593611811.

xls Printed: 05/24/2022

sGMS Revision Record

Date Name Worksheet Name Update Description

Moved to Fast Response Template
01/20/06 Joe Koss Fast Response Sign-in Sheet file
 593611811.xls Printed: 05/24/2022
VS_Revision Record

Date Name Worksheet Name Update Description

 Verification Station Board - Three Sided Layout
FEET 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0

5.0
Side
3
4.5

1st Shift Problem Solving 2nd Report Card - Liaison FINAL Report Card -
1st Report Card - Q-
4.0 Alarm Escalation Proc. Final (Night Letter) LGR (GM-Customer)
Defect Tally Sheet PR&Rs
PPSRs Completed PPSRs Completed PPSRs Closure Chart

3.5 Practical Practical Monthly

Procedure
Problem Problem PPSR
SOLVING SOLVING
Escalation
Station - Alarm Closure
3.0 Verification #1 #2 Tracking
Tally Sheet
Immediate Response Action Sheet
Day/Aft Shift 2nd Shift Problem Solving
Daily Meeting Sign-in
PPSRs Completed PPSRs Completed PPSRs Closure Chart Customer Incidents -
2.5
PR&Rs Liaison Issues Trend Chart
SHEET
Side ALARM
Sign-in
Practical Practical Monthly
Problem Problem PPSR
MEETING
2.0 1 Side SHEET / STATION
ACTION VERIFICA-TION SOLVING SOLVING Closure
2
REPORT Cards
RESPONSE DAILY #1 #2 Tracking Issues List Tracking of the
IMMEDIATE PR&R Weekly / Monthly
1.5
Liason
Defect Pareto Mtg. Assignmts.
OPEN Problem Solving Tracking

FTQ Trend Chart Scrap Trend Chart

1.0 Chart Time Time
Time Trend DEFECTS Sheet over over
Defects Over PARETO TOP 5 Assignment Chart Chart
Meeting
0.5
Monthly WEEKLY Trend Trend
AND STATUS FTQ SCRAP
TRACKING
PROBLEM

Side Side Side

1 2 3
 Common Inspection Criteria METHOD
Defect Tally Sheet General Motors
Specific Inspection Criteria
METHOD
1
Verification Station:
2
Shift: 1st / 2nd 50

3 Date: 51
(circle one) Revised: 5/31/2007
4 52

5 53

6 54

7 55

10

11 Honda Specific Inspection Criteria METHOD

12 70

13 71

14 72

15

16 Toyota Specific Inspection Criteria METHOD

17 80

18 81

19 82

32 83

84

85

196

86

87

88

89

95

95
 PROCESS SCORE CARD FOR ALARM TRIGGERS GREATER THAN ONE:
Supervisor-
TRIGGER 1 ALARM 1 (Customer Disatisfier) IDENTIFY EACH ALARM TRIGGER PULLED BY CIRCLING THE HASH
MARKS THAT SET OFF THE ALARM (CALL FOR HELP)
Team Leader -
Dept. Approval: TRIGGER 2 (WIP) ALARM 1 2 3
TRIGGER 3 ALARM CONFIRM & PLACE 1 2 3 4
Associate(s) Name: INTO UP-STREAM DEFECT BOX
Number of completed boxes / totes (for each part #) =

DATE Process Name Available Minutes

TRIGGER 2 ALARM (WIP) TRIGGER 1 ALARM 450

TRIGGER 3 ALARM PLATER AND/OR MODLING DEFECTS ONLY 3 PC TRIGGER 1 PC TRIGGER Unscheduled Downtime Problems
(* = "Other" Defect: Describe)

Good Parts CHROME DEFECTS Plater Assembly ASB ASB ASB ASB ASB ASB ASB ASB ASB ASB TOTAL

TAPE RELEASING
Plan Act BL CB ST DW S1 NS OC PS PT RF SK SH WC REWORK

RACK TAB NOT

LABEL WRONG

TAPE MISSING
FUSER BURNT
SCRAP

MISALIGNED
CHROME BURN

TABS TORN

TAPE HI/LO

GATE NOT
*
WHITE/ SHINY

TRIMMED

IN SPEC
WHITE WASH
SKIP PLATE
DEFORMED

TABS

OTHER
+/- TOTAL

SCRATCH

SURFACE
CHROME
BLISTER
REWORK

NICKEL

ROUGH
COLOR

SPOTS
TOTAL TOTAL

SHOW
STAIN

PAINT
LINE /
SCRAP SCRAP

PITS
OFF
Part # HOUR Cum Cum Plated Assy

Reserved for Early Start (O/T = 1 hr)

07:00-
08:00 AM

08:00-
09:00 AM

09:00-
10:00 AM

10:00-
11:00 AM

11:00-
12:00 PM

12:00-
01:00 PM

01:00-
02:00 PM

02:00-
03:00 PM

03:00-
03:30 PM

DEFECT
CUMMLATIVE
TOTALS
Cummlative Totals= A B Total Scrap C D E
Direct Run %
Scrap% (C/(B+C))= ((B-D)/(B+C))=

Post to COB
 IMMEDIATE RESPONSE ACTION SHEET / ALARM SHEET

VERIFICATION STATION: Y / N = Yes /No (circle one for each question, #2 - #5) *S=Supplier, A=Assembly/Build issue
VERIFICATION STATIONS RESPOND PRODUCTION RESPONDS
(Completed by the Verification Operator) (Completed by the responder)
Corrective Action:
1-Identify Point of Cause Station # ?
2-Standardized work followed?
#
Date/ Product
Serial# Defect Description / Number
Who Was
Time
Escalation Immediate Fix 3-Correct Tools / Fixtures / Error Proofing?
*S Who
Time
Breakpoint
Shift Line Called Level 1-5 What was done with the defective Part? 4-Correct Parts? A Answered CSN #
5-Parts in spec?
6-What did you do to STOP a REPEAT defect from occurring?
1-Stat #_________ 2- Y / N 3- Y / N 4- Y / N 5- Y / N
1 6:

1-Stat #_________ 2- Y / N 3- Y / N 4- Y / N 5- Y / N
2 6:

1-Stat #_________ 2- Y / N 3- Y / N 4- Y / N 5- Y / N
3 6:

1-Stat #_________ 2- Y / N 3- Y / N 4- Y / N 5- Y / N
4 6:

1-Stat #_________ 2- Y / N 3- Y / N 4- Y / N 5- Y / N
5 6:

1-Stat #_________ 2- Y / N 3- Y / N 4- Y / N 5- Y / N
6 6:

1-Stat #_________ 2- Y / N 3- Y / N 4- Y / N 5- Y / N
7 6:

1-Stat #_________ 2- Y / N 3- Y / N 4- Y / N 5- Y / N
8 6:

1-Stat #_________ 2- Y / N 3- Y / N 4- Y / N 5- Y / N
9 6:

1 1-Stat #_________ 2- Y / N 3- Y / N 4- Y / N 5- Y / N
0 6:

1 1-Stat #_________ 2- Y / N 3- Y / N 4- Y / N 5- Y / N
1 6:

1 1-Stat #_________ 2- Y / N 3- Y / N 4- Y / N 5- Y / N
2 6:
 IMMEDIATE RESPONSE ACTION SHEET / ALARM SHEET
Verification Station:
VERIFICATION STATIONS RESPOND PRODUCTION RESPONDERS
(Completed by the Verification Operator) (Completed by the responder)

Point of
Corrective Action: Cause Breakpoint
Intermediate Action 1. Define (What is the problem?)
Date/ Who Was (Containment) 2. Measure (How Many Defects for this Occurrence) Supplier Who When did
# Product Defect Description / Number Time Escalation Time
Shift Called What did you do to contain 3. Analyze (Why did this problem occur?) Mold Answered defect free
Level
1-5 the defective Part? 4. Improve (What are you going to do to fix it?) Plate material flow
5. Control (Is the part back into Spec?) Assembly/ begin again
Build Issue

D
M
1 A
I
C

"Lesson Learned"
WHAT DID YOU DO TO
PREVENT A REPEAT
DEFECT FROM OCCURRING
D
M
2 A
I
C

"Lesson Learned"
WHAT DID YOU DO TO
PREVENT A REPEAT
DEFECT FROM OCCURRING
D
M
3 A
I
C

"Lesson Learned"
WHAT DID YOU DO TO
PREVENT A REPEAT
DEFECT FROM OCCURRING
D
M
4 A
I
C

"Lesson Learned"
WHAT DID YOU DO TO
PREVENT A REPEAT
DEFECT FROM OCCURRING
 D
M
5 A
I
C

"Leason Learned"
WHAT DID YOU DO TO
PREVENT A REPEAT
DEFECT FROM OCCURRING
D
M
6 A
I
C

"Leason Learned"
WHAT DID YOU DO TO
PREVENT A REPEAT
DEFECT FROM OCCURRING
D
M
7 A
I
C

"Leason Learned"
WHAT DID YOU DO TO
PREVENT A REPEAT
DEFECT FROM OCCURRING
 Verification Station - Alarm Escalation Procedure
Alarm Trigger Immediate Action
Level One (1) defect Inspector alerts Production Team Team Leader responds;
1 Leader
Inspector enters type of defect,
time, name of person contacted Responder institutes
Name: ____________ 1st Shift
Phone:
Name:_____________ 2nd Shift
Phone:
Name:
Name:
Name:
Level No response to Alarm within 10 minutes Quality Coordinator
2 Name: ______________ 1st Shift
Second (2 Total) defect - Exactly the Phone:
Name: ______________ 2nd Shift
same defect as in Step#1 Phone:
Name:
Phone:
Level No response to Alarm within 20 minutes Contact Area Supervisor
3 Name:_____________1st Shift
Third (3 Total) defect - Exactly the same Phone:
defect as in Step#1 Name: ____________ 2nd Shift
Phone:
Level No response to Alarm within 20 minutes Contact Operations Manager
4 Name: _____________1st Shift
Foufth (4 Total) defect - Exactly the Phone:
same defect as in Step#1 Name:_____________ 2nd Shift
Phone:
Level No response to Alarm within 20 minutes
5 investigates cause of slow
Fifth (5 Total) defect - Exactly the same
defect as in Step#1
Contact Plant manager
Name:______________
Phone:
Types of Response
Determines Point of Cause
containment/corrective action and
fills out right side of Immediate
Response Action Sheet (and
Containment Form, if applicable)
Institutes a Buddy check if necessary
to make sure the Verification Station
doesn't see this defect again this
shift.
Same as above plus
investigates cause of slow
response
Document corrective actions
for defect and slow response
on Immediate Response
Action Shhet
Same as above plus
investigates cause of slow
response
Same as above plus
investigates cause of slow
response
Same as above plus
response, and potentially Stop
Production
 Verification Station - Alarm Escalation Procedure

Alarm Trigger Immediate Action Types of Response

Level 1 Verification Station Visual Signals to Team Member alerts Assembly BSM Team Leader responds; Determines
Call for Help Team Leader Point of Cause within the assembly
process.
Alarm Trigger One: (Customer Disatisfier)
1 Part - Assembly Defect
(RED Shaded Defect Description Area on PSC Sheet)

Alarm Trigger Two:

(Higher Frequency-Easy to Detect)
3 Parts - Assembly Defect
(Gray Shaded Defect Description Area on
PSC Sheet)
Collection Bin
Reject Parts

Inspector enters type of defect, time,

1 2 name of person contacted Responder institutes:
Name: Jenny W. 1st Shift Containment/corrective action and fills out
Phone: right side of Immediate Response Action
1 2 3 Name: April S. 2nd Shift Sheet (and Containment Form, if
Phone: applicable) Institutes a Buddy check if
Name:
Alarm Trigger Three: Phone:
necessary to make sure the Verification
(Upstream process Escapes) Station doesn't see this defect again
4 Parts - Total Any Type of Plating and/or
Molding Defects
(Non-Shaded Defect Description Area on PSC Sheet)

Level 2 RESPONSE TIME: (10 minutes) Assembly BSM Team Leader plus Same as above plus investigates
Team Leader is Unable to Contain or Resolve the Quality Coord. cause of slow response
issue at the Point of Cause within 10 minutes. Name: Debbie K. 1st Shift
Phone:
Name: Shelly Yokam 2nd Shift
REPEAT DEFECT CONDITION: Phone:
2nd Occurenence: Exact Same defect as in
Alarm Trigger 1, or 2nd Group collected for Alarm
Document corrective actions for
Triggers 2
defect and slow response on
Immediate Response Action Sheet

Level 3 RESPONSE TIME: (20 minutes) Asb. T/Ldr, Quality Coord plus Same as above plus investigates
No corrective action to Alarm within 20 minutes Assembly Supervisor cause of slow response
Name:Amy W. 1st Shift
REPEAT DEFECT CONDITION: Phone:
3rd Occurrence: Exact Same defect as in Name:Edvin B. 2nd Shift
Alarm Trigger 1, or another Group collected for Phone:
Alarm Triggers 2 or 3.

Level 4 RESPONSE TIME:(30 minutes) Asb. T/Ldr, Quality Coord, Assembly Same as above plus investigates
No corrective action to Alarm within 30 minutes Supr plus Assembly Manager cause of slow response
Name: Roy I. 1st Shift
REPEAT DEFECT CONDITION: Phone:
Name:James N. 2nd Shift
4th Occurrence: Exact Same defect as in Phone:
Alarm Trigger 1, or another Group collected for Name: Hillary Bradley 3rd Shift
Alarm Triggers 2 or 3.

Level 5 RESPONSE TIME: (40 minutes) Same as above plus investigates

No corrective action to Alarm within 40 minutes cause of slow response, and
potentially Stop Production
REPEAT DEFECT CONDITION: Plant Manager
John B ext 5555
5th Occurrence: Exact Same defect as in
Alarm Trigger 1, or another Group collected for
Alarm Triggers 2 or 3.
Verification Station Review for week of: Shift:
PROBLEM REPORT OUT DAY Initials
Title MON TUE WED THU FRI SAT SUN

Plant Manager

Quality Manager

Engineering Manager

Maintenance Manager

Area Supervisor

Other
Daily Leadership Review-VS Operator Report Out
1. Review the First Time Quality and Scrap Charts
Is it getting worse, better or staying the same?

2. Review Alarms from Previous Shift(s)

What are the problem(s)?
Was the Immediate Action Response Sheet utilized?
Was the response timely?
Was Point of Cause and Root Cause identified?
Did the defect re-occur and was the escalation process used?

3. Review Feedback from Downstream Customers:

Were there any issues for the past 24 hours?
Were the details of the issue communicated to the team members?
Has a Quality Alert Been Posted?
Is the issue being checked for at the Verification Station?
Weekly Problem Solving-Team Report Out
4. Review the Control Charts of Top Defects
What are the Top Defects and What is the next issue to be worked on?

5. Problem Solving Team Report Out and Review

Team member reports out to current problem solving step.
Are there any road blocks that need to be removed?
Are there any other resources that need to be assigned?
Is the Tracking Report up to date and statused appropriately?
Do any Problem Solving Assignments need to be escalated?(i.e. Shainin, 6-Sigma)
 DAILY VERIFICATION STATION MEETING
Instructions: The purpose of this meeting is to review customer satisfaction data, daily VS data, and, where applicable, alarm sheet response actions.
Make assignments as required and review Assignment Action Sheet for any updates

Verification Station:
(circle one)
Required Attendance: All attendees are listed below and must sign in when attending a meeting

Attendee or designate Monday Tuesday Wednesday Thursday Friday

DATE
TIME 10:15 AM 7:00 PM 10:15 AM 7:00 PM 10:15 AM 7:00 PM 10:15 AM 7:00 PM 10:15 AM 7:00 PM

Plant Manager

Operations Manager

Quality Manager

Engineering Manager

Weekly Problem Solving Meeting

Weekly Problem Solving Meeting

Materials Manager

HR Manager

Production Manager

Area Supervisor

Team Leader

Quality Engineer

Verification Station Operator

Other

Other

Other

Other

Other

Other

Other

Other

Other

Other

Other
Other
 Assignment Action Sheet
(from daily and /or weekly review)

Expected Actual
Shift Assign to Task Name Start Date Completion Completion
Date Date
 Defect Tracking Bar Chart
MONTH: TOTAL:
DEFECT Desc. / QTY 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62

WEEK 1

WEEK 2

WEEK 3

WEEK 4

WEEK 5
This chart is generated on Mondays
from data entered for the prior week.

This chart is to be used in conjunction

with the weekly problem solving
meeting.
VERIFICATION STATION:
DEFECTS OVER TIME
300
290
280
270
260
QUANTITY DEFECTIVE

250
240
230
220
210
200
190
180
170
160
150
140
T
TARGE

130
120
110
100
90
80
70
60
50
WEEKLY 40
COLOR
KEY 30
20
Wk # 1
10
Wk # 2
0
Wk # 3
Wk # 4
Wk # 5

JUN JUL AUG SEP OCT NOV DEC JAN FEB MAR APR MAY
WEEKLY and MONTHLY
 WEEKLY
COLOR
VERIFICATION STATION
KEY

Wk # 1
DEFECTS OVER TIME
Wk # 2 300
Wk # 3 290
Wk # 4 280
Wk # 5 270
260
QUANTITY DEFECTIVE

250
240
230
220
210
200
190
180
170
160
150
140
130
120
110
100
90
80
70
60
50
40
30
20
10
0

JUN JUL AUG SEP OCT NOV DEC JAN FEB MAR APR MAY
WEEKLY and MONTHLY
 PROBLEM TRACKING AND STATUS

Problem Date Date Status

Shift Start Date Description of Problem Assigned To Solution
Number Solved Validated R-Y-G
 VERIFICATION STATION
WEEKLY
COLOR Practical Problem Solving - Number Closed
KEY

Wk # 1
20
19
Wk # 2
18
Wk # 3 17
Wk # 4 16
Wk # 5 15
14
13
12
QUANTITY

11
10
9
8
7
6
5
4
3
2
1
0

JUN JUL AUG SEP OCT NOV DEC JAN FEB MAR APR MAY
WEEKLY and MONTHLY
 Supplier Name
Month Year
June 2022
Select Month at
Right -> 6

Dock Audit Performance

31
Green No PR&R type defects

Red Found a PR&R type defect 29

28 30

22 24 26
21 23 25 27

13 15 17 19
12 14 16 18 20

2 4 6 8 10
1 3 5 7 9 11

Failure Report
Date of Failure No. of Units Rejected Failure Description
 Supplier name - Liaison Issues
Month Year
June 2022

Located at the GM-Customer Plant

31
Green No PR&R type defects

Red Found a PR&R type defect 29

28 30

22 24 26
21 23 25 27

13 15 17 19
12 14 16 18 20

2 4 6 8 10
1 3 5 7 9 11

Failure Report
Date of Failure No. of Units Rejected Failure Description
 GM-Customer PR&R
Month Year
June 2022

31

29
28 30

22 24 26
21 23 25 27

13 15 17 19
12 14 16 18 20

2 4 6 8 10
1 3 5 7 9 11

LEGEND:

Green No PR&Rs

Red Customer Quality Disruption

(eg. PRR, Pull, Spill)
CURRENT MONTH

No
Customer
Complaints
 VERIFICATION STATION
(circle one)
CUSTOMER
COLOR CUSTOMER INCIDENTS - # DAYS RED
KEY
31
Customer 30
LIAISON 29
28
Dock
Audit 27
GP-12 26
VS-Asy 25
24
23
QUANTITY DAYS RED

22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
0

JUN JUL AUG SEP OCT NOV DEC JAN FEB MAR APR MAY
MONTHLY
 VERIFICATION STATION: Model Line/Vision Area
CUSTOMER (circle one)
COLOR
KEY CUSTOMER INCIDENTS - # DAYS RED
Customer 31
30
LIAISON
29
Dock Audit 28
GP-12 27
26
25
24
23
22
QUANTITY DAYS RED

21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
0
JUN JUL AUG SEP OCT NOV DEC JAN FEB MAR APR MAY
MONTHLY
ea
MAY
 Side #2
Instrument Panel
Verification Station
TEAM PROBLEM SOLVING

Side #2
Q-1 Instrument Panel
Verification Station
Problem Solving
 Side #3
Q-1 Instrument Panel
Verification Station
Defects LEAVING the Verification Station
Defect Tally Sheet
Alarm Escalation Procedure
Immediate Response Action
Sheet
Daily Meeting Sign-in
Weekly Problem Solving Meeting Sign-in
Meeting Assignment Log/Tracking
Weekly & Monthly: Defects Over Time
Weekly Pareto-Top 5 Defects
1st Shift Problem Solving
2nd Shift Problem Solving
Problem Solving Tracking
1st Report Card - Q-Final
2nd Report Card - Liaison (Night Letter)
FINAL Report Card - LGR (GM-Customer)
PR&Rs
FTQ (First Time Quality) Trend Charts (over time)

Scrap Trend Chart (over time)

Current PR&R LIAISON REPORT
Current PR&R LIAISON REPORT
Customer Incidents - Trend Chart
Customer Incidents - Trend Chart
PPSR's Closure Chart
PPSR's Closure Chart
 PPSR's Completed
PPSR's Completed
PPSR's Completed
PPSR's Completed
1st Report Card - Q-2
2nd Report Card - Q-FINAL
3rd Report Card - Liaison Report
- CHART MARKERS -
GREEN
YELLOW
RED
BLUE
PURPLE
LIAISON REPORT

FAST RESPONSE
ATTENDANCE
SIGN-IN SHEET
Blank Forms Drawer Labels

VERIFICATION
STATION
- BLANK FORMS -

Defect Tally Sheet Immediate Resp./Action

Daily VS Sign-In Meeting Assignment

Sheet

Practical Problem Solving Weekly VS Meeting

Report Sign-In

Problem Tracking & PPSR Closure Chart

Status

MONTHLY REPORT CUSTOMER INCIDENTS

CARDS TREND CHART
COMPLETED FORMS LABELS

VERIFICATION
STATION
COMPLETED FORMS

Defect Tally Sheet Immediate Resp./Action

- 1st Shift - - 1st Shift -

Defect Tally Sheet Immediate Resp./Action

- 2nd Shift - - 2nd Shift -

Daily VS Meeting Sign-in Daily Meeting Assignment

Sheet

Weekly Pareto Defects Over Time

TOP 5 Defects Charts Monthly Trend Charts

Practical Problem Solving Practical Problem Solving

Reports Reports
- 1st Shift - - 2nd Shift -

MONTHLY REPORT CUSTOMER INCIDENTS

CARDS TREND CHART
MONTHLY REPORT CUSTOMER INCIDENTS
CARDS TREND CHART