《GM-1805-QN.pdf》由会员分享,可在线阅读,更多相关《GM-1805-QN.pdf(33页珍藏版)》请在三一文库上搜索。
1、 3rd Revision: March 2003 GM 1805 QN Key Characteristics Designation System Extra Additional Standard PQC Functional Checks, Verification/Traceability, Safety Compliance and Component Handling All Products and Processes Levels of Care KPC KCDS Pyramid Extra Additional Standard PQC Functional Checks,
2、 Verification/Traceability, Safety Compliance and Component Handling All Products and Processes Levels of Care KPC Extra Additional Standard Extra Additional Standard PQC Functional Checks, Verification/Traceability, Safety Compliance and Component Handling All Products and Processes Levels of Care
3、KPC KCDS Pyramid 3rd Revision: March 2003 GM 1805 QN Table of Revisions January 1991: 1st Issue June 1996: 1st Revision November 1998: 2nd Revision Applicable to Vehicle Groups through MY 2003 Applicable to all Powertrain programs which end by Jan 2006 March 2003: 3rd Revision Applicable to Vehicle
4、Groups for 2004 MY and beyond Applicable for all Powertrain programs in production after January 2006 The Key Characteristics Designation System reference manual GM 1805 QN was developed by a joint UAW-GM Quality Network Team 3rd Revision: March 2003 GM 1805 QN Table of Contents Section 1. Scope 2.
5、Purpose 3. General: Benefits, Fundamental Concept for Characteristics 4. Definitions 5. Product Variation (includes Loss Function) 6. Levels of Care 7. The Three Stages of KCDS 8. Selection Criteria for Parts 9. Product Characteristics Pyramid 10. Selection Criteria for Product Characteristics 11. T
6、ools 12. Team Approach 13. Objectives of the Team 14. Composition of the Team 15. Data Responsibility 16. Documentation and Communication 17. Reference Section Figures and Tables 1A GM KCDS Process 2A Summary of Levels of Care vs. Cost 4A Characteristic Definition 7A Three Stages of KCDS 8A GM Manda
7、ted Parts and B. Suppliers (internal and external) of products and processes to General Motors that are used in the design, manufacture, assembly, and distribution of GM products. 1.2 The Key Characteristic Designation System (KCDS) will commonize General Motors approach for the identification and d
8、ocumentation of parts with Safety Compliance Relationships, Functional Check Requirements, Product Identification, Verification b. Indicates design release responsibility clearly through established review and approval processes for drawings, releases and related information; c. Includes considerati
9、on of Safety 1. Includes consideration of Characteristics that require Extra Care; 2. Provides a means and discipline for timely authorization (engineering release) of production; 3. Communicates completely and in a timely manner any design changes, including temporary changes; 4. Establishes intend
10、ed/desired effective points for engineering changes and requests operations to gather break points for such changes; 5. Implements appropriate practices for all releases, including original changes, part substitution, tryouts and rework kits. 6. Sound engineering practices result in design informati
11、on systems that are adequate for meeting regulatory requirements. C. Responsibility - The overall responsibility of Product Engineering is as follows: a. Determine product design requirements related to government regulations and vehicle safety. 3rd Revision: March 2003 GM 1805 QN b. Communicate the
12、se requirements within Product Engineering and to other appropriate Functional Areas. c. Design, Develop, and Validate the product to meet these requirements. d. Take the lead role in the identification of safety/compliance parts and communicate this information to other appropriate functional areas
13、. e. Reconcile the design with available manufacturing and assembly technology such that the product, as built, meets these requirements. f. Communicate build and system function specifications as necessary. D. Validation Practices - Validation methods and related test procedures are determined by P
14、roduct Engineering and are documented in the ADV Process E. Identifying and Prioritizing Parts - This section addresses the concept of identifying and prioritizing parts such that those parts, assemblies and systems that are important to regulatory compliance and safety receive attention (additional
15、 care) during product build. This information is made available by engineering to downstream users such as operations, and materials management functions. a. Purpose. The following is a listing of the principle purposes for identifying and prioritizing parts, assemblies and systems related to safety
16、 and regulatory compliance: - Influence the selection of appropriate production tooling and processes by providing guidance for the operations function in applying process evaluation techniques such as process capability studies and machine qualifications. - Guide the product assurance function in t
17、he design and day-to- day operation of control systems, (e.g., determine applications for statistical process control, process monitoring, inspection, product and process auditing). - Influence product production cost by limiting documentation requirements to specific production or product assurance
18、 operations. - Assist the engineering function by providing an engineering memory and reminder of which parts and their specific specifications that relate to compliance. - Identify for the materials management function those products and/or special characteristics that are to be controlled by the s
19、upplier as part of the certification process. F. Responsibilities. The product engineering function is responsible for taking the lead role in the determination of parts, assemblies or systems that have a relationship to safety or compliance with governmental requirements. This arrangement is necess
20、ary since the product engineering function is uniquely knowledgeable about product requirements and the specifications important to meeting requirements. In particular, the product engineering function is aware of product legal requirements and also has a key role in the resolution of product proble
21、ms related to regulatory or safety issues. Other functional disciplines should provide consultation to product engineering during identification of safety/compliance parts and their special characteristics. The North America Structure such as manufacturing/assembly, quality control, reliability, mat
22、erial handling and manufacturing engineering. b. The overall responsibility of Operations is as follows: - Manufacture and assemble products that conform to design specifications related to government regulations and vehicle safety. - Comply with regulatory requirements that specifically apply to Op
23、erations; (e.g., emissions testing and tire record keeping). - Conform to practices that support GM needs in regulatory areas, (e.g., process and quality control practices and specific record keeping that substantiates certification). - Support GMs participation in government investigations regardin
24、g compliance with regulations. c. Safety/Compliance Parts 3rd Revision: March 2003 GM 1805 QN 1. Those parts, assemblies, and systems that may affect meeting government regulations including avoidance of safety and emissions related defects. 2. Manufacturing and assembly plants are to establish and
25、maintain a quality system with appropriate control practices applicable to Safety and Compliance requirements. The methods of control may include product verification checks, product/process monitoring, product sampling or auditing, statistical quality control, statistical process control, functiona
26、l tests, or other methods to ensure that products conform to design specifications. 3. In general, appropriate control practices for part and characteristics can be categorized into three levels of care: “Standard Care”, “Additional Care” and “Extra Care”. 8.2 Functional Check - Requirements A. Perf
27、ormance checks can be developed for any component or system that has a designed operation or function. B. Only plant controllable and functional MVSS items are candidates. 8.3 Product Identification, Verification and Traceability Requirements A. Benefits: Facilitates DREs, MEs, Assembly Plants and S
28、uppliers in identifying or tracking specific component usage for campaign prevention, warranty, and/or performance issues. a. This entails a corporate database system and associated plant floor equipment to collect data from the part/component suppliers, assembly plants etc. The data is archived and
29、 is accessible to authorized personnel. GM IS&S is responsible for this system as well as the parts marking standards defined in the IS&S document GM-1737. B. The focus of this section is to help identify Level II Verification & Traceability Components and Level III Verification only components, dur
30、ing the VDP process. This section lists the tools that help identify and assess the product identification and traceability requirements during the product and process design activities of GVDP. a. Engineers (DRE/DE) must verify that their product/process designs utilize the above procedure for esta
31、blishing Product Identification and Traceability. b. Internal and external suppliers who are responsible for the design and release of components & modules shall comply. c. GM assembly plants shall verify and/or trace the parts/components as documented in GPDS/MPPs. d. Material which has been design
32、ated for individual parts/components usage verification, and/or traceability will be labeled/marked or tagged according to the requirements of the General Motors Specifications for Part and Component Barcodes ECV/VCVS, GM 1737, and subsequent revisions. e. The part/component bar code label, marking
33、or tag will be affixed to each part/component in the location specified by engineering and included on the part print and /or MPP. f. The bar code information label, marking or tag shall be affixed to each part/component in such a manner that it will remain with the part/component throughout the pro
34、duction cycle and final approval, until the vehicle is 3rd Revision: March 2003 GM 1805 QN released for shipping. If removable labels/tags are used the bar code information in human readable form shall be stamped into the component or affixed by other means. g. Alternate methods of retrieving the tr
35、ace information are permitted under the following conditions. The trace information is recorded internal to the part. It is electronically available. The data can be automatically transferred to normal repository without losing current functionality or data integrity. h. If the labels, marking or RF
36、 tags do not meet the above requirements, the supplier will be responsible for all additional costs incurred by the user plants. Also a deviation would be required from GM IS&S as per GM1737. i. Repairs - Are handled in accordance with Assembly plant VCVS procedure QS-08-P-APP11. j. Vehicles/parts/m
37、odules/components must not be shipped without complete records for items designated under this procedure as specified in the assembly plant VCVS procedure. The records will be transferred to the global data central database per plant requirements. k. Suppliers of traceability parts, container or ind
38、ividual, are expected to use good manufacturing practices in the documentation of traceability identifier numbers and the parts shipped. As a minimum, this number shall be traceable to the build date of the material being shipped. l. Manufacturing and intermediary plants shall keep traceability info
39、rmation available for the current model plus five (5) years. m. Vehicle assembly locations forward the data to the central data base per plant IS&S requirements. Retention of all information at the vehicle level in the central database is the current model year plus five (5) years. C. The Error Proo
40、fing Bill of Process (BOP) contains Error Proofing requirements for product and process designs. Engineers must verify that their product/process designs comply with the BOP. Table 8A lists the GM Corporate mandated Parts and Components. Component Description Product ID, Traceability & Verification
41、1 Powertrain modules including Engines, Transmissions, Transfer Cases and other Powertrain modules GMPT Quality System 2 Electronic Control Modules that are able to transmit and receive serial data information on a serial data bus (i.e., class 2, GMLAN) Required by GMEC NOA NOA-001 Rev A Dec 19, 200
42、0 & GM-W4710 3rd Revision: March 2003 GM 1805 QN Component Description Product ID, Traceability & Verification 3 International, Federal & State Rules & Regulations Corporate mandate to be complied 4 Safety & Theft Passive Sensors Corporate mandate to be complied 5 Computer generated Labels Those req
43、uired to comply with some specific International, Federal & State Rules & Regulations 3rd Revision: March 2003 GM 1805 QN D. General Application Guidelines: The following list can aide you in determining which parts or components may drive Product Verification and Traceability, based on the results
44、of a comprehensive business case analysis and Risk Assessment. Table 8B Component Description Product ID, Traceability & Verification 1 Sequenced Modules or sub assemblies with or without traceable components in the above table. Also Traced using Supplier databases Risk Assessment, Warranty & PFMEA,
45、 & Business Case 2 High Warranty and Hardy Perennials Risk Assessment, Warranty & PFMEA, & Business Case 3 J.D. Power and Quality Issues Risk Assessment, Warranty & PFMEA, & Business Case 4 Tier-1& 2 major & minor Module and sub-assemblies suppliers and Multiple Suppliers Risk Assessment, Warranty &
46、 PFMEA, & Business Case 8.4 Component Handling Best Practices Requirements A. Additional handling requirements as provided by the supplier are included in assembly plant processes. B. Component Handling Best Practices are followed to avoid damage and contamination to components. C. These are in addi
47、tion to the standard handling practices. 9.0 Product Characteristic 9.1 Product characteristics are classified into three categories to focus our resources on the characteristics that significantly affect customer satisfaction and operational effectiveness. 9.2 The KCDS Pyramid (Figure 9A) ranks pro
48、duct characteristics from the lowest (Standard) to the highest (Key). 3rd Revision: March 2003 GM 1805 QN Although all product characteristics are important, the Key Product Characteristics are the highest priority. They are shown at the top of the Product Characteristic Pyramid above in Figure 9A.
49、Figure 9B shows the relationship between a Key Product Characteristic (KPC) / Product Quality Characteristic (PQC) and its Key Control Characteristics (KCC). Many factors can affect a KPC and PQC. For example, changes in the material, equipment, and methods and systems that are used to make a product can change its characteristics. 9.3 Although not preferred, Key Product Characteristics and Product Quality Characteristics can be monitored directly without determining the Key Control Characteristics (KCCs). Ongoing control of the KPC / PQC is required. Once KCCs are de
链接地址:https://www.31doc.com/p-3769238.html