This document details a procedure for the General Electric Appliance business, it’s sites and suppliers. This procedure provides a uniform method of evaluating, documenting, dispositioning and submitting first piece samples, including component parts, sub-assemblies, major assemblies and in some cases tooling. This procedure also defines the major first piece submittal requirements including part, tool, and process measurements.

Part/Component Qualification Requirements - Saros # 973170002

First Piece Evaluation Procedure - Document No. 4.6.3.1.0.0, Purchasing Quality System Manual Located at: GEA EmployeeNet/Purchasing/Documents

The successful first piece procedure is a milestone in the part qualification proccess. It provides information as to the ability of the tool or process to make a minimal number of parts (under specific or controlled conditions) that meet the drawing and specificaitons. With an approved first piece, the part or process may now start the extended process capability run to prove capability under varying conditions. See Saros # 9721800026 for the Process Capabilty Procedure.

In addition to first piece part evaluation, the Company’s commitment to the "six sigma" quality level philosophy requires that additional evaluations are made to ensure conformance of tooling, equipment, and processes to the capability levels necessary to insure compliance on all parts and processes whenever CTQ (Critical-to-Quality) characteristics are specified. These additional measures include prior-to-shipment recording, and GEA review of, CTQ related tool measurements and equipment or process parameter controls that directly or indirectly influence final part or assembly characteristics. The determination of which CTQ related tool dimensions or process parameters to be checked in this prior-to-shipment review should be based on the team consensus. (Design Engineering, AME, AQE, and Site Quality) This document will only attempt to recommend and establish general guidelines for these additional measures.

Site Quality for each business shall be the overall owner of the First Piece Inspection process and is responsible for using the process and assigning owners for each of the required process flow steps shown under "Responsibilities and Procedures for First Piece:".

Use First Piece Report form GEA 1134A-C Part 1 (Rev 1/95) and MABG 1134B-C Part 2 (Rev 7/90) or electronic equivalent.

CTQ dimensions, at a minimum, must be checked on all feasibility parts, design confirmation parts, (prototype and production), and all long lead tooling and equipment items previously released. A deviation is required on "C" dispositions of long lead tools. Status will be reported at T and P reviews (refer to Standing Instruction 900001 section 1 for T and P review instruction).

All part/component/material characteristics or specifications on the drawing must be measured or appraised from production tools (all cavities and multiple tools), equipment, etc. when initially submitted for first piece.

Each characteristic or specification measured/appraised must be evaluated to the Engineering Drawing requirements and a disposition code applied that clearly shows the first pieced characteristic/specification. In addition, all CTQ characteristics or specifications measured are to be clearly indicated on the first piece submittal by an upper case "CTQ" surrounded by brackets as in "(CTQ)".

First piece disposition codes are as follows:

Thereafter on resubmittals, at a minimum, the following characteristics need to be (re)inspected and a new dispositioned assigned:

- CTQ characteristics/specifications

- revised drawing characteristics/specifications

- non "A" or "B" dispositioned characteristics/specifications

- dimensions involved in tooling modification or repair

Refer to Table 1 and the First Piece Process Flowchart for specific steps and responsibilities.

1. General Responsibilities: Table 1 - Steps 001 - 005

1. Overall responsibility for the First Piece Process belongs to each respective Site Quality Control Department. This procedure is intended to be used as a tool to help facilitate the First Piece Process. The actual title of the responsible individual(s) may vary from site to site. Therefore, Site Quality will assign specific owners to each element of the process for which they are responsible. See sample form -1.
2. It is the responsibility of the Initiating Design Engineer to issue the BCN with the first piece requirements (including quantities) defined.

1. If initiated from Technology, the Design Engineer is responsible.
2. If initiated from Site Manufacturing, the Production Engineer is responsible.

3. All program or block change due dates for first piece approval are to be identified and documented by the Program Manager/Engineer for A and B Programs and by the Initiating Design Engineer for C Programs.
4. The Program Manager/Engineer (A and B Programs ) or the Initiating Design Engineer (C Programs) are responsible for setting and enforcing first piece requirements and time schedules per the NPI guidelines.
5. The Initiating Design Engineer has the overall ownership to resolve any first piece issues on individual parts until all items have an "A" disposition.
6. For purchased parts, Purchasing will provide first piece forms and instructions to the Source Code 1 (SC1) supplier for the part or subassembly. The SC1 supplier is responsible to perform first piece inspection, fill out the First Piece Report form and submit it to the using GEA site for processing. For purchased subassemblies, the SC1 supplier is responsible to ensure the sub-tier Source Code 8 (SC8) suppliers perform first piece inspection on components, fill out the First Piece Report forms and return them to the SC1 supplier. The SC1 supplier will complete first piece inspection on the completed subassembly, fill out a First Report form, compile a package of all required First Piece Report forms and submit the package to the using GEA site. Detailed instructions for supplier first piece are available in the ISO 9002 Manual in the Purchasing Applications Program Manager

2. Submitting the First Piece Report (FPR): Table 1 - Steps 006 - 010

1. Initiate the FPR using information on the BCN. Refer to Exhibit 1 and the preceding instructions for each "Numbered Circle" on the form. Use the continuation form (Exhibit 2) as required for each part.

1. Fill out all information on the FPR for circles numbered 1 - 4 and 6 - 8.
2. Contact the appropriate Production Control and/or Mfg. Representative and arrange for the First Piece Samples to be made.
3. Deliver the FPR, associated drawings, and any other necessary instructions to the Site Inspection location or Supplier.

3. Make the First Piece Samples per the BCN.

1. Schedule the build of the First Piece Samples.
2. Make the First Piece Samples per the BCN and Deliver the samples to the Site Inspection location or Supplier.

 

3. Measuring the First Piece Samples and Recording the data on the FPR:

Table 1 - Steps 011 - 013

1. The responsible QC Engineer through the Site Inspection Department, Supplier, or approved measuring house is responsible for the measurement of the samples per the drawing specifications and any other instructions provided. Refer to Exhibit 1 and the preceding instructions for each "numbered circle" on the form.

1. Fill out all information on the FPR for circles numbered 5 and 9.
2. Measure the samples and record all data for bubbles 10 - 14.

1. All part parameters are to be numbered sequentially in the Item Number column (circle number 10). In addition, the drawing is to be labeled with the corresponding item number for easy identification.
2. In the Drawing Specification column (circle number 11) the specific specification for each Item, including the nominal and tolerance is to be recorded. [Note: If the tolerance is the default tolerance for the entire drawing, place an * beside the nominal. Record an * in the Remarks section (circle number 17) and write the drawing tolerance after it.]
3. All CTQ specifications are to be clearly indicated on the FPR by recording an upper case "CTQ" surrounded by parenthesis after the drawing specification (circle number 11). Example: 1.500 +/- .005 (CTQ).
4. Record the drawing zone in the Dwg. Zone column (circle number 12) for each item.
5. The actual measurement values are to be recorded in the Data section (circle number 13). There is room to record data from six samples per Item Number. [Note: If there are more than six, continue recording the data on the next row. Make sure that the information previously recorded for bubbles 10 - 12 is either copied down to the next row, or place an " in the blocks on the next row to indicate that it is a continuation from the previous Item.]
6. Record the measuring device used to measure each characteristic in the Test Measurement Equipment column (circle number 14). [Note: If the same device is used for every item, i.e. a CMM, simply note it after the first item and indicate that it applies for all items on the FPR.]
7. Use the Remarks section circle number 17) to only record any other information pertaining to the First Piece Report.
8. Check the appropriate YES/NO blocks in the lower right gray section of the FPR (circle number 19) for each of the following: a. FPR Parts included with the report.

b. Process Capability included with the report.

c. Process Procedure included with the report.

d. Quality Planning included with the report.

3. Site Quality or Supplier is responsible for the accuracy and completeness of the FPR. Review the report to assure that among other things: all items on the drawing have been measured, all CTQ’s have been identified, that the correct number of significant digits are used, all tool cavities have been captured if applicable, and that there is no missing information from the previous steps.
4. Site Quality or Supplier is to deliver the FPR to the appropriate Site QC "status tracker" along with the samples, drawings, and all other documents.
5. The Site logs the FPR and delivers the completed FPR and samples to the initiating Design Engineer or Production Engineer for dispositioning.

4. Dispositioning FPR: Table 1 - Steps 014, 015, 018 and 019

Refer to the First Piece Process Flowchart

1. It is the Initiating Design Engineer’s responsibility to assure that all items on the FPR are dispositioned. However, if it is other than an "A" or "B" disposition, the Initiating Design Engineer is to assemble the drawing sign-off team to evaluate other options and to determine corrective action. Refer to the Definitions section of this procedure and/or bubble 18 on the FPR for clarification of the disposition codes.
2. Evaluate the data for the sample(s) and determine if it meets the drawing specifications and record the appropriate disposition code for each Item on the FPR (circle number 15).
3. Perform the following tasks for each of the following disposition codes:

1. "A" Disposition - No other tasks.
2. "B" Disposition

1. Determine the new specification and/or tolerance limits and record them on the FPR (circle number 16).

Issue a BCN to change the drawing to the new specifications. The BCN Number and Sheet Number used to process the "B" Disposition will be the same as the initial BCN but with an "F" suffix added to the Sheet Number.

Example : Initial BCN - - - BCN 2200012

Sheet No. 3

FPR BCN - - - BCN 2200012

Sheet No. 3F

2. [Note: This should actually be the last step in the process in order to capture the results of all activity into one BCN for the drawing.]

3. "C" Disposition

1. Assemble the drawing sign-off team to evaluate data and determine options for corrective action.
2. Initiate and document a corrective action plan.
3. Issue a deviation for all parts to be used in production until the corrective action has taken place. Record the deviation number and the number of parts covered by it on the FPR (circle number 20).
4. Resubmit "corrected" samples for First Piece Evaluation.

5. "D" Disposition

1. Assemble the drawing sign-off team to evaluate data and determine options for corrective action.
2. Initiate and document a corrective action plan.
3. Resubmit "corrected" samples for First Piece Evaluation.

6. "P" Disposition

1. Assemble the drawing sign-off team to concur with the disposition or evaluate other options. If it remains a "P", determine the new specification and/or tolerance limits and record them on the FPR (circle number 16).

4. After all items have been dispositioned, the FPR is to be signed and dated by the Initiating Design Engineer or authorized Design Engineering Representative (circle number 21).

5. Quality Review

1. The AQE/Site QC is to review the FPR and complete the following items:

1. Review the Disposition Code for each characteristic evaluated and assign the lowest level Disposition Code (A, B, C, D or P) by checking the appropriate block (circle number 18).
2. Add the FPR Sheet Number when "B" Disposition. The FPR Sheet Number is the same as in "circle number 8" but with an ‘F’ suffix.
3. Upon concurrence with the dispositions, sign and date the FPR (circle number 21).
4. Note: For C Programs, the Site QC will review the FPR and, if necessary, coordinate the results with AQE / Site ME or PIE prior to signing in the space provided - Site Quality Control.
5. Deliver the completed and signed FPR to the Site QC "status tracker" along with the samples, drawings, and all other documents.

6. Tracking and Reporting: Table 1 - Steps 016 and 017

Specific process flow elements, roles and responsibilities to be assigned by Site Quality:

* If initiated from Technology: Design Engineer. If initiated from Manufacturing: Production Engineer

The following form can be used as required to document the individuals responsible for each step in the process for any or all parts. Refer to Table - 1 on the prior page for suggested responsibilities. It also may be advisable to log the date received at each step by the individual for tracking purposes.

For All Parts and Assemblies A/B/C Programs

1 a. Production / Design Engineer

b. Buyer

c. Initiator

d. QC Engineer

e. Project Coordinator

f. EAU (estimated annual usage)

2 a. Drawing Number (For Parts Being First Piece Evaluated)

b. Part / Group Number

c. Revision

d. Part Name

e. Internal Manufacturer

3 a. First Piece Report No.

b. Submittal Number

c. Prior First Piece Report No.

d. Prior Disposition

6 a. Parts Submitted For: Check Blocks

Dimension [ ]

Laboratory [ ]

Appearance [ ]

b. Samples Required - Indicate number of samples for each item above

Code Site

1 AP-5

2 AP-2

3 AP-1

4 AP-3

A Leiser

B MABE Refrigeration

C Bloomington

G LaFayette

L Chicago - Range

Y Decatur

Others as Required

Codes 5, H, M, X, D, P, N, V, K - Not used at this time

8 a. Project No.

- Check Block

Part Revision [ ]

New Supplier [ ]

New Part [ ]

Tooling [ ]

Other ___________

5 a. First Piece Report requested by - Name

b. First Piece Report prepared by - Name

c. Location - Where First Piece Activity is Taking Place

d. Date First Piece Report Completed

e. Page Number - Pg. _____ of ____

Measurement Phase: (cont.)

9 a. First Piece Sample Information

Part Weight ___________________________

Number of Pieces Inspected _______________

Date Inspected __________________________

Tool Number ___________________________

Cavity No./ID _____ ______________________

BUYER - GEA Purchasing function

PROCESS CAPABILITY - A predetermined methodolgy of sampling representative data from a new or existing process that determines the ability of the process to repeatedly meet the drawing specifications.

PROGRAM CLASS (A/B/C)

The program/project will be assigned a risk value of A, B, or C in accordance with the following matrix. Refer to Standing Instruction SI 900001 for detailed instructions on the NPI process.

QUALITY PLAN - A documented part/process plan that details the actions required to ensure that part or process conforms to the drawing and specification requirements. Such a plan would document items such as what are the CTQ’s, how they will be measured, who will measure them, how often they will be measured, etc.

SIX SIGMA - Six standard deviations between population nominal and specification limit

AME - Advanced Manufacturing Engineer

AQE - Advanced Quality Engineer

BCN - Business Change Notice

BCR - Business Change Request

CCB - Change Control Board

CIB - Change Implementation Board

CTQ - Critical to Quality

DE - Design Engineer

EMPIS - Engineering Materials and Process Information Service

FPR - First Piece Report (GEA Form 1134A-C Part 1 and Part 2)

FQE - Field Quality Engineer

GD&T - Geometric Dimensioning and Tolerancing

IAS - International Approval Services (Formerly AGA)

ISO - Organization for International Standards

LSL - Lower Specification Limit

MCS - Material Coordination Specialist

NPI - New Product Introduction

OCE - Office of the Chief Engineer

OSHA - Occupational Safety and Health Administration

PCE - Process Control Engineer

PIE - Process Improvement Engineer

PMQE - Purchased Material Quality Engineer

PMQS - Purchased Material Quality Specialist

PPM - Parts per Million

PPM - Purchasing Program Manager

SC# - Source Code #

SPC - Statistical Process Control

UL - Underwriter’s Laboratory

USL - Upper Specification Limit

RESPONSIBILITY & AUTHORITY: The Manager Advanced Quality Engineering has the responsibility for maintaining this document. The Site Quality Managers and Manager Supplier Quality has the responsibility for implementation.

COUNSEL with regard to interpretation and implementation of this procedure will be provided by Manager Advanced Quality Engineering.

* Approval given by electronic message