CG4277

SQ – Exhaust Systems SOR Appendix F

Document Owner: Scott E Miller
Author: Lisa Linton
Revision: 005 – 07/16/2018

Herein are the minimum requirements that shall be incorporated into the manufacturing process for the above
commodity. This Part Specific SOR is in addition to and not intended to replace any requirements as outlined in
the GM Supplier Quality SOR (GM 1927-03). 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 both informed and in
agreement to any modifications of the requirements below.

The required tasks indicated below are based on experience, best practices and lessons learned to improve part
quality using APQP Continuous Improvement activity in GM projects and are applicable to all impacted suppliers
and parts in the supply chain. All deviations requested for “shall” items are to be detailed in CG3404 M7 Technical
Issues List found in eSOR Appendix M7, and reviewed and approved by General Motors Supplier Quality prior to
sourcing.

Note: “Shall” in this document is mandatory. “Should” is highly recommended.

Index
1. General Design Requirements 2
2. General Equipment Requirements 2
3. General Process Requirements 2
4. Assembly Requirements 3
5. Inspection Requirements 3
6. Barcode/Label & Permanent Traceability
Requirements  4
7. Rework Requirements  4
8. Miscellaneous Requirements  4
Appendix A – Revision History 5
Appendix B – Definitions & Acronyms  6

References
GM 1927-03a – Exhaust
GM 1927-03 System SOR

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 CG4277
SQ – Exhaust Systems SOR Appendix F
Document Owner: Scott E Miller
Author: Lisa Linton
Revision: 005 – 07/16/2018

1. General Design Requirements

1.1. Supplier must perform road load data measurements on time in order to guarantee that simulations
during design phase were representative to vehicle application and fulfill durability according to VTS,
SSTS, and SOR specifications.

Las mediciones son realizadas por GM, y sus resultados son suministrados a Servintec.
En los planes de validación se consideran los siguientes procedimientos, responsabilidad método y
cantidad:

Evaluation
Procedure

Method
Reqm't Title Procedure Title Reg. Responsibility

Type

Qty
No.

Vehicle Exhaust
Backpressure and
Subsystem back pres-sure GMW14891,   GM DV    
Induction Restriction
Measurement
Exhaust System
Subsystem leakage GMW15261 Component and Joint   Servintec PV   8
Leakage Test

Air Induction System and

Exhaust System Isolator
Isolator dy-namic stiff-ness GMW14203   GM PV    
- Dynamic Stiffness
Evaluation Procedure

Exhaust Hanger Bracket

Interface Attachments -
Exhaust side hanger drive Servintec (40
GMW14182 Drive Point Dynamic   PV T 5
point dynamic stiffness dias)-MM
Stiff-ness/Mobility Level
Evaluation Procedure

Exhaust System Tail

Pipe - Sound Pressure Servintec-
Airborne Noise -tailpipe noise GMW14218   DV    
Level (SPL) Evaluation MM-GM
Procedure
Exhaust System -
Radiated Exhaust system
Radiated Sound Servintec (5
Noise – Component Shell GMW14161   DV T 1
Pressure Level (SPL) dias)-MM-GM
Noise
Evaluation Procedure
Subjective Noise
Subjective noise and vibration GMW14485   GM DV T 1
Evaluation

Cyclic Corrosion Servintec

Corrosion performance GMW14872   PV T 1
Laboratory Test (5dias)-MM

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 CG4277
SQ – Exhaust Systems SOR Appendix F
Document Owner: Scott E Miller
Author: Lisa Linton
Revision: 005 – 07/16/2018

Thermal Shock Cycle Servintec

GMW14380,   PV T 3
Test for Mufflers -MM
Exhaust System
GMW14381, Suspension Durability   Servintec-MM PV T 3
Test
Subsystem reliability Durability Test of
GMW14390, Exhaust Pipe Con-   Servintec-MM PV T 6
nections
Weld acceptance crite-
GMW14058 ria and repair proce-     PV    
dures Arc welds - steel

Las pruebas pueden ser subcontratadas en los laboratorios de Brasil de Maganeti Marelli o España y en los
casos de soldadura estos se realizarían en el laboratorio de West Arco acreditado con la norma ISO/IEC
17025:2017.

2. General Equipment Requirements

2.1. The supplier and their toolmakers must have the resources in place (overtime, working holidays, etc.)
to implement short term changes on short notice to support build schedules, testing, pilot series, and
SOP.

Servintec actualmente opera al 55% de su capacidad instalada en un solo turno

En caso de requerir por subida de cadencia la organización puede disponer de 2 turnos adicionales.
Se tiene un procedimiento de APQP en el cual se tiene cronogramas como timing plan y son coherentes con
el Global APQP Project Plan determinado por GM de acuerdo a los Gate Review (1,2 y3).
Las pruebas de serie piloto son incluidas en los timing plan de Servintec de acuerdo a los launch plan (PPV
MRD – MRD MVB ns - MRD MVB s) y su relación con los (Try outs-PPVs- MVB ns - MRD MVB s) y el
SORP.

3. General Process Requirements

3.1. Production
3.1.1. The supplier must meet the demands as per Component Technical Specifications.

En el TECHNICAL REVIEW y en el APQP Kick-Off Meeting Checklist and Supplier Feasibility Commitment
se establece las cantidades y una revisión de los programas por parte de GM y Servintec.

3.1.2. The supplier must adhere to KPC’s/PQC’s from spec / D-FMEA

De acuerdo al Amef de diseño entregado por GM a Servintec se incluyen los KPC’s/PQC’s en los planes de
control, amef, y diagramas de proceso.

3.1.3. When manual loading of part, 100% Poke Yoke / Error proofing for presence of part.
Servintec tiene establecido dispositivos de ensamble y control para garantizar que las
especificaciones dimensionales de producto.

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 CG4277
SQ – Exhaust Systems SOR Appendix F
Document Owner: Scott E Miller
Author: Lisa Linton
Revision: 005 – 07/16/2018

3.1.4. Error detection and prevention as close/prior to source as possible. Master samples of the
error proofing (“rabbits”) must be as agreed with GM SQE.
3.1.5.
Los dispositivos de control y algunos de ensamble poseen master negativo y positivo los
cuales son acordados con el SQE, se identifican con color rojo y verde respectivamente.

3.1.6. The Part Drop Policy needs to be agreed to and documented with the supplier and GM team.

3.1.7. Preventive Maintenance must be applied and agreed to by the supplier and GM team.

El programa de mantenimiento preventivo incluye todos los herramentales requeridos para

los procesos de fabricación y de control de las partes los cuales son sometidos a
verificaciones programadas que incluyen actividades específicas para garantizar la calidad
del producto.

3.2. In-Line-Testing Verification

3.2.1. For emission relevant components with specified leakrate, 100% leak testing must be
performed to meet specifications per SOR, SSTS.

Servintec realiza pruebas de estanqueidad al 100% de los sistemas de escape y es

identificando de forma automática la conformidad y no conformidad de las piezas.
Dentro de los paramentos que se controlan son presión, tiempo, y volumen de fuga
permitida.

3.2.2. For all connection points to vehicle and other exhaust parts, 100% gage check is required
with variable data able to be taken / recorded if applicable for mating points, i.e. flange
flatness (sealing surface at 4 places), hanger rods (U/D, C/C, F/A positions), tailpipe tip
alignment; must have verification of PASS

Se realiza un estudio de capacidad (Cpk) de acuerdo al SPC para las siguientes

especificaciones:
Puntos de anclaje
Planitud del flange
Posicionamiento de las varillas

Y Se realiza estudio por atributos (DPU/cartas P) en pruebas de fuga y dispositivos de

control.

3.3. End of line Test (EOL)

3.3.1. Approved parts will be signed off physically with permanent traceability to min: Production
day, shift, serial number, P/N. Permanent traceability will be possible down to requested
single part level. Information will be available to requesting GM Plant within: A: < 24 hours for
period up to SORP + 6 months; B: < 48 hours for period SORP + 6 months until end of life.

Actualmente las partes se identifican con un marcado al la final de la línea en el cuerpo del silenciador
con la especificación determinada por el cliente.
Se incluirá una identificación por código de barras de las diferentes estaciones que participan en la
elaboración del producto permitiendo identificar (operador-fecha-estación de trabajo).

3.4. Welding Operators

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 CG4277
SQ – Exhaust Systems SOR Appendix F
Document Owner: Scott E Miller
Author: Lisa Linton
Revision: 005 – 07/16/2018

3.4.1. Operators (welders) for manual, semi-automatic, and automatic welding operations shall
possess authorization according to EN standards confirmed by appropriate welder certificate
(welding method, material, and position).

La competencia de los operadores de Servintec es verificada periódicamente por el SENA y

las evaluaciones de desempeño por la organización West Arco.

3.4.2. The supplier is responsible to comply with welding audits and other PCPAs that apply.
Servintec realiza auditoria bajo el Cqi 15 y con la ayuda de expertos de la organización West
Arco

3.5. Bending Operations

3.5.1. During bending, there should be no tube weld seam allowed on the back of the bend. All
bends must be programed to have the tube weld seam on the most non-compromised plane
of the pipe.

Servintec mantiene un programa de mantenimiento preventivo para las dobladoras CNC con
el fin de garantizar la conformidad de los dobleces. Realiza un programa para que las CNC
garanticen el doblado y curvas de acuerdo a las especificaciones de plano.

3.5.2. It is mandatory to have mandrel ball detection for all mandrel bends. This must be included in
the PFMEA and Process Control Plan.

Los controles de doblado se incluyen en el AMEF de proceso y planes de control de acuerdo

con la frecuencia requerida.

3.5.3. It is recommended that Tier 2 bent pipes shipped into a tier 1 supplier be leak tested to insure
no splits, etc.

Servintec no tiene proveedores para las operaciones de doblado.

3.6. Rework
3.6.1. Any rework on welding joints shall be performed based on appropriate rework instruction,
including release of reworked parts. Rework must be approved by GM DE and adhere to the
GM welding specification.

La estación de re trabajo posee instrucciones para el desarrollo de estas operaciones y está

en área diferente al proceso en línea para evitar mezclas de producto y estas se ingresan a
la línea con la aprobación del área de calidad.

3.6.2. Scrap/Reworked parts should be sorted out from ordinary process to closed boxes, or are to
have an isolated piece-flow in order to avoid entry back into manufacturing/assembly
processes.

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 CG4277
SQ – Exhaust Systems SOR Appendix F
Document Owner: Scott E Miller
Author: Lisa Linton
Revision: 005 – 07/16/2018

Servintec posee un procedimiento para el producto no conforme donde se dispone este

material y no se puede disponer hasta que el área de calidad determine su estado final, todo
está soportado bajo registros que permiten hacer trazabilidad en cualquier momento.

3.6.3. Process should have a secured Reject handling process (production released first when
rejects is in NOK box sensor monitored)

La organización actualmente maneja un sistema de tarjetas de color amarillo y rojo para

identificar el material rechazado y están se descargan al Sistema de inventario de la
organización.

3.6.4. Process control of rework process (piece flow, rework, & inspection) to be shown in P-FMEA.

La organización posee la metodología del AMEF P en el cual se consideran diferentes

modos de fallo de acuerdo a las características críticas determinadas por GM o Servintec.

3.6.5. Reworked parts must be tested / checked before release into production.

Todos los productos reprocesados son verificados en los dispositivos de control y banco de
fuga para garantizar la especificación funcional y dimensional.

3.7. Contamination
3.7.1. Only cleaned packaging (containers, racks) based on part cleanliness specification will be
used for transportation, intermediate storage, and shipment (free from dirt, oil, etc.)
Servintec por acuerdo con el cliente siempre ha entregado el producto a granel y se ha
garantizado de esta manera su estado sin presentar ningún problema, en caso de requerir un
manejo diferente se dispondrá de acuerdo al nuevo requerimiento. Los medios de empaque
y transporte son adecuados para el manejo del producto en la planta para evitar
contaminación por suciedad y el envió a GM se acuerda por el DCL.

3.7.2. Packaging will be secured against dirt and/or damage, and will be stored only in appropriate
space (recommend no storage outdoors, if possible).

Servintec posee un área de almacenamiento el cual no está a la intemperie y está en otra

área diferente a la de producción para evitar contaminación.

3.7.3. All parts or components which are sensitive to contamination (impact on leakages) shall be
cleaned according to specification and secured against dirt during storage and manufacturing
process. The need for protective caps to avoid entrance of contaminants during shipment to
the customer and handling at customer plant has to be evaluated during the PFMEA,
Container review.

Se considera tapones a las salidas del Sistema de escape para evitar que partes externas
puedan entrar y contaminar el Sistema y ocasione ruido en el vehículo por vibración de
partes extrañas.

4. Assembly Requirements

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 CG4277
SQ – Exhaust Systems SOR Appendix F
Document Owner: Scott E Miller
Author: Lisa Linton
Revision: 005 – 07/16/2018

4.1. Where high-severity modes are identified in the FMEA (severity 8-10) for potential component mixture
(e.g., seals, connectors, terminals, wires), the supplier shall have 100% automated verification of
components or an equivalent process with proven capability.

Los modos de fallo identificados para severidad 8-10, se encuentra la prueba de fuga y las
dimensiones las cuales se controlan con un dispositivo (banco de fuga) y dispositivos de control en la
cual se verifican los puntos de anclaje y algunos de ruteo.

Para garantizar la calidad de los procesos de soldadura de ensambles principales cómo también las
unidades de producción requeridas, Servintec está en la capacidad de implementar este proceso
mediante celdas automatizadas, el plan de implementación y su factibilidad será concertado en su
momento con el cliente.

Inspection Requirements

4.2. Where safety/regulatory failure modes are identified in the FMEA (severity 9/10), the corresponding
detection ranking shall be 3 or lower (per 4th edition AIAG PFMEA Manual - table Cr3 criteria).
4.2.1. Detection Rankings of 4 are also acceptable if either of the following conditions are met:
4.2.1.1. There is permanent traceability back to the original operation where the failure
mode occurs
En la actualidad no hay reglamentos a nivel nacional para sistemas de escape, las
normas aplicadas a pruebas de emisiones como la NTC 5365 y NTC 4231 hacen
referencia a las pruebas de HC, Co, aplicadas en la revisión técnico mecánica.

4.2.1.2. There are no manual operations between the detection and the original operation.
(e.g. automated line)
No aplica

4.3. Where failure modes are identified in the FMEA with a severity ranking of 7 or 8, the corresponding
detection ranking shall be 4 or lower.

4.4. Requirements for powdered metal components:

4.4.1. NDT quality verification records required for tiered supplied components
4.4.2. NDT quality inspection process and controls required if manufactured at the Tier I

5. Barcode/Label & Permanent Traceability Requirements

5.1. There shall be permanent traceability of the part from the final assembly station to customer shipment.
5.1.1. Permanent traceability data shall include, but not be limited to the following:
5.1.1.1. Production day
5.1.1.2. Shift
5.1.1.3. Serial Number S/N
5.1.1.4. Part Number P/N
5.1.1.5. For Example:
Row 1) “GM” plus 8-digit P/N
Row 2) Julian build date, plus permanent traceability (serial # or
military time)

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SQ – Exhaust Systems SOR Appendix F
Document Owner: Scott E Miller
Author: Lisa Linton
Revision: 005 – 07/16/2018

Row 3) Contract Manufacture DUNS

5.1.2. Permanent traceability will be possible down to requested single part level. Information will be
available to requesting GM Plant within: A: <24 hours for period up to SORP +6 months
B: <48 hours for period SORP +6 months until end of
life
La marcación de las partes se realiza en un equipo especial para este proceso, mediante esta marcación se
asegura la trazabilidad

6. Rework Requirements

6.1. All rework or repair processes in the supplier manufacturing facility shall be incorporated in the
production Control Plan and PFMEA, and approved via PPAP.

Las operaciones de reproceso se incluyen el en PFMEA y plan de control

6.1.1. 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.

6.2. Reworks made to a part shall be inspected by someone different from who performed the repair and
documented for permanent traceability.

Las operaciones de retrabajo son realizadas por personal diferentes al que produjo la falla y las partes
son liberadas por el área de calidad.

6.3. Where safety/regulatory failure modes are identified in the FMEA (severity 9-10), component reworks
shall not be allowed outside the manufacturing facility.

Los sistemas de escape no poseen características de regulación o de seguridad

6.4. For reworks, outside of the original manufacturing facility (under an engineering TWO), at a minimum,
the following shall be 100% inspected prior to shipment on all impacted components.

No se realizan retrabajos fuera de la planta y todos los retrabajos son revisados 100% en la planta

6.5. All rework tools shall be kept in a locked box or area and ensure only authorized operators can
access.
6.6.
Existe un área de retrabajo aislada del área de producción. Las piezas para retrabajo se identifican con
sticker de color rojo como el cual el medio de almacenamiento para evitar mezclas con producto
conforme.
All reworked areas shall be visually identified (e.g., paint marking, sticker).

Las áreas se encuentran identificadas como las piezas a retrabajar.

7. Miscellaneous Requirements

7.1. Customer Support:

7.1.1. The supplier shall assure adequate Project resources at all times during the Project. If, at any
time during the Project, the GM team members are able to demonstrate that Project timing or

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 CG4277
SQ – Exhaust Systems SOR Appendix F
Document Owner: Scott E Miller
Author: Lisa Linton
Revision: 005 – 07/16/2018

Quality is being compromised due to a lack of resources, then GM reserves the right to
allocate external resources at the Supplier’s expense.
7.1.2. All parts from field complaints should follow the Warranty Parts Return Process, and must be
analyzed with Results and Action plan provided to the appropriate GM-organization (i.e.
Supplier Quality and Engineering).

Appendix A – Revision History

Rev Date Remark Responsible Approver Approving

Organization
001 12/08/15 Initial release S. Miller, P. Dias Scott E Miller Supplier Quality
002 08/30/2016 Added - GM Confidential S. Miller Scott E. Miller Supplier Quality
Added permanent traceability data to 6.1 S. Miller / Lisa Linton
003 10/30/2017 Scott E. Miller Supplier Quality
Revision changed to numbers Lisa Linton /
004 05/24/2018 Author added to header Anthony Chrisopoulos Scott E. Miller Supplier Quality
Title block changed to new naming convention
5.3. Added to address requirements for
powered metal components
5.3.1. NDT quality verification records for tiered
005 7/16/2018 supplied components added Lisa Linton / Scott E. Miller Supplier Quality
5.3.2. NDT quality inspection process and Anthony Chrisopoulos
controls required if manufactured at the Tier I
added

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 CG4277
SQ – Exhaust Systems SOR Appendix F
Document Owner: Scott E Miller
Author: Lisa Linton
Revision: 005 – 07/16/2018

Appendix B – Definitions & Acronyms

Definitions

Acronyms
APQP: Advanced Product Quality Planning
FMEA: Failure Mode and Effects Analysis
PPAP: Production Part Approval Process
SOR: Statement of Requirements
SQE: Supplier Quality Engineer
TWO: GM Temporary Work Order authorizing a product or supply chain change

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 CG4277
SQ – Exhaust Systems SOR Appendix F
Document Owner: Scott E Miller
Author: Lisa Linton
Revision: 005 – 07/16/2018

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