CG4165 Supplier Quality (SQ) Part Specific Statement of

Requirements for Blow Molded Parts

Document Author: Samuel Cohen

Document Owner: Regine Bile
Revision Date: March 6, 2017

BLOW MOLDED PARTS

Please sign, date and return this document as a record of your understanding of these
requirements.

Below are the minimum requirements to be incorporated into the manufacturing process for this specific
commodity. This Part Specific SOR is in addition to and not intended to replace any requirements as
outlined in the GM Supplier Quality Requirements (Appendix F17). The expectation is for GM to receive
parts that meet 100% of the requirements. It is understood that advances in technology may require
modifications to the following requirements to ensure state of the art processing and testing. It is the
responsibility of the supplier to ensure that the process is state of the art and that the GM SQE is
informed and in agreement to any modifications of the requirements below.

1 - DESIGN:
 A tolerance study must be completed for all critical components with a direct
link and effect for a general function (assembled parts).
 A wall thickness tolerance must be agreed between GM and the supplier prior
to the sourcing to assure design feasibility.
 Class A surfaces have to be considered during the design phase in regard to
split lines, sink marks, burrs, etc… which are not allowed.
 The tooling concept has to be submitted prior to the start building to the GM
DRE / SQE and Tool Analysts approval.
 The specification of scrap ratio of materials used in the mixture must be agreed
between GM and supplier prior start of validation.
.

2 - EQUIPMENT:

 For graining parts a vacuum pump in the blow molding machine is desirable for
a better product appearance.
 When a cutting process is required an automated guillotine must be used and a
standard cutting knife change frequency must be established, band saw is
forbidden.
 The guillotine nest and clapping must assure the part position during the cutting
process and guarantee the repeatability.
 The automated guillotine must be safe and prevent accidents in any
circumstance.

GM Confidential CG4165
 CG4165 Supplier Quality (SQ) Part Specific Statement of
Requirements for Blow Molded Parts

Document Author: Samuel Cohen

Document Owner: Regine Bile
Revision Date: March 6, 2017

3 - Tooling:

 Standoff/crash bars must be permanently affixed or locked in place (if

applicable).
 Die alignment must be checked every quarter at a minimum.
 Die face proximity must be checked every quarter at a minimum.
 Pinch rings must be maintainable using a removable insert.
 Pinch Rings can be made from dissimilar material or softer material being Brass
or Bronze. Softer material must be reviewed for damage every quarter and
replaced if damaged.

4 . MANUFACTURING PROCESS:
 Raw material received at molder should be:
o Exactly as per Invoice
o Exactly as per specification
o Identifiable with traceability
o Free from contamination

 Storage of raw material at molder should:

o Never be stored in damaged bags
o Never be stored in wet conditions
o Use silos (if possible) and piped into manufacturing facility directly to
each machine.

 Regrind material at molder should:

o Regrind same materials
o Use closed non-contamination system from molding operation through
storage of regrind material.

 Blow Mold Processing

o Material temperature processed per approved material specification.
o Blow time, Cool time, Air pressure, & Mold temperature must be per
process sheet.
o Molded components must be de-flashed along parting line either by trim-
less tool or experienced trim operator.
o Blow Mold tool must not produce flash or quality issues due to tool
damage or poor build/modification.
o Molded components must be directly placed in protective
cartons/containers to be transported to assembly.

GM Confidential CG4165
 CG4165 Supplier Quality (SQ) Part Specific Statement of
Requirements for Blow Molded Parts

Document Author: Samuel Cohen

Document Owner: Regine Bile
Revision Date: March 6, 2017

o Blow Molder must ensure cleanliness for those parts that are submitted
for post molding activity.
o Welded parts must comply with the part specific SOR for welding
process.

5. QUALITY PROCESS
 When a leakage test is requested in the drawing, the supplier must check 100% of
the parts and mark them with a permanent symbol when approved, the equipment
must contain an alarm in case of failed part.
 For drawing containing Geometric Dimensioning and Tolerancing (GD&T), the
supplier must consider a GD&T gage in the shop floor (based on GM1925) or a
CMM to check all the batches.
 The weight of the product must be checked in the process and the frequency shall
be agreed with the Supplier Quality Engineer
 The supplier must provide a robust control plan to check “pass through” or directed-
buy components.
 The PFMEA and Process Control Plan must contain labeling and label error
proofing. If error proofing is not in the process, redundant inspection must be in
place.
 The supplier must have an efficient traceability and respect the FIFO (First In, First
Out).
 Pallets must be free of all debris.

Traceability & Labeling

For all assemblies the supplier shall have at a minimum electronic traceability data
readily available upon request by GM for the following:
 Manufacturing date of assembly and all component parts
 Lot or sequence traceability of assemblies and component parts
 All quality alerts, reworks, new operator training, major line disruption, and
tooling / equipment maintenance tied to manufacturing date or lot number
 Verification that assembly passed all required testing per control plan including
revalidation of rework
 In addition, traceability shall be electronically tied to inventory control and
production equipment in a way that prevents non-conforming product to be used
in manufacturing or shipped from the manufacturing location.
 Print on demand barcode labels for each end item assembly and sub assembly
part.
Final shipping label cannot be printed unless all subsequent label scans throughout the
process have been completed and each assembly in the box has been scanned.

GM Confidential CG4165
 CG4165 Supplier Quality (SQ) Part Specific Statement of
Requirements for Blow Molded Parts

Document Author: Samuel Cohen

Document Owner: Regine Bile
Revision Date: March 6, 2017

PFMEA and Control Plan Requirements

 PFMEA and Control Plan Requirements (See Diagram 1 & 2):

 Supplier must use rankings in Diagram 1 to determine PFMEA occurrence and
detection.
 PFMEA severity must match DFMEA severity (including system DFMEA and
part-specific DFMEA). If failure is not listed on the DFMEA then supplier shall
use the PFMEA severity ranking in Diagram 1.
 For failure modes with a severity ranking of 9 or 10, the corresponding detection
ranking shall be 3 or lower (per 4th edition AIAG PFMEA manual - table Cr3
criteria - See Diagram 1). Detection Rankings of 4 are also acceptable if either of
the following conditions are met:
o There is traceability back to the original operation where the failure mode
occurs or
o There are no manual operations between the detection and the original
operation. (i.e. automated line)
 For failure modes with a severity ranking of 7 or 8, the corresponding detection
ranking shall be 4 or lower (see Diagram 1).
 Supplier shall ensure that tiered supplier PFMEAs adhere to the severity and
detection requirements stated above
 All rework or repair processes in the supplier manufacturing facility shall be
incorporated in the production PFMEA and Control Plan and approved via PPAP.
o There shall be no rework permitted for failure modes with a 7-10 severity
ranking unless approved in writing by the GM Supplier Quality Manager or
above, unless written permission is provided by GM Supplier Quality
Manager or above.
 For the purpose of this requirement: “Rework” shall be defined as any work on the
product that outside the validated or PPAP approved process and/or materials.
 All types of fasteners shall be verified for presence within the assembly process
and have a detection of 5 or less.
 Visual Management of Safety Value Stream:
o For failure modes with a severity ranking of 9 or 10, the supplier shall
institute a visual management system that ties PFMEA to Control Plan to
Work Cell to Operator Instruction to Verification/Inspection to Inventory
control.(see column 7 of Diagram 2)
Quality Checks Frequency:
All line items in this section apply starting at IVER, all subsequent MRDs, and will
continue throughout the life of the program.
 Checks are at a minimum to be completed at start/end of shift, any tool,
secondary equipment, or process change, disruption of normal production, and/or

GM Confidential CG4165
 CG4165 Supplier Quality (SQ) Part Specific Statement of
Requirements for Blow Molded Parts

Document Author: Samuel Cohen

Document Owner: Regine Bile
Revision Date: March 6, 2017

after each scheduled PM of equipment. Final Production Frequency and Lot

Acceptance Test size to be developed by the supplier and approved by the SQE
at a frequency that supports no product (lot) can leave the supplier facility without
every element of the Process Control Plan being complete with satisfactory
results for the determined lot.
 If tooling or secondary equipment moves/changes location or capital equipment,
checks and process set-up are to be reconfirmed and an A to B Comparison of
the part to last known good part. GM SQE shall be notified prior to
moves/changes for re-PPAP.
 Example: If tooling and/or equipment moves from tool
shop to manufacturing DUNs location.
 Example: Molding parts in a press that has not
previously proven to make quality parts.
 Upon failure on any element of the Process Control Plan, supplier shall
quarantine all parts between the failed part and last known good part.
 In addition the supplier shall document and provide to General Motors upon
request the following:
 Process Parameters and Set-up Sheets
 Scan/CMM data of the final assembly prior to each MRD starting at IVER,
all subsequent MRDs and upon request thereafter.
 Conformance to the process checks, steady state monitoring, and LAT
testing requirements. This includes traceability.
 Performance to Rate Requirements for each station according to the
production process flow.

Component Based Release Process: (Could address CCC as well)

 For PPAP of component part numbers under the Tier 1, supplier shall receive PPAP
package from tiered suppliers per the GM 1927 requirements.
 Tier 1 shall review and approve PPAP for RASIC A components in accordance the
GM 1927 requirements.
 For RASIC B components, supplier shall obtain a Level 1 PPAP (or SQMS PPAP
report) from tiered supplier.
o Tier 1 shall submit a Level 1 PPAP to GM SQE for each component
representing the tiered PPAP status, regardless of RASIC.

GM Confidential CG4165
 GA PFMEA - SEVERITY RANKING GA PFMEA - OCCURRENCE RANKING GA PFMEA - DETECTION RANKING
Probability of Opportunity for
Effect on Product/Customer Rank Effect on Process/Manufacturing Rank Failure Rate Rank Detection Control
Failure Detection
SAFETY and/or REGULATORY REQ not
NO DETECTION
met May ENDANGER OPERATOR (machine or > 100 per thousand NO DETECTION
10 VERY HIGH 10 10% - There is no detection method or the defect cannot be
- NO Warning assembly) - NO Warning > 1 in 10 OPPORTUNITY 10
detected in the assembly plant
[GCA50 Safety no Warning]

SINGLE SENSORY CHECK - PERIODIC

SAFETY and/or REGULATORY REQ not
Examples : visual check OR touch

DIAGRAM 1
met May ENDANGER OPERATOR (machine or 50 per thousand NOT LIKELY TO DETECT
9 9 5% RANDOM AUDIT
- WITH Warning assembly) - WITH Warning 1 in 20 AT ANY STAGE 9
Examples: GCA, drive audits, random audits, random torque
[GCA50 Safety With Warning]
checks, random visual inspection
MAJOR DISRUPTION
ATTRIBUTE GAUGING - PERIODIC
- scrap 100% of product, line shut down, or stop
LOSS of PRIMARY Function Examples : Squeak & rattle track, GCA water test inspection
shipping.
- vehicle inoperable, does not affect 20 per thousand PROBLEM DETECTION SINGLE SENSORY CHECK - 100% SUBSEQUENT
8 - Yard Hold/Ship Hold - 4 hours or more 8 2%
safe vehicle operation 1 in 50 POST PROCESSING 8 OPERATION
- Scrap Vehicle
[GCA50 Walk Home no Warning] Examples: visual check OR touch, CARE line, functional test
- Mainline / Shop Hold - Excessive down time
(without gauge, not automatic), verification station
greater than 4 hours

HIGH
DEGRADATION of PRIMARY Function SIGNIFICANT DISRUPTION ATTRIBUTE GAUGING - SUBSEQUENT OPERATION
- vehicle operable, but at reduced level - scrap some product, deviation from Examples: go/no go, manual torque check, length of socket,
of performance primary process (decreased line speed or added click wrench, functional test (with gauge, not automatic), squeak
[GCA50 Walk Home with Warning] manpower) & rattle track, water test inspection (100%)
-Added manpower Outside Station/Group VARIABLE GAUGING - PERIODIC
Document Owner: Regine Bile

Team Lead: example 100% Contain, Mark, etc. Examples: torque audit - once/shift, body leak tester (BLT)
Revision Date: March 6, 2017

10 per thousand PROBLEM DETECTION AT

7 for a shift 7 1% SINGLE SENSORY CHECK - 100% IN STATION
SOURCE 7
Document Author: Samuel Cohen

1 in 100
- Loss of Trace Examples: visual check OR touch
- Scrap Major Component/Assembly -Example: MULTIPLE VISUAL INSPECTIONS - first check is in station
Frame, Engine, Trans, etc. DOUBLE SENSORY CHECK - 100% SUBSEQUENT
- Mainline stopped for 1.5 Hours OPERATION
- Repair likely to cause collateral damage to Examples: (visual AND tactile) visual with paint mark or visual
nearby KCSS/PQC/Electrical parts. with pull test

DATA RECORDING that notifies the operator of a discrepant part

(pass/fail) without line lock-out
ATTRIBUTE GAUGING - IN STATION
MODERATE DISRUPTION Examples: go/no go, manual torque check, length of socket,
- 100% of product reworked off-line click wrench
LOSS of SECONDARY Function
-Standard / Procedure is offline repair 2 per thousand PROBLEM DETECTION VARIABLE GAUGING - SUBSEQUENT OPERATION

GM Confidential
- vehicle operable, but comfort / 6 6 0.2%
-Mainline Stopped for 20 Minutes or More 1 in 500 POST PROCESSING 6 Examples: auto functional test (such as door closing tool)
convenience functions inoperable
- Repair likely to cause collateral damage to DOUBLE SENSORY CHECK - 100% IN STATION
nearby parts - Primary process followed. Examples: (visual AND tactile) visual with paint mark or visual
with pull test
Kitting or Sequencing using positional pick, and marking each
line on the run sheet.

CANNOT COMPLETE SUBSEQUENT OPERATION

NOTIFICATION ONLY - IN STATION
Examples: pick lights (part picks without line lock-out), fixturing
MODERATE DISRUPTION MODERATE or tooling, hoist scaling, bar code reader, torque controlled tools
DEGRADATION of Secondary Function
- some product reworked off-line with lights, break away tools, any test that notifies the operator of
- vehicle operable, but comfort / .5 per thousand PROBLEM DETECTION AT
5 - Standard Repair done online and 5 0.05% a discrepant part without line lock-out.
convenience functions at reduced level of 1 in 2,000 SOURCE 5
downstream Kitting or Sequencing using Operator Assist Technology, with
performance
-Mainline Stopped for more than 7 Minutes Self Acknowledgement.
Examples: Voice Pick, Projector Pick, etc.
Requirements for Blow Molded Parts

VARIABLE GAUGING - IN STATION

Examples: hand held laser gap and flush gauge

AUTO LINE STOP - SUBSEQUENT OPERATION

Examples : scanning (bar code readers), vision system, error
MODERATE DISRUPTION
ANNOYANCE (vehicle is still operable) proofing tied to the vehicles (not pick bins) such as pressure
- 100% of product reworked in-station .1 per thousand PROBLEM DETECTION
- appearance or audible noise 4 4 0.01% mats, limit switches, fixturing or tooling, counter, PLC controls.
- Line Stop Repair (In Station) - Andon Pull ; 1 in 10,000 POST PROCESSING 4
- noticed by >75% of customers NGFTT, DVT, or VAST (when shipping holds are in place).
Less than 7 Minutes
PART PICK w/Feedback - IN STATION, or in kitting/sequencing
(with notification and line lockout)
CG4165 Supplier Quality (SQ) Part Specific Statement of

CANNOT COMPLETE CURRENT OPERATION

AUTO LINE STOP - IN STATION
MODERATE DISRUPTION
ANNOYANCE (vehicle is still operable) Examples: scanning (bar code readers), vision system, error
- some product reworked in-station .01 per thousand PROBLEM DETECTION AT
- appearance or audible noise 3 3 0.001% proofing tied to the vehicles (not pick bins) such as pressure
- Line Stop Repair (In Station) - Andon Pull ; 1 in 100,000 SOURCE 3
- noticed by 50% of customers mats, limit switches, fixturing or tooling, counter, PLC controls or
Less Than 3 Minutes
torque tools (low torque, high torque, no torque; angle monitoring
LOW for cross-threading), garage doors

CG4165
DEFECT PREVENTION - IN STATION (cannot assemble with
MINOR DISRUPTION
ANNOYANCE (vehicle is still operable) ERROR DETECTION defect)
- slight inconvenience to process, operation, or < 0.001 per thousand
- appearance or audible noise 2 2 0.0001% AND/OR PROBLEM 2 Examples : scanning with part lock prior to assembly (cannot
operator 1 in 1,000,000 PREVENTION
- noticed by <25% of customers continue to assemble), vision system with part lock prior to
-Repair (In station) - No Line Stop
assembly

DETECTION NOT
Failure is eliminated through
NO EFFECT 1 NO EFFECT VERY LOW 1 APPLICABLE; ERROR 1 ERROR PROOFED - the defect cannot happen
preventive control. PREVENTION

* Occurrence is not how many get out of station, occurrence

numbers are based on how many times a particular failure
 CG4165 Supplier Quality (SQ) Part Specific Statement of
Requirements for Blow Molded Parts

Document Author: Samuel Cohen

Document Owner: Regine Bile
Revision Date: March 6, 2017

DIAGRAM 2

*Detection rankings of “4” are also acceptable if either of the following conditions are met:
o Traceability back to the original operation where the failure mode occurs.
o No manual operations between detection and the original operation (i.e. automated line)
** Clarification: No Rework or TWO on the work step that is the Point of Cause for the failure mode.
Example: If a safety critical screw is driven into a plastic screw boss, it cannot be backed or and re-driven unless it
was validated as part of the normal process that way.

GM Confidential CG4165
 CG4165 Supplier Quality (SQ) Part Specific Statement of
Requirements for Blow Molded Parts

Document Author: Samuel Cohen

Document Owner: Regine Bile
Revision Date: March 6, 2017

6. REQUIRED QUALITY INFORMATION AT GLOBAL APQP TECHNICAL

REVIEW (TASK #2)
 Please gather the following information in a binder or envelope marked “Quality”
and submit it with your bid package. If you have any questions relative to the
required information, please contact your GM Supplier Quality Engineer for
clarification.
 All information must relate to the manufacturing site that the product will be
manufactured and must reference the RFQ number and part numbers. All listed
information is required in your Quote Package. Be prepared to answer questions
during the Technical Review Meeting.

Note: Referenced GM 1927 documents indicate required formats as specified

Required Information Explanation Reference Submitted

Engineering
Engineering & Technical Support Identify where the engineering and technical support will be located.
Explain how they communicate with the manufacturing location.
Preliminary SFMEA / DFMEA  Show how the DFMEA is used for continuous improvement and how lessons learned are AIAG FMEA
Block Diagram incorporated.
 Explain how they communicate to the manufacturing location.
 Provide a preliminary DFMEA to PFMEA Gap Analysis Tool (Summary Page)
 Explain how any Gaps between the DFMEA to PFMEA and Gaps in Required vs Planned
Detection will be closed. 

ADVP&R Cover Sheet When required by SOR GM 1829
Outsourcing of Prototype Include plans for tracking and maintaining responsibility for all prototype tools, parts and
Manufacturing (if applicable) quality documentation requirements.
Manufacturing
Facilities Identify where the facility is located / DUNS #. For Greenfield/Brownfield specify Sister Plant
DUNS # when available. Sister Plant shall be considered as back-up plant in case of
Greenfield/Brownfield failure.
Describe the facility's experience with supplying to GM and/or other OEMs.
Describe any modifications required to the facility. Provide layout. For Greenfield/Brownfield
site provide production capacity planned
Has any SQE from GM reviewed the facilities? If so, who and when? For a
Greenfield/Brownfield: has any SQE from GM reviewed Sister Plant?
Preliminary Process Flow Chart Describe proposed production process utilizing manufacturing block diagram. GM 1927-35
Identify any special manufacturing techniques, test methods or containment procedures utilized. Manufacturing
Identify any new manufacturing technologies & training needs for the organization. Block Diagram
Tooling & Equipment Describe in detail what is included in the tooling price.
Timing Charts Highlight any concerns relative to timing that may impact providing a quality process/part on GM1927-2 or
time. equivalent
Preliminary PFMEA Include potential failures, potential causes and error occurrence prevention/defect outflow GM1927-37 and
detection. AIAG FMEA
Explain how the PFMEA is used for continuous improvement and how lessons learned are
incorporated.
 Clearly identify any failure modes that will not have the required level of detection. (sec 3
PFMEA and Control Plan Requirements)
Quality
Preliminary Process Control Plan Include error proofing and any part traceability techniques. AIAG APQP

GM Confidential CG4165
 CG4165 Supplier Quality (SQ) Part Specific Statement of
Requirements for Blow Molded Parts

Document Author: Samuel Cohen

Document Owner: Regine Bile
Revision Date: March 6, 2017
Warranty Plans Describe plans to meet IPTV targets.
Provide warranty data for similar parts, and plans for error proofing, data analysis & record
keeping.
Provide process defect rate for sister plant in case of Greenfield/Brownfield
Capability Studies Provide capability data on similar parts and tolerances.
Quality Improvement Plans Include quality data showing current performance, continuous improvement methodology and
action plans.
Gages / Checking Fixtures Describe in detail what gages/checking fixtures are planned. GM1925
End of Line / Functional Testing Describe in detail what continuous compliance testing is planned.
Describe the manufacturing facilities testing capabilities.
ISO/TS16949 Registration Include proof of registration to GM specific requirements. Maintain certified status in GQTS. GQTS
If the manufacturing facility does not have registration (suppliers with new facilities), submit
registration timeline/implementation plan.
Supplier Quality Statement of Review and sign. GM1927-3
Requirements
Part-Specific Quality & Process Review and sign (if applicable)
Statement of Requirements
Built in Quality Supplier Describe plans to meet BIQS or provide evidence that production currently meets the BIQS GM1927-36
requirements. GM1927-30

Program Management
Organizational Information  Provide a company overview highlighting joint venture relationships, business over time and GM1920
import experience (if applicable).
Provide an organization chart identifying people who will be involved in quality and program
management. Launch team remains until GP-12 (GM1920) exit.
Launch Experience Describe new product launches, experiences and lessons learned.
Training Programs Describe the operator-training program. Are critical operations identified?
Team Feasibility Commitment Identify any concerns with any areas of program execution. AIAG APQP
Appendix D
Commitment Letter  For a Greenfield/ Brownfield provide signed by CEO/MD letter confirming supplier plans to
setup a production site in a new country

Subcontractor Management
Subcontractor Plans Describe plan for management of subcontractors (in-house resources/expertise, APQP, etc.).
Identify proposed component suppliers and/or sourcing plans for subcontractors.
Explain subcontractor capacity and Run @ Rate plans.
Describe plan to manage quality issues related to subcontractors.
Complex Systems / Subassemblies Describe experience with Complex Systems/Subassemblies.
Describe supply chain communication process that supports engineering data, customer
requirements, scheduling, etc.
Sequencing Describe experience with Build In-line Vehicle Sequence and/or Ship In-line Vehicle Sequence.
Describe plan for managing broadcast requirements.

GM Confidential CG4165
 CG4165 Supplier Quality (SQ) Part Specific Statement of
Requirements for Blow Molded Parts

Document Author: Samuel Cohen

Document Owner: Regine Bile
Revision Date: March 6, 2017

Authorized Supplier Management: Please print and sign name below showing that you received
this SOR.

Initial each section below and mark whether you agree or disagree. Marking agree means that
you are in agreement and will comply with the entire section and take no exception with any line
item. If there is exception(s), mark disagree, add item to Appendix M7 and create one deviation
request form for each exception. Bring a signed hard copy & electronic version of this SOR,
Appendix M7, deviation request(s), and documents from Section 5 to your technical review.

Initials Section

1.0 – Design

2.0 – Equipment

3.0 – Manufacturing Process

4.0 – Quality Process

5.0 – Required Quality Information at Global APQP Technical Review

Print Name Signature Title

Date Program & Model Year Part Name

Supplier Manufacturing Location DUNs

Suppliers are not allowed to make any changes to this Supplier Quality Part Specific
SOR.

GM Confidential CG4165
 CG4165 Supplier Quality (SQ) Part Specific Statement of
Requirements for Blow Molded Parts

Document Author: Samuel Cohen

Document Owner: Regine Bile
Revision Date: March 6, 2017

Change History

Date Version Change Summary Approver Approving

Organization
9/22/2010 Initial Release Regine Bile Supplier Quality
and Development
11/10/2015 1 Added PFMEA requirements and Regine Bile Supplier Quality
Quality Check Frequency and Development
2/5/2016 2 Added Traceability and Labeling Regine Bile Supplier Quality
requirements and Development
10/14/2016 3 Revised Manufacturing Regine Bile Supplier Quality
requirements and Development
3/6/2017 4 Tooling: Added lessons learned Regine Bile Supplier Quality
for die maintenance & and Development
standoff/crash installation

GM Confidential CG4165