance of qualified internal
auditors is evidence of compliance.
4.1.11 Supplier Quality Management System Development (cl. 7.4.1.2)
“Goal of supplier conformity with [ISO/TS 16949]” may be met by either of the
following:
?Sub-tier suppliers to achieve accredited third party certification to ISO/TS
16949, or the current version of ISO 9001.
?Successful assessments of the Sub-tier suppliers in conjunction with the requirements in
4.1.11.1 of this document for 2nd party auditor.
The frequency of these reviews shall be appropriate to the sub-tier supplier impact on customer satisfaction.
NOTE: 1: This supplier development clause, cl. 7.4.1.2, applies to suppliers of the organization who are providers of production materials, or production or service parts, directly to a supplier to Chrysler, Ford, General Motors or other customers subscribing to this document. Also included are providers of heat-treating, painting, plating or other finishing services.
Indirect and service providers are not included in this requirement, e.g. distributors adding no
manufacturing value, logistics, sequencers, parts packagers, tooling & equipment.
NOTE 2: The use of customer-designated suppliers to the organization (subcontractors) does
not relieve or eliminate the responsibility of the supplier for ensuring the quality of subcontracted parts, materials and services.
4.1.11.1 Customer acceptance of 2nd Party Audits and Criteria for Approval General Motors will recognize 2nd Party audits as compliance to ISO/TS 16949:2009, Clause 7.4.1.2 and as an alternative to ISO 9001:2008 certification. The statement of authorization below provides the requirements and conditions for GM approval.
The organization that utilizes 2nd party assessment to comply with clause 7.4.1.2 is required by General Motors to utilize second party assessors who satisfy all elements of the criteria specified as “GM approved 2nd Party requirements” stated below.
GM-approved 2nd Party requirements:
1. The organization (2nd Party) must be IATF certified and registered to ISO/TS16949:2009.
2. The organization (2nd Party) cannot be on ISO/TS 16949:2009 probation or suspension.
3. The organization (2nd Party) must utilize a qualified ISO Lead Auditor, or a qualified Internal Auditor with evidence of their successful completion of training, such as PPAP "Internal Auditing for ISO/TS 16949:2009," or evidence of a minimum of five internal ISO/TS 16949 audits under the supervision of a qualified Lead Auditor.
4. The organization (2nd Party) must audit annually each qualifying supplier for whom it has performed a 2nd Party assessment, and maintain records of these audits.
5. The duration of these audits must conform to the full application of the Audit Day Requirements table of the current edition of Automotive Certification Scheme for ISO/TS 16949 Rules for Achieving IATF Recognition.
6. Any of the IATF recognized and currently approved auditors may perform such audits when contracted by the organization.
4.1.11.2 Supplier Development of Specially Designated Small Suppliers
When a supplier to an organization is so small as to not have adequate resources to develop a system according to ISO/TS 16949:2009 or ISO 9001:2008, certain specified elements may be waived by the organization of their supplier. The organization shall have decision criteria for determining “specially designated small suppliers”’. Such decision criteria will be in writing, and applied consistently in the application of this provision. The existence and use of such decision criteria shall be verified by 3rd party auditors.
NOTE 1: ISO9001:2008 and ISO/TS16949:2009 contain fundamental quality management system requirements of value to any size of provider of production/ service parts/ materials. There are a number of methods to implement a compliant system, so it is recognized that a simpler Quality Management System approach could be used for the smaller suppliers of organizations to which ISO/TS 16949, clause 7.4.1.2 applies.
NOTE 2: “Small”may also refer to volume supplied to automotive.
4.1.12 Heat Treating Processes
Clause 8.2.2.2 of ISO/TS 16949:2009 requires that the organization shall audit each manufacturing process to determine its effectiveness. Applicability and effectiveness of heat treating processes shall be determined utilizing the most current version of CQI-9, (Currently in the3rd Edition),, Special Process: Heat Treat System Assessment (HTSA), published by AIAG, and records maintained. The effectiveness evaluation shall include the organization’s self-assessment, actions taken, and that records are maintained.
This requirement shall also apply to heat treat suppliers to the organization pursuant to ISO/TS 16949:2009 Clause 7.4.1.2 (supplier development clause).
.
NOTE 1: 2nd Party assessment by a competent auditor and meeting the above requirements will satisfy the self-assessment requirement.
NOTE 2: Implementation effectiveness should be based on evidence that the organization has a process in place that includes elements such as auditors identified, schedule for self-assessment in place including schedule adherence, supplier development process identified for applicable suppliers, monitoring of progress, defined corrective action process and record-keeping.
4.1.13 Plating Processes
Clause 8.2.2.2 of ISO/TS 16949:2009 requires that the organization shall audit each manufacturing process to determine its effectiveness. Applicability and effectiveness of plating processes shall be determined utilizing the most current version of CQI-11 Special Process (Currently 2nd Edition), Plating System Assessment (PSA), published by AIAG, and records maintained. The effectiveness evaluation shall include the organization’s self-assessment, actions taken, and that records are maintained.
This requirement shall also apply to plating suppliers to the organization pursuant to ISO/TS 16949:2009 Clause 7.4.1.2 (supplier development clause).
NOTE 1: 2nd Party assessment by a competent auditor and meeting the above requirements will satisfy the self-assessment requirement.
NOTE 2: Implementation effectiveness should be based on evidence that the organization has a process in place that includes elements such as auditors identified, schedule for self-assessment in place including schedule adherence, supplier development process identified for applicable suppliers, monitoring of progress, defined corrective action process and record-keeping.
4.1.14 Coating Processes
Clause 8.2.2.2 of ISO/TS 16949:2009 requires that the organization shall audit each manufacturing process to determine its effectiveness. Applicability and effectiveness of coating processes shall be determined utilizing the most current version CQI-12 Special Process (Currently 2nd Edition),: Coating System Assessment (CSA), published by AIAG, and records maintained. The effectiveness evaluation shall include the organization’s self-assessment, actions taken, and that records are maintained.
This requirement shall also apply to coating suppliers to the organization pursuant to ISO/TS
16949:2009 Clause 7.4.1.2 (supplier development clause).
NOTE 1: 2nd Party assessment by a competent auditor and meeting the above requirements will satisfy the self-assessment requirement.
NOTE 2: Implementation effectiveness should be based on evidence that the organization has a process in place that includes elements such as auditors identified, schedule for self-assessment in