posted 12 March 2000 02:16 AM               

1. Scope

ISO/TS 16949 and this document define General Motors fundamental quality system requirements for suppliers (see Definitions 3.9), as an alternative to Quality System Requirements (QS-9000). The requirements in this document shall be included in any scope of registration/certification to ISO/TS 16949 issued by a GM-recognized certification body in order for the ISO/TS 16949 certificate to satisfy General Motors supplier requirement for QS-9000 third party registration/certification. (See ISO/TS 16949 Remarks for certification).

Service parts and materials applicability does not include aftermarket (See Definitions 3.2) parts or suppliers.

All ISO/TS 16949 requirements and the requirements of this document shall be documented in the suppliers quality system.

Copies of this document are available from General Motors.

2. References

2.1 Chrysler, Ford, General Motors Quality System Requirements (QS-9000), Third Edition, March, 1998.

2.2 Chrysler, Ford General Motors Production Part Approval Process (PPAP), Second Edition, February, 1995.

2.3 Chrysler, Ford, General Motors Statistical Process Control (SPC) reference manual, First Edition, 1992.

2.4 ISO/IEC Guide 62:1996

2.5 International Accreditation Forum Application of ISO/IEC Guide 62, Issue 1, dated 2 June 1997

2.6 Automotive certification scheme for ISO/TS 16949, Rules for Achieving IATF Recognition

Copies of QS-9000, PPAP, SPC and other related manuals are available from AIAG at 01-248-358-3003, and Carwin Continuous at 44-1708-861333. Copies of ISO documents are available from the American National Standards Institute (ANSI) at (212) 642-4980.

Additional references are listed as requirements in section 4.

3. Definitions

Where inconsistent terminology exists between ISO/TS 16949 and this document, this document shall take precedence. Otherwise the definitions from ISO/TS 16949 apply to this document.

3.1 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 General Motors Service Part Operations Purchasing activity is required to deactivate a part.

3.2 Aftermarket Parts
Replacement parts not procured or released by OEM for service part applications which may or may not be produced to original equipment specifications.

3.3 Consulting
For the purposes of QS-9000, 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 IAF Guidance on the Application of ISO/IEC Guide 62, Issue 1, dated 2 June 1997 to ISO/IEC Guide 62:1996.]

3.4 Customer
References to "customer" in ISO/TS 16949 and this document shall be interpreted as the procuring division of General Motors for suppliers pursuing third party registration to ISO/TS 16949 to satisfy General Motors QS-9000 third party registration requirement.

3.5 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.

3.6 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, initial process studies should be conducted at several points in the evolution of new processes (e.g. at the equipment or tooling subcontractors plant, after installation at the suppliers plant). These studies should be based on variables data evaluated using control charts. See Production Part Approval Process manual.

3.7 PPM
PPM is a method of stating the performance of a process in terms of actual nonconforming material. PPM data can be used to prioritize corrective actions. Definition of defective units varies with customer (e.g. all sorted, only those found to be wrong, all in box).

3.8 Quality Indices
See Chrysler, Ford, General Motors Statistical Process Control reference manual.

3.9 Supplier
Suppliers 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 Chrysler, Ford, General Motors or other customers subscribing to this document.

3.10 Subcontractor
Subcontractors are defined as 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.

3.11 Value-Added Production Processes
Activities or operations for which a customer would be willing to pay, if given the option.

4. Requirements

4.1 ISO TS 16949 - Related Requirements

All references to clauses in this section pertain to ISO/TS 16949, unless otherwise stated.

4.1.1 Tooling Management

The requirements for tooling management (cl. 4.2.6) can be waived for warehouses or distributors.

4.1.2 Records Retention

Production part approvals, tooling records, purchase orders and amendments shall be maintained for the length of time that the part (or family of parts) is active (see Definitions 3.1) for production and service requirements plus one calendar year unless otherwise specified by the customer.

NOTE: All customer purchase orders/amendments are included in this requirement. Supplier purchase orders/amendments for customer-owned tooling are included in this requirement.

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.

Records of internal quality system audits and management review shall be retained for three years.

Retention periods longer than those specified above may be specified by a supplier in their procedures. The supplier shall eventually dispose of records.

These requirements do not supersede any regulatory requirements. All specified retention periods shall be considered "minimums".

4.1.3 Internal Audit

Internal auditors should be qualified as recommended in ISO 10011-Part 2 as a minimum.

4.1.4 Electronic Communication

Reference cl. 4.15.6.4.

NOTE: Examples of such systems for suppliers to GMs 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) ship schedules such as the ANSI ASC X12 862 or 866 transaction sets or the EDIFACT DELJIT message.

4.1.5 Shipment Notification System

Reference cl. 4.15.6.5.

NOTE: Examples of such systems for suppliers to GMs North American Operations are: 1) the ANSI ASC X12 856 transaction set, or 2) the EDIFACT DESADV message. For EDI assistance, contact 01-810-947-5566. For EDIFACT assistance, and confirmation of the required implementation date for a supplier, contact 01-248-265-9907.

4.1.6 Special Characteristics

The supplier shall use General Motors Key Characteristic Designation System definitions and symbology to comply with ISO/TS 16949 special characteristics requirements (e.g. cl. 4.2.4.7, 4.9.1.4). Reference QS-9000, Appendix C for General Motors definitions and symbols.

4.1.7 Design Changes

All design changes, including those proposed by subcontractors, shall have written customer approval, or waiver of such approval, prior to production implementation. See cl. 4.4.9.1 and the Production Part Approval Process manual.

For proprietary designs, impact on form, fit, function, performance, and/or durability shall be determined with the customer so that all effects can be properly evaluated.

4.1.8 Official Language Version

The English language version of QS-9000 OR ISO/TS 16949 and this document shall be the official version for purposes of third party registration.

Sanctioned translations shall:

be for reference only,
reference the English version as the official language,
not contain ISO 9001 text verbatim, and
include General Motors in the copyright statement.

Any other translations are not authorized.

4.1.9 Subcontractor Development

The supplier shall perform subcontractor quality system development with a goal of compliance to either ISO/TS 16949 or QS-9000 (See cl. 4.6.2.2). Subcontractors should be compliant to ISO/TS 16949 and the requirements of this document. The supplier and its subcontractors shall deploy these requirements externally to the supply chain as appropriate.

NOTE: General Motors does not require subcontractor registration/certification at this time.

4.1.10 Part Approval Process

The supplier shall comply with the Chrysler, Ford, GM Production Part Approval Process (PPAP) manual to comply with cl. 4.2.4.11.

4.1.11 Regulations

NOTE: A "procedure" may replace the word "process" in cl. 4.1.7.2.

4.1.12 Customer Satisfaction

Trends in customer satisfaction (see. Cl. 4.1.1.3) and customer dissatisfaction should be compared to those of competitors, or appropriate benchmarks, and reviewed by senior management.
4.2 General Motors - Specific Requirements

4.2.1 Third-Party Registration Requirements

All Production and Service Part Suppliers to General Motors, including GM Holdens, shall be third-party registered to QS-9000 by December 31, 1997, unless otherwise specified. Suppliers to Delco Electronics shall be third-party registered to QS-9000 by July 31, 1998. Suppliers to GM-Chile, GM-Ecuador, GM Asia Pacific Operations (APO) except GM Holdens, shall be third-party registered to QS-9000 by December 31, 1999. New suppliers must be QS-9000 registered prior to shipment of product.
Certification to ISO/TS 16949, including the requirements in this document, by a GM-recognized certification body using an automotive registration scheme recognized by General Motors may satisfy General Motors requirement for QS-9000 third party registration.

4.2.2 General Procedures and Other Requirements

The GM North American publications listed below contain additional requirements or guidelines which shall be met, if applicable, by GM North American Operations (NAO) suppliers. Specific questions on the content of these publications should be directed to the appropriate contact at the GM procuring division. Information on the latest revision dates for these publications and ordering information can be obtained by calling Boise Cascade Office Products at 1-800-421-7676 or 810-758-5400.
NAO Suppliers shall verify that they are using the latest version of these documents at least annually.

4.2.2.1 C4 Technology Program, GM - Supplier C4 Information, (GM1825).
- Assists suppliers in understanding and executing GMs C4 strategy.
- Provides Year 2000 readiness information

4.2.2.2 Key Characteristics Designation System, (GM 1805 QN)
- Defines GMs approach to "special" characteristics.

4.2.2.3 Supplier Submission of Material for Process Approval (GP-4), (GM1407).
- Shipping procedure for all pilot parts.

4.2.2.4 Supplier Quality Processes and Measurements Procedure (GP-5), (GM 1746).

4.2.2.5 Supplier Submission of Match Check Material (GP-6), (GM1689).
- Notification by purchasing division if required.

4.2.2.6 Component Verification & Traceability Procedure (GP-7), (GM1730).

4.2.2.7 Continuous Improvement Procedure (GP-8), (GM1747).
- Required of all suppliers; replaces part certification procedure.

4.2.2.8 Run at Rate (GP-9), (GM1960)
- Required for all new parts; physical verification that the production process is capable of producing quality products at quoted rates.

4.2.2.9 Evaluation and Accreditation of Supplier Test Facilities (GP-10), (GM1796).
- Third party registration to QS-9000 in accordance with QS-9000 Appendix B will satisfy the GP10 requirements for GM North American locations of laboratory facilities utilized by the suppliers for inspection and testing of their own product for purposes of conformance to the specified requirements. Laboratories utilized for commercial laboratory services are excluded from this provision. See ISO/TS 16949, cl. 4.10.6, and Scope above.

4.2.2.10 Early Production Containment Procedure (GP-12), (GM1920).
- Required of all parts requiring production approval

4.2.2.11 Traceability Identifier Requirements for Selected Components on Passenger and Light Truck Vehicles - Traceability Identifier Requirement (TIR 15-300), (GM1731).

4.2.2.12 Specifications for Part and Component Bar Codes ECV/VCVS, (GM 1737).

4.2.2.13 Procedure for Suppliers of Material for Pre-Prototype and Prototype Sample Approval (GP-11), (GM1820).
- Required for all prototype parts.

4.2.2.14 Packaging and Identification Requirements for Production Parts (GM 1738)

4.2.2.15 Shipping/Parts Identification Label Standard (GM 1724)
- This GM standard was developed in conjunction with and is an extraction from the AIAG Shipping/Parts Identification Label Standard B3. GM variations on and additions to the AIAG standard are noted.

4.2.2.16 Shipping and Delivery Performance Requirements (GM 1797)

4.2.2.17 All GM-specific requirements (GM 9000), referenced in this section of the QS-9000, now available from Boise Cascade Office Products.

4.2.3 ISO/TS 16949 Applicability

ISO/TS 16949 applies to all contracted GM suppliers (see Definitions 3.9) who opt to use it, with this document, to satisfy General Motors QS-9000 requirements.

4.2.4 UPC Labeling For Commercial Service Applications

GM Service Parts Operations (SPO) requires use of UPC labeling for certain commercial applications rather than AIAG labeling. Contact your SPO buyer for instructions.

4.2.5 Layout Inspection and Functional Test

Unless specified otherwise by a GM procuring division, there is no customer established frequency for layout inspection after receiving production part approval (PPAP). Reference is made to ISO/TS 16949 cl. 4.10.4.2.

4.2.6 Customer Signature on Control Plan

General Motors does not provide waivers to suppliers for control plan approval because General Motors signatures on the Control Plan are not required.

4.2.7 GM Holdens-Specific Requirements

The following additional documents are required for suppliers to GM Holdens in Australia:
- Pre-Production/Pilot Material GP4 Supplement (SGP04), February, 1996
- Breakpoint Identification & Procedure (SPB01), February, 1996

4.2.8 PPAP

Suppliers to General Motors shall use the Production Part Approval Process (PPAP) with appropriate subcontractors (see Definitions 3.10, and QS-9000 Appendix I).

4.2.9 Year 2000 Supplier Readiness

The supplier shall have a timed action plan to address the Year 2000 software/hardware date code issue prior to the advent of the year 2000. This plan shall address Year 2000 readiness of the suppliers products, business operating systems (including Electronic Data Interchange), subcontractors, and provide for both individual unit and enterprise testing of all solutions or remediations made. This action plan shall be made available to the customer or the customers agent upon request. For more information, see http://www.aiag.org and the C4 Technology Program, GM - Supplier C4 Information manual, (GM1825).

4.2.10 Certification Body/Registrar Notification

A supplier shall notify their certification body/registrar in writing within five (5) working days when General Motors places the site in Level II Controlled Shipping ("Containment").

4.2.11 Other QS-9000 Requirements