General Motors

QUALITY SYSTEMS BASICS AUDIT

SUPPLIER: DATE:
SUPPLIER DUNS NO:
SUPPLIER LOCATION: AUDITOR:

This audit corresponds to the current Quality Systems Basics requirements as defined
in the QSB presentation dated 11/24/04. This audit applies to all suppliers regardless of
which revision of the QSB presentation was used for training. This audit supercedes
any previous audit and presentation revisions. If a QSB audit was conducted using the
audit form approved for use at that time and prior to this revision date, it is not
necessary to repeat the audit.

AUDIT SUMMARY

POTENTIAL AUDIT
KEY STRATEGIES STATUS IS CORRECTIVE ACTION REQUIRED
SCORE SCORE

16 16 G
FAST RESPONSE
CONTROL OF NON- 24 24 G
CONFORMING MATERIAL

12 12 G
STANDARDIZED WORK
STANDARD OPERATOR 20 20 G
TRAINING

24 24 G
RISK (RPN) REDUCTION
ERROR PROOFING 12 12 G
VERIFICATION

28 28 G
LAYERED AUDITS

12 12 G
C.A.R.E.

12 12 G
LESSONS LEARNED
TOTAL SCORE: 160 160
Audit status is equal to
AUDIT STATUS the lowest color status of G
theabove strategies.

Note: YELLOW and RED status on any question requires corrective actions.
Follow-up may be done on site or via E-mail; at the auditor's discretion.
Application of this audit's results to the supplier's status is at the SQE's discretion.

STATUS FOR INDIVIDUAL QUESTIONS

0 - No implementation: Corrective Action Required
R
1 - Written implementation plan: Corrective Action Required, or
R 2 - In place, not followed: Corrective Action Required.
Y 3 - YELLOW: requirement partially implemented
G 4 - GREEN: requirement met
Note: Status and Code entered automatically from audit sheet..

QSB Audit Form 07.04 Rev. 022205


QUESTION EVIDENCE REQUIRED
FAST RESPONSE
Is there a system in place to Daily leadership meeting addresses significant
immediately respond to significant Quality concerns, designates owners and
internal and external quality failures? assigns report out dates. Attendees should be
cross- functional and multi-level.
Owner report out includes tracking form,
problem solving form, PFMEA, Control Plan,
workforce notification, etc..
Fast Response issues are linked to Layered
Audits, C.A.R.E., Lessons Learned,
Standardized Work Instructions, etc...
The concern is communicated to the
appropriate employees. Quality status is
posted.
CONTROL OF NONCONFORMING PRODUCT
Is there a system in place to ensure A consistent tagging system is used to identify
products that do not conform to suspect and nonconforming product. Preferred
specified requirements are prevented system is Stoplight visual management where
from unintended use? red indicates scrap or rejected material and
yellow indicates suspect material. Green or any
other color (except yellow or red) indicates
acceptable product.
Containment form or nonconforming material
form identifies expected quantity and locations
of suspect material.
Nonconforming and suspect material are
segregated.
Breakpoint maintenance requires 100%
inspection and management authorization for
release.
QSB Audit Form 07.04
QSB AUDIT
LOOK FOR… COMMENTS SCORE R/Y/G
Fast Response Tracking form or
equivalent, a living document with
issue, owner, report date, exit criteria
and status indicated (preferably
R/Y/G). Fast Response form should be
4 G
displayed in meeting area, preferably a
large (8' x 4') dry erase board or
equivalent.
Problem solving form (5S, 8D)
referenced, Control Plans, PFMEA.
Follow an issue from Fast Response
Tracking Form through the exit criteria. 4 G
Layered audit and C.A.R.E. checklists,
Standardized Work Instructions,
Lessons Learned contain past or 4 G
present Fast Response issues.
Quality Q or equivalent is posted and
up to date. Compare Quality "Q" to
Fast Response Tracking Form for 4 G
correlation.
SCORE / POTENTIAL 16 16
Color coding of scrap containers, hold
tags, scrap labels, in-process tags,
travelers, routers, etc… If red tags are
used for both scrap and suspect
material, tag must have disposition. 4 G
Suspect tags should have last
operation performed.
Containment worksheet or equivalent,
nonconforming material area and
associated documentation. 4 G
Segregation areas are identified and/or
foot printed: scrap bins, rework tables,
hold areas, etc… 4 G
Containment procedure, data and
nonconforming material area. Form
with authorized signature and 4 G
approved inspection of product.
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 QSB AUDIT

QUESTION EVIDENCE REQUIRED LOOK FOR… COMMENTS SCORE R/Y/G

Product removed from the approved process Procedure and forms that identify
flow is reintroduced into the process at or prior process for releasing product back into
to point of removal. process. 4 G

Does leadership review containment results? Form or meeting minutes that

demonstrate management's review 4 G
process.

STANDARDIZED WORK
Is there a system in place to develop
standardized work instruction
(methods and sequence) for all
operations?
SCORE / POTENTIAL 24 24
Standardized Work Instructions are posted at Review instructions; must include work
all operations where there are human elements, operator work path, and
operators. operation cycle time. 4 G
All affected operators are trained in the use of Operator Training records or equivalent
Standardized Work Instructions posted at each operation. 4 G

Procedure requires multi-disciplinary teams and Standardized Work Instruction forms:

continuous improvement. issued by, revision dates, etc… 4 G

STANDARD OPERATOR TRAINING
Is there a system in place to define Operator training records document specific
the minimum content and tracking for areas of training such as safety, quality record
all operators new to an operation keeping, gaging, etc…?
and/or for operators in need of
refresher training?
Trainers verify quality at a frequency to assure
all standards are met . Trainer or equivalent
audit employee within shift and again
approximately one day later. Trainers verify
Standardized Work Instructions are being
followed.
SCORE / POTENTIAL 12 12
Revisions and dates of completed
forms for operators working in
manufacturing area. Procedure for 4 G
storage and easy retrieval of records.
Training record, audit checklist,
operator Quality documentation. New
operators following Standardized Work
Instructions. 4 G

Downstream operations are notified of new
operators?
Training records for supplemental employees
document refresher training within the last three tracking forms for operator refresher
months.
Records reflecting training status of all
operators posted at each operation.
New operator tags, labels, stamps or
equivalent to show product affected by 4 G
an operator in training.
Documentation, scheduling, and
4 G
training.
Operator Tracking Sheets or
equivalent posted at all operations. All
operators listed including supplemental
employees. Review training dates and 4 G
tracking sheet revision dates.

SCORE / POTENTIAL 20 20

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QUESTION
RISK (RPN) REDUCTION
Is there a system in place for
reducing the risk of all production
processes by reducing the highest
RPN values?
Has a multi-disciplinary team
identified and analyzed (Pareto Chart, failures with a top 5 list and action plans.
etc...) past Quality failures (both
external and internal)?
ERROR PROOFING VERIFICATION
Is there a system in place to verify
that error proofing/ detection devices verification for error proofing/detection devices.
used in manufacturing and assembly
are functioning properly?
QSB Audit Form 07.04
EVIDENCE REQUIRED
PFMEAs are present for all manufacturing
processes including support functions
(receiving inspection, labeling, shipping, etc…).
Severity, Occurrence, Detection charts are
used to assign appropriate RPN values.
PFMEAs are living documents that meet
customer and AIAG requirements.
Multidisciplinary teams are responsible for
periodic reviews of PFMEA and coordination of
the RPN reduction activities? The frequency of
reviews is determined based on customer input,
process capability, process changes, etc… A
system to prioritize the sequence for reviewing
different PFMEAs is utilized.
Proactive approach to reduction of highest RPN Top RPN list, tracking charts and multi-
values has been implemented. Top RPN list
with action plans.
RPN reduction tracking charts updated and
reviewed by management.
Identification and tracking of past Quality
Occurrence and Detection ratings for past
failures accurate and reflect past corrective
actions and/or error proofing..
Procedure requiring documentation of
Procedure requires reaction plan and
immediate corrective action when device fails
verification.
QSB AUDIT
LOOK FOR… COMMENTS SCORE R/Y/G
Valid RPN numbers and revision dates
with some correlation to known
problems (PRRs, etc…). PFMEA
available for all part numbers and all
operations, especially high risk such as
labeling and rework. Documentation 4 G
that customer requirements and AIAG
guidelines are addressed by PFMEAs.
Multi-disciplinary team agenda or other
evidence of RPN reduction activities.
Documentation that frequency and
prioritization of reviews is based on
customer input, process capability,
process changes, AIAG guidelines,
etc… Review checklists, agendas or 4 G
equivalent that assure adequate
PFMEA review (all process controls on
PFMEA, occurrence and detection
ratings are accurate, etc...).
disciplinary team minutes noting
improvement actions and completion 4 G
details.
Management review minutes and
posting of tracking charts. 4 G
Multi-disciplinary team meeting notes,
action plans and past quality failures
top 5 list..
4 G
Updated Detection ratings on PFMEA.
Note revision date of PFMEA
documentation to address error 4 G
proofing and verification of past
failures.
SCORE / POTENTIAL 24 24
Master list of all devices that
prevent/detect the manufacture or
assembly of nonconforming product.
Documentation of device verification at 4 G
a minimum of once per day.
Verification logs, escalation or failure
notification forms, and corrective action 4 G
forms.
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 QSB AUDIT

QUESTION EVIDENCE REQUIRED LOOK FOR… COMMENTS SCORE R/Y/G

Management reviews verification results. Verification failures on Fast Response
Tracking Sheets, Layered Audit,
Management Review agenda, 4 G
Verification tracking forms available.

SCORE / POTENTIAL 12 12
LAYERED AUDITS
Is there a system in place to verify the Checklist of high risk items (customer used Completed audits at a frequency of
documented manufacturing/assembly features) audited a minimum of once per shift? once per shift performed by operator or
process through layered audits? inspector. 4 G

Evidence and documentation of immediate Audit checklist, audit work instructions,

corrective action for nonconformance? internal corrective actions. 4 G

Where appropriate, Standardized Work is Layered audit checklists.

verified through layered audits?
Layered Audit procedure requires daily
verification of quality documentation by a
supervisor?
Procedure requiring upper management to
audit part, process, system and voice of the
customer?
4 G
Completed audits at a frequency of
once per day performed by a 4 G
supervisor or lead person.
Completed audits performed by
managers demonstrating their
assessment of manufacturing, quality
documentation, process parameters, 4 G
systems and customer activities.

C.A.R.E.
Is there a system to designate and
100% inspect customer satisfaction
items?
System to document results and communicate
to management.
Addition of Layered Audit issues to the Lessons Completed Lessons Learned forms
Learned system.
Procedure implemented to require 100%
inspection of identified customer satisfaction
items. When 100% is not feasible, an
alternative method of increased inspection is
utilized. Procedure includes review of warranty
returns, past problems, high RPNs, pass-
though items and PRR's.
Procedure requires immediate reaction to
failures.
Leadership reviews C.A.R.E. results.
Layered Audit tracking forms, posted
audit results, management review 4 G
notes or meeting agenda.
that reflect layered audit results,
nonconformances and lessons 4 G
learned.
SCORE / POTENTIAL 28 28
Audit list of customer satisfaction
items, especially pass through items. If
alternatives to 100% inspection are
utilized, documentation to support 4 G
when and what method is used as well
as duration.
Audit form requires corrective action.
System to report failures to
management (Fast Response and 4 G
Layered Audits).
Form or meeting minutes that
demonstrate leadership's review
process. 4 G

SCORE / POTENTIAL 12 12
LESSONS LEARNED

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 QSB AUDIT

QUESTION EVIDENCE REQUIRED LOOK FOR… COMMENTS SCORE R/Y/G

Is there a system in place to capture Lessons Learned procedure and the associated Lessons Learned forms. Continuous
or identify information that will procedures reference Lessons Learned. Improvement, APQP, and RPN
support continuous improvements to Reduction team checklists or notes. 4 G
all operations/processes?

Computerized files or paper documentation that Completed Lessons Learned forms. To

contain completed Lessons Learned
forms/records.
Appropriate procedures (Corrective Action,
Continuous Improvement) require review of
Lessons Learned. Leadership reviews Lessons
Learned process to assure implementation.
assure implementation; review dates,
distribution lists, and posted Lessons 4 G
Learned.
Completed Corrective action forms.
Continuous improvement team notes
and agendas. Leadership notes or
agenda indicating Lesson Learned 4 G
system is reviewed.

SCORE / POTENTIAL 12 12
0 No implementation: Corrective Action Required
1 Written implementation plan: Corrective Action Required
2 In place, not followed: Corrective Action Required
YELLOW: requirement partially
3 Note: Enter appropriate score based on R Y G score criteria and hit enter. Correct color will appear in R/Y/G cell.
implemented
4 GREEN: requirement met

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