(Early Production Containment)
These services are one more of the quality tools focused on the containment of quality products. This tool is mainly used to ensure proper and fault-free use during the testing, pre-production and production stages.
The services of GP-12 or also known as services of Early Containment are part of the production parts approval process. This type of early containment is applicable to all pre-production components, production, and applies to all new and modified parts that require PPAP for project start-up. GP-12 containments should not be used to convey quality issues as these issues should be addressed through the CS1 or CS2 controlled delivery procedures. Once a GP12 service is established there must be a containment plan in place during commissioning so that any quality problems are quickly identified at the supplier's premises and not at the customer's premises.
The purpose of GP-12 containments is to document the supplier's efforts to gain control of its processes during start-up. The aim is to identify, correct and eliminate any quality problems that may arise quickly at the supplier's location and not at the customer's plant.
There are two control plans at the project stage which are the Prelaunch Control Plan and Production Control Plan. The pre-launch control plan should take into account all known critical conditions of the part, as well as possible areas of concern identified during the production part approval process. The GP-12 containments serve to update the Control Plan and the advanced quality planning generally of GM, Chrysler and Ford products prior to the mentioned launch, thus guaranteeing a high level of quality. safe launch plan (safe launch plan).
The early containment of GP-12 production parts requires a significant improvement of the production control plan seeking to raise the level of process reliability in order to ensure that all products initially shipped meet customer expectations.
It is the responsibility of the supplier and the containment team that will perform the GP-12 containment to establish a containment process containing the following elements:
- Identification of the person responsible for the containment process.
- Development of a pre-launch control plan consisting of additional controls. Inspection audits and tests to identify non-conformities during the production process.
- Depending on the dominant factor in the production process, the following additional controls may be included:
- Increased frequency, sample size and redundant inspection.
- Mandatory containment with the support of complementary audits.
- Addition of inspection/control elements.
- Verification of labels and traceability elements.
- Improved process controls and records.
- Validation of error proof by introducing known defects.
- Increased participation and visibility of senior management.
- Immediate implementation of containment when non-conformities are discovered.
- Identification of the measuring equipment and data collection devices to be used where appropriate.
- Documentation of the Prelaunch Control Plan, including functional tests and error testing, using the Control Plan format referred to in the Reference Manual of the Advanced Product Quality Planning and Control Plan. The development and documentation of the Pre-Release Control Plan is expected to occur during the Advanced Product Quality Planning process. The Prelaunch Control Plan is not a substitute for the Production Control Plan, but is superior to the Production Control Plan and is used to validate it.
- Use the early production containment plan for all pre-production requirements and for the quantity or duration of the production shipment specified by the purchasing and projects division. Normally, the specified quantity or production duration is intended to reflect the customer acceleration plan (ramp up plan) at the full production rate.
- As part of meeting the requirements of GP-12, each shipment should be labeled with a green dot signed by a designated senior management representative, usually the highest level manager at the production facility. The point green must have a diameter of 1.25 to 2 inches).
Finally, the supplier may be eligible to exit the early containment stage of production on its own after meeting the GP-12 exit criteria. In the event that the supplier will continue to detect non-conformities, it is expected that the GP-12 containment duration will continue until the customer is assured that the quality issues have been satisfactorily resolved.