The objective of this research is to develop a component based enhanced production process after End of Line (EOL) testing. This process will add more quality validation evaluations, but will not require any disassembling of the parts or damage to them. It will help the suppliers to avoid scrap and rework parts as well as General Motors (GM) to reduce warranty and recalls.
An Enhanced Production Process was implemented in March, 2016 at a supplier in Mexico. The Enhanced Audit Station implementation is to ensure that the supplier is satisfying the Production Part Approval Process (PPAP) requirements. The most important four components are: Touch Appearance Lighting and Color (TALC), Appearance Approval Report (AAR), Dimensional Checks, and Function Testing.
Through statistics, a pilot study was conducted to correlate the selected variables to reduce warranty. The study is to verify the supplier’s adherence to the key points of quality related to PPAP: Design Failure Mode and Effect Analysis (DFMEA), Process Failure Mode and Effect Analysis (PFEMA), First Time Quality (FTQ), Incidents per Thousand Vehicles (IPTV), Problem Resolution Report (PRR), Controlled Shipping (CS), and the complexity of the part.