Director. SFO GPSC, GM India ... (Without notifying to GM and without proper
internal ... 100% Compliant to QSB & Special process Audit ( CQI11 & CQI12 etc)
...
Prashant Swadia Director SFO GPSC, GM India
Agenda •Our Vision •Quality Case Study
• Problem Description •Analysis of the problem • Impact & Lessons learned • Supplier Performance & Expectation
GM Vision is Clear “To be the world leader in transportation products and related services”
2009 GPSC Priorities Global Purchasing and Supply Chain Supply Chain & Logistics
Quality / Launch
Program Management
Current / Future Business
Develop & Execute
Total Cost Approach
Launch New
Best Landed
Supply Chain
Supporting
Programs @ Right
Cost Globally
Capabilities
Quality/Cost
Quality, Right
Schedule, Build &
Improvements
Time, Right Cost
Ship the Plan Daily
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Quality Case Study
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Problem Statement Part is a safety critical component Part consists of Connector , which is a sheet metal component & calls for heat treatment . Connector helps to link front and rear Parts Part Connector broken in the field, after few load applications on the part. Cases were reported from the Field and a suspect vehicle population was identified.
Problem Analysis During failure analysis of warranty returned connectors , it was
observed that failure happened due to Brittle Fracture
By process study, Reason found for brittle fracture as heat treatment
(Tier 2 Process)
From Tier 1 supplier it was understood , Heat Treatment source was
changed. (Without notifying to GM and without proper internal validation). By traceability, only the connectors heat treated from the new supplier failed and no failure reported from the old heat treatment source The new heat treat source was not having controls on the process
parameter and no special audit (CQI) done before approving the source.
Impact on Supplier Field Recall on suspect population Red in quality Bid list due to field action. (Which stops future business awards)
Lesson Learned Supplier to follow the Customer Notification Process – AIAG PPAP Requirement and GM specific process SPCR (Supplier process change request) When there is a change in process or design, supplier to do internal validation and to check with customer for the vehicle level testing . Robust Tier 2 supplier selection and approval method to be followed by Tier 1
Supplier Performance Strategy & Expectation
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Supplier Performance Strategy – Grow the Best GROW
FIX
EXIT
Performance is Based on All Priorities Delivery/Quality/Launch/Current-Future Business Grow the best Fix those that have strategic value No choice but to Exit the rest
GM Expectation from Suppliers Proactive Conformance to AIAG APQP Requirements and GM Global APQP Tasks
Develop Detail Plans for Each Part / System Maintain Program Timing
Identify Issues Early in Program and Drive Correction
Expect these Same Requirements from Sub-Suppliers Personal engagement of supplier senior leadership Proactive control of suppliers’ processes
100% Compliant to QSB & Special process Audit ( CQI11 & CQI12 etc)
GM Expectation from Suppliers
Early warning of manufacturing issues Contain what can’t be fixed Immediate response to any potential part quality issue Maintain Communication with GM. Relentless pursuit of continuous improvement Absolute adherence to GM requirements and maintenance of a “zero-defect mentality”
