Purpose: The GAP analysis is documenting two independent GAPS's:

1. The DFMEA severity 9 & 10s carried over to the PFMEA

Are all the 9 & 10s in the DFMEA that are effected by the suppliers or Sub-suppliers process cap
Have System Engineering & DRE analyzed potential causes by sytem, sub-system, & component
Component DFMEA? Has Severity ranking rolled down?
2. Are the PFMEA Severity 9 & 10's detection levels meeting the requirements? Is appropriate miti
Where the SQ Part/Process Specific CG update has occurred allowing a detection level greater than 3 fo
noted in the “Action/Item” section on the “Risk Mitigation Action Plan” tab(s) referencing the SQ comm
not require additional level of approval but must still be uploaded to SQMS in accordance with the requ
Quality Manual.

Scope: This analysis includes only severity 9 & 10's from the DFMEA
The Supplier GAP analysis is required to include all severity 9 & 10's that are passed down to the
and Processes for all directed RASIC A & B, and non-directed sub-suppliers.

Example:
Code Sub-Supplier Name
A Supplier ABC

PLAN Phase: RFQ / TECH REVIEW (Before sourcing)

Baseline DFMEA and PFMEA available for review

Any deviations to this requirement must be noted at this time (SQ CG deviations/ SOR Appendix)
* DREs to support ensuring severity requirements from upper level system are provided and understoo
available in eSOR).
* Supplier shall quote all severities 9s and 10s with proper PFMEA detection (Level 3 or better unless ot
specific CG)
* Supplier shall document gaps to this requirement (Ex. CG3404 M7 Technical Issues list, GM 1927 21 D
Form)

DO Phase: Tooling Kick-off (Before CRV 2 and 3)

* Program / Part specific DFMEA and PFMEA Finalized upon latest Engineering tooling changes. Supplie
and aligned.
* At P-release design to process gaps must be identified and closed.
** DFMEA approval moved to prior to P-release (formally at VTC)
* Error Proofing / Detection planned for implementation acording to CG4338 SQ SOR requirement. Sup
Mitigation plan for PDT discussion.
* Document and update the GM 1927 21 DFMEA PFMEA Gap Analysis Process and Transition form.
 CHECK Phase: Parts non-saleable (before CRV4)
* Program / part specific DFMEA and PFMEA reviewed again to check if there are changes in Gaps.
** Supplier to review gaps again and document / update GM 1927 21 DFMEA PFMEA Gap Analysis P
** Review Risk Mitigation Action and check Error proofing / Detection effectiveness.
** Gaps not meeting the requirements should be reviewed and agreed through PDT.

ACT Phase: PPAP readiness ( before CRV5)

* DFMEA and PFMEA finalized and adjusted for any changes and ECRs; document / finalize GM 1927 21
Transition form.
* SQE to review and ensure all severities 9 and 10 error proofing / detection are captured on shop floor
Reviewed during PDT.
** Supplier to confirm Error-proofing / Detection effectiveness / robustness.
** Supplier to confirm Risk Mitigation plan Closed / Complete status.
** GM 1927 21 DFMEA PFMEA Gap Analysis Process and Transition form (for sev 9 and 10 not meeti
before submit for Director's approval.

CONCLUDE Phase: PPAP (before fully approved)

* All Error proofing devices are working / functional on shop floor and verified by SQE.
* GM 1927 21 DFMEA PFMEA Gap Analysis Process and Transition form (for sev. 9 and 10 not meeting
by SQ /Eng Director.

GAP Analysis Process RASIC

R: Responsible A: Approve S: Support I: Inform

Step# Step GM DRE TS/ETL/SSLE GM SQ Mgr/

Director

Prepare DFMEA extract for

communication to Supplier for PFMEA
1 development & Communicate DFMEA R S --
extract in Appendix B or C of the SOR (as
required per training)

Add DFMEA extract to the GAP Analysis

2 S S --
workbook (GM 1927 21)
3 Prepare GAP Analyis document S S --
Schedule Supplier D-P GAP analysis (GM
4 S S --
1927 21 process)

Conduct Supplier D-P GAP analysis

meeting and document GAPs and
5 document required issues in the Severity S S --
and Detection Transition Form (GM 1927
21 process)

SQE Submits Transition Form for required

6 S S A
approvals
Step 1: Prepare DFMEA extract for PFMEA development & Communicate DFMEA extract in Appendix B or C o

DRE prepares the DFMEA extract (if didn't receive, contact DRE or Technical Specialist)

Step 2: Add DFMEA extract to the GAP Analysis workbook GM 1927 21

Step 3: Prepare GAP Analysis document

Input failure modes line numbers from DFMEA Extract for all SEV 9 & 10's
If Supplier is Design Responsible, Input additional failure mode line numbers from Supplier DFMEA for a
Input the associated DFMEA SEV 9 & 10s from the DFMEA Extract in Gap Analysis form
Input the associated PFMEA line number and SEV in Gap Analysis form (PFMEA SEV should match the D
Input the PFMEA DET value in Gap Analysis form
If D to P GAP and/or DET GAP have been identified, document Action Plan in Action / Item. (These GAP
IF no GAP is identified, document what the Detection is in the Action / Item

Step 4: Schedule Supplier D-P gap analysis (GM 1927 21 process)

Supplier schedules Gap analysis meeting with GM team (GM Supplier Quality Engineer, GM DRE, GM T
Plant Quality Engineer) and supplier team

Conduct Supplier D-P Gap analysis meeting and document GAPs. If Gap Still exsists, fill out the GM 1
Step 5:
Transition Form.
Supplier fills out the Transition Form Tab and review with GM team for buyoff

Step 6: SQE Submits Transition Form for required approvals

SQE fills out E-approval number on the transition form after receiving the E-approval
SQE shares the transition sign off form with the Supplier
Supplier uploads the E-approved Transition form to the SQMS system for PPAP approval under Custom

Entry Notes for GM 1927 21 DFMEA PFMEA Gap Analysis and Risk Mitigation Form

In header: If GM is Design Responsibe input GM DRE. If supplier is Design Responsible input Supplier D

In column (G) PFMEA Line No. XXX, If the Failure is not included in the PFMEA, enter a "?" or in case it b

When an entry is Identified with a "?" Or "Code ?" Leave column H "SEV"blank, and input a "10" into co

Starting at CRV2 & CRV3 on the top righthand side of gap analysis place a "X" in the Box will auto popu
Completed risk mitigation: Example Below

To Auto-Populate from previous Analysis X

Place an "X" in the box

Due Date Column "V" Entry in this signifies status of the Risk Mitigatio
or
Complete 3/2/2022

Complete
ers or Sub-suppliers process captured in the PFMEAs?
tem, sub-system, & component failure modes and identified in

quirements? Is appropriate mitigation being conducted?

detection level greater than 3 for Severity Rankings of 9 & 10, it should be
” tab(s) referencing the SQ commodity specific Part/Process Specific CG and does
QMS in accordance with the requirements as outlined in the GM 1927 Supplier

0's that are passed down to the sub-supplier manufacturing PFMEA's

-suppliers.

When entering a line item from a sub-supplier PFMEA, say

Supplier ABC's line 44, would be entered as A44.

deviations/ SOR Appendix)

tem are provided and understood up front (GM DFMEA extracted information is

ction (Level 3 or better unless otherwise required by the commodity/process

chnical Issues list, GM 1927 21 DFMEA PFMEA Gap Analysis Process and Transition

neering tooling changes. Suppliers to ensure all severity 9s and 10s are captured

G4338 SQ SOR requirement. Supplier to identify and document Gaps with Risk

Process and Transition form.

 if there are changes in Gaps.
21 DFMEA PFMEA Gap Analysis Process and Transition form. ( Goal: ZERO Gaps)
on effectiveness.
eed through PDT.

document / finalize GM 1927 21 DFMEA PFMEA Gap Analysis Process and

ection are captured on shop floor. Gaps to be tracked and closed prior to Full-PPAP.

bustness.
s.
form (for sev 9 and 10 not meeting the detection requirement) reviewed by PDT

verified by SQE.
m (for sev. 9 and 10 not meeting the detection requirements) have been approved

ysis Process RASIC

S: Support I: Inform C: Consult
GM EGM/ GM Supplier
Supplier
Director SQE Plant Mgr

-- -- S --

-- -- R --

-- S R --
-- S R --

-- S R --

A R S A
MEA extract in Appendix B or C of the eSOR

hnical Specialist)

0's
mbers from Supplier DFMEA for any SEV 9 & 10's
ap Analysis form
(PFMEA SEV should match the DFMEA SEV)

Plan in Action / Item. (These GAPs are automatically calculated)

Item

Quality Engineer, GM DRE, GM Technical Specialist, GM Validation Engineer, GM

ap Still exsists, fill out the GM 1927 21 DFMEA PFMEA Gap Analysis Process and

buyoff

he E-approval

or PPAP approval under Customer Specific Requirement

gation Form

sign Responsible input Supplier DRE.

PFMEA, enter a "?" or in case it belongs to a Sub-Supplier Code + ? (A?)

V"blank, and input a "10" into column I "Actual Detection".

e a "X" in the Box will auto populate from the previous Right side of the Analysis and carry over

nifies status of the Risk Mitigation Process:

A date signals estimated completion of the gap closure

Complete signal the Risk Mitigation efforts are complete, and this is the intended dectection level at full PPAP
evel at full PPAP
Commodity Process Location Date
CRV 3 CRV 4 CRV 5 Participants:
Program SQE Supplier
Process Diagram DRE Other
Tech Review Gap Analysis CRV 3 Gap Analysis CRV 4 Gap Analysis CRV 5 Gap Analysis
Failure Modes to Control : 0 Failure Modes to Control : 0 Failure Modes to Control : 0 Failure Modes to Control : 0

DFMEA to PFMEA Severity 9 DFMEA to PFMEA Severity DFMEA to PFMEA Severity DFMEA to PFMEA Sever-
& 10 9 & 10 9 & 10 ity 9 & 10

Confirmed Misaligned Confirmed Misaligned Confirmed Misaligned Confirmed Misaligned

Tech Review Detection Analysis CRV 3 Detection Analysis CRV 4 Detection Analysis CRV 5 Detection Analysis

PFMEA Detection Rating PFMEA Detection Rating PFMEA Detection Rating PFMEA Detection Rating
0 10 20 30 40 50 60 0 10 20 30 40 50 60 0 10 20 30 40 50 60 0 10 20 30 40 50 60

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

Failure Modes Failure Modes Failure Modes Failure Modes

CIP Summary 897621592.xlsx Revision: 03/10/17

GM Confidential 10 Issue Date: 03/23/17
 Code Sub-Supplier Name
A
B
C
D
E
F
G
B
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z

Sub-Supplier List 897621592.xlsx Revision: 03/10/17

GM Confidential 11 Issue Date: 03/23/17
 Risk Mitigation Action Plan
Commodity/Program: Design Responsible: DRE: To Auto-Populate from previous Analysis
Gap Analysis Date: SQE: Place an "X" in the box
DFMEA PFMEA DFMEA PFMEA
Failure Line Line Actual Req D to P DET Complete Line Line Actual Req D to P DET
Mode No XXX SEV. No XXX SEV. DET. DET. GAP GAP Action / Item Date No XXX SEV. No XXX SEV. DET. DET. GAP GAP
1 1 1 1 1
2 1 1 1 1
3 1 1 1 1
4 1 1 1 1
5 1 1 1 1
6 1 1 1 1
7 1 1 1 1
8 1 1 1 1
9 1 1 1 1
10 1 1 1 1
11 1 1 1 1
12 1 1 1 1
13 1 1 1 1
14 1 1 1 1
15 1 1 1 1
16 1 1 1 1
17 1 1 1 1
18 1 1 1 1
19 1 1 1 1
20 1 1 1 1
21 1 1 1 1
22 1 1 1 1
23 1 1 1 1
24 1 1 1 1
25 1 1 1 1
26 1 1 1 1
27 1 1 1 1
28 1 1 1 1
29 1 1 1 1
30 1 1 1 1
31 1 1 1 1
32 1 1 1 1
33 1 1 1 1
34 1 1 1 1
35 1 1 1 1
36 1 1 1 1
37 1 1 1 1
38 1 1 1 1
39 1 1 1 1
40 1 1 1 1
41 1 1 1 1
42 1 1 1 1
43 1 1 1 1
44 1 1 1 1
45 1 1 1 1
46 1 1 1 1
47 1 1 1 1
48 1 1 1 1
49 1 1 1 1
50 1 1 1 1
51 1 1 1 1
52 1 1 1 1
53 1 1 1 1
54 1 1 1 1
55 1 1 1 1
56 1 1 1 1
57 1 1 1 1
58 1 1 1 1
59 1 1 1 1
60 1 1 1 1
61 1 1 1 1
62 1 1 1 1
63 1 1 1 1
64 1 1 1 1
65 1 1 1 1
66 1 1 1 1
67 1 1 1 1
68 1 1 1 1
69 1 1 1 1
70 1 1 1 1
71 1 1 1 1
72 1 1 1 1
73 1 1 1 1
74 1 1 1 1
75 1 1 1 1
76 1 1 1 1
77 1 1 1 1
78 1 1 1 1
79 1 1 1 1
80 1 1 1 1
81 1 1 1 1
82 1 1 1 1
83 1 1 1 1
84 1 1 1 1
85 1 1 1 1
86 1 1 1 1
87 1 1 1 1
88 1 1 1 1
89 1 1 1 1
90 1 1 1 1
91 1 1 1 1
92 1 1 1 1
93 1 1 1 1
94 1 1 1 1
95 1 1 1 1
96 1 1 1 1
97 1 1 1 1
98 1 1 1 1
99 1 1 1 1
100 1 1 1 1
101 1 1 1 1
102 1 1 1 1
103 1 1 1 1
104 1 1 1 1
105 1 1 1 1
106 1 1 1 1
107 1 1 1 1
108 1 1 1 1
109 1 1 1 1
110 1 1 1 1
111 1 1 1 1
112 1 1 1 1
113 1 1 1 1
114 1 1 1 1
115 1 1 1 1
116 1 1 1 1
117 1 1 1 1
118 1 1 1 1
119 1 1 1 1
120 1 1 1 1
121 1 1 1 1
122 1 1 1 1
123 1 1 1 1
124 1 1 1 1
125 1 1 1 1
126 1 1 1 1
127 1 1 1 1
128 1 1 1 1
129 1 1 1 1
130 1 1 1 1
131 1 1 1 1
132 1 1 1 1
133 1 1 1 1
134 1 1 1 1
135 1 1 1 1
136 1 1 1 1
137 1 1 1 1
138 1 1 1 1
139 1 1 1 1
140 1 1 1 1
141 1 1 1 1
142 1 1 1 1
143 1 1 1 1
144 1 1 1 1
145 1 1 1 1
146 1 1 1 1
147 1 1 1 1
148 1 1 1 1
149 1 1 1 1
150 1 1 1 1
151 1 1 1 1
152 1 1 1 1
153 1 1 1 1
154 1 1 1 1
155 1 1 1 1
156 1 1 1 1
157 1 1 1 1
158 1 1 1 1
159 1 1 1 1
160 1 1 1 1
161 1 1 1 1
162 1 1 1 1
163 1 1 1 1
164 1 1 1 1
165 1 1 1 1
166 1 1 1 1
167 1 1 1 1
168 1 1 1 1
169 1 1 1 1
170 1 1 1 1
171 1 1 1 1
172 1 1 1 1
173 1 1 1 1
174 1 1 1 1
175 1 1 1 1
176 1 1 1 1
177 1 1 1 1
178 1 1 1 1
179 1 1 1 1
180 1 1 1 1
181 1 1 1 1
182 1 1 1 1
183 1 1 1 1
184 1 1 1 1
185 1 1 1 1
186 1 1 1 1
187 1 1 1 1
188 1 1 1 1
189 1 1 1 1
190 1 1 1 1
191 1 1 1 1
192 1 1 1 1
193 1 1 1 1
194 1 1 1 1
195 1 1 1 1
196 1 1 1 1
197 1 1 1 1
198 1 1 1 1
199 1 1 1 1
200 1 1 1 1

Total 0 DFMEA PFMEA

Severity DFMEA DET DET
10 0 10 0 10 0
9 0 9 0 9 0
8 0 8 0 8 0
7 0 7 0 7 0
6 0 6 0 6 0
5 0 5 0 5 0
4 0 4 0 4 0
3 0 3 0 3 0
2 0 2 0 2 0
1 0 1 0 1 0

Tech Review GAP Analysis 897621592.xlsx Revision: 03/10/17

GM Confidential 12 Issue Date: 03/23/17
 Risk Mitigation Action Plan
Commodity/Program: Design Responsible: DRE: To Auto-Populate from previous Analysis
3/22/2022 SQE:
Gap Analysis Place an "X" in the box
DFMEA PFMEA DFMEA PFMEA
Failure Line Line Actual Req D to P DET Complete Line Line Actual Req D to P DET
Mode No XXX SEV. No XXX SEV. DET. DET. GAP GAP Action / Item Date No XXX SEV. No XXX SEV. DET. DET. GAP GAP
1 1 1 1 1
2 1 1 1 1
3 1 1 1 1
4 1 1 1 1
5 1 1 1 1
6 1 1 1 1
7 1 1 1 1
8 1 1 1 1
9 1 1 1 1
10 1 1 1 1
11 1 1 1 1
12 1 1 1 1
13 1 1 1 1
14 1 1 1 1
15 1 1 1 1
16 1 1 1 1
17 1 1 1 1
18 1 1 1 1
19 1 1 1 1
20 1 1 1 1
21 1 1 1 1
22 1 1 1 1
23 1 1 1 1
24 1 1 1 1
25 1 1 1 1
26 1 1 1 1
27 1 1 1 1
28 1 1 1 1
29 1 1 1 1
30 1 1 1 1
31 1 1 1 1
32 1 1 1 1
33 1 1 1 1
34 1 1 1 1
35 1 1 1 1
36 1 1 1 1
37 1 1 1 1
38 1 1 1 1
39 1 1 1 1
40 1 1 1 1
41 1 1 1 1
42 1 1 1 1
43 1 1 1 1
44 1 1 1 1
45 1 1 1 1
46 1 1 1 1
47 1 1 1 1
48 1 1 1 1
49 1 1 1 1
50 1 1 1 1
51 1 1 1 1
52 1 1 1 1
53 1 1 1 1
54 1 1 1 1
55 1 1 1 1
56 1 1 1 1
57 1 1 1 1
58 1 1 1 1
59 1 1 1 1
60 1 1 1 1
61 1 1 1 1
62 1 1 1 1
63 1 1 1 1
64 1 1 1 1
65 1 1 1 1
66 1 1 1 1
67 1 1 1 1
68 1 1 1 1
69 1 1 1 1
70 1 1 1 1
71 1 1 1 1
72 1 1 1 1
73 1 1 1 1
74 1 1 1 1
75 1 1 1 1
76 1 1 1 1
77 1 1 1 1
78 1 1 1 1
79 1 1 1 1
80 1 1 1 1
81 1 1 1 1
82 1 1 1 1
83 1 1 1 1
84 1 1 1 1
85 1 1 1 1
86 1 1 1 1
87 1 1 1 1
88 1 1 1 1
89 1 1 1 1
90 1 1 1 1
91 1 1 1 1
92 1 1 1 1
93 1 1 1 1
94 1 1 1 1
95 1 1 1 1
96 1 1 1 1
97 1 1 1 1
98 1 1 1 1
99 1 1 1 1
100 1 1 1 1
101 1 1 1 1
102 1 1 1 1
103 1 1 1 1
104 1 1 1 1
105 1 1 1 1
106 1 1 1 1
107 1 1 1 1
108 1 1 1 1
109 1 1 1 1
110 1 1 1 1
111 1 1 1 1
112 1 1 1 1
113 1 1 1 1
114 1 1 1 1
115 1 1 1 1
116 1 1 1 1
117 1 1 1 1
118 1 1 1 1
119 1 1 1 1
120 1 1 1 1
121 1 1 1 1
122 1 1 1 1
123 1 1 1 1
124 1 1 1 1
125 1 1 1 1
126 1 1 1 1
127 1 1 1 1
128 1 1 1 1
129 1 1 1 1
130 1 1 1 1
131 1 1 1 1
132 1 1 1 1
133 1 1 1 1
134 1 1 1 1
135 1 1 1 1
136 1 1 1 1
137 1 1 1 1
138 1 1 1 1
139 1 1 1 1
140 1 1 1 1
141 1 1 1 1
142 1 1 1 1
143 1 1 1 1
144 1 1 1 1
145 1 1 1 1
146 1 1 1 1
147 1 1 1 1
148 1 1 1 1
149 1 1 1 1
150 1 1 1 1
151 1 1 1 1
152 1 1 1 1
153 1 1 1 1
154 1 1 1 1
155 1 1 1 1
156 1 1 1 1
157 1 1 1 1
158 1 1 1 1
159 1 1 1 1
160 1 1 1 1
161 1 1 1 1
162 1 1 1 1
163 1 1 1 1
164 1 1 1 1
165 1 1 1 1
166 1 1 1 1
167 1 1 1 1
168 1 1 1 1
169 1 1 1 1
170 1 1 1 1
171 1 1 1 1
172 1 1 1 1
173 1 1 1 1
174 1 1 1 1
175 1 1 1 1
176 1 1 1 1
177 1 1 1 1
178 1 1 1 1
179 1 1 1 1
180 1 1 1 1
181 1 1 1 1
182 1 1 1 1
183 1 1 1 1
184 1 1 1 1
185 1 1 1 1
186 1 1 1 1
187 1 1 1 1
188 1 1 1 1
189 1 1 1 1
190 1 1 1 1
191 1 1 1 1
192 1 1 1 1
193 1 1 1 1
194 1 1 1 1
195 1 1 1 1
196 1 1 1 1
197 1 1 1 1
198 1 1 1 1
199 1 1 1 1
200 1 1 1 1

Total 0 DFMEA PFMEA

Severity DFMEA DET DET
10 0 10 0 10 0
9 0 9 0 9 0
8 0 8 0 8 0
7 0 7 0 7 0
6 0 6 0 6 0
5 0 5 0 5 0
4 0 4 0 4 0
3 0 3 0 3 0
2 0 2 0 2 0
1 0 1 0 1 0

CRV 3 GAP Analysis 897621592.xlsx Revision: 03/10/17

GM Confidential 13 Issue Date: 03/23/17
 Risk Mitigation Action Plan
Commodity/Program: Design Responsible: DRE: To Auto-Populate from previous Analysis
Gap Analysis Date: SQE: Place an "X" in the box
DFMEA PFMEA DFMEA PFMEA
Failure Line Line Actual Req D to P DET Complete Line Line Actual Req D to P DET
Mode No XXX SEV. No XXX SEV. DET. DET. GAP GAP Action / Item Date No XXX SEV. No XXX SEV. DET. DET. GAP GAP
1 1 1 1 1
2 1 1 1 1
3 1 1 1 1
4 1 1 1 1
5 1 1 1 1
6 1 1 1 1
7 1 1 1 1
8 1 1 1 1
9 1 1 1 1
10 1 1 1 1
11 1 1 1 1
12 1 1 1 1
13 1 1 1 1
14 1 1 1 1
15 1 1 1 1
16 1 1 1 1
17 1 1 1 1
18 1 1 1 1
19 1 1 1 1
20 1 1 1 1
21 1 1 1 1
22 1 1 1 1
23 1 1 1 1
24 1 1 1 1
25 1 1 1 1
26 1 1 1 1
27 1 1 1 1
28 1 1 1 1
29 1 1 1 1
30 1 1 1 1
31 1 1 1 1
32 1 1 1 1
33 1 1 1 1
34 1 1 1 1
35 1 1 1 1
36 1 1 1 1
37 1 1 1 1
38 1 1 1 1
39 1 1 1 1
40 1 1 1 1
41 1 1 1 1
42 1 1 1 1
43 1 1 1 1
44 1 1 1 1
45 1 1 1 1
46 1 1 1 1
47 1 1 1 1
48 1 1 1 1
49 1 1 1 1
50 1 1 1 1
51 1 1 1 1
52 1 1 1 1
53 1 1 1 1
54 1 1 1 1
55 1 1 1 1
56 1 1 1 1
57 1 1 1 1
58 1 1 1 1
59 1 1 1 1
60 1 1 1 1
61 1 1 1 1
62 1 1 1 1
63 1 1 1 1
64 1 1 1 1
65 1 1 1 1
66 1 1 1 1
67 1 1 1 1
68 1 1 1 1
69 1 1 1 1
70 1 1 1 1
71 1 1 1 1
72 1 1 1 1
73 1 1 1 1
74 1 1 1 1
75 1 1 1 1
76 1 1 1 1
77 1 1 1 1
78 1 1 1 1
79 1 1 1 1
80 1 1 1 1
81 1 1 1 1
82 1 1 1 1
83 1 1 1 1
84 1 1 1 1
85 1 1 1 1
86 1 1 1 1
87 1 1 1 1
88 1 1 1 1
89 1 1 1 1
90 1 1 1 1
91 1 1 1 1
92 1 1 1 1
93 1 1 1 1
94 1 1 1 1
95 1 1 1 1
96 1 1 1 1
97 1 1 1 1
98 1 1 1 1
99 1 1 1 1
100 1 1 1 1
101 1 1 1 1
102 1 1 1 1
103 1 1 1 1
104 1 1 1 1
105 1 1 1 1
106 1 1 1 1
107 1 1 1 1
108 1 1 1 1
109 1 1 1 1
110 1 1 1 1
111 1 1 1 1
112 1 1 1 1
113 1 1 1 1
114 1 1 1 1
115 1 1 1 1
116 1 1 1 1
117 1 1 1 1
118 1 1 1 1
119 1 1 1 1
120 1 1 1 1
121 1 1 1 1
122 1 1 1 1
123 1 1 1 1
124 1 1 1 1
125 1 1 1 1
126 1 1 1 1
127 1 1 1 1
128 1 1 1 1
129 1 1 1 1
130 1 1 1 1
131 1 1 1 1
132 1 1 1 1
133 1 1 1 1
134 1 1 1 1
135 1 1 1 1
136 1 1 1 1
137 1 1 1 1
138 1 1 1 1
139 1 1 1 1
140 1 1 1 1
141 1 1 1 1
142 1 1 1 1
143 1 1 1 1
144 1 1 1 1
145 1 1 1 1
146 1 1 1 1
147 1 1 1 1
148 1 1 1 1
149 1 1 1 1
150 1 1 1 1
151 1 1 1 1
152 1 1 1 1
153 1 1 1 1
154 1 1 1 1
155 1 1 1 1
156 1 1 1 1
157 1 1 1 1
158 1 1 1 1
159 1 1 1 1
160 1 1 1 1
161 1 1 1 1
162 1 1 1 1
163 1 1 1 1
164 1 1 1 1
165 1 1 1 1
166 1 1 1 1
167 1 1 1 1
168 1 1 1 1
169 1 1 1 1
170 1 1 1 1
171 1 1 1 1
172 1 1 1 1
173 1 1 1 1
174 1 1 1 1
175 1 1 1 1
176 1 1 1 1
177 1 1 1 1
178 1 1 1 1
179 1 1 1 1
180 1 1 1 1
181 1 1 1 1
182 1 1 1 1
183 1 1 1 1
184 1 1 1 1
185 1 1 1 1
186 1 1 1 1
187 1 1 1 1
188 1 1 1 1
189 1 1 1 1
190 1 1 1 1
191 1 1 1 1
192 1 1 1 1
193 1 1 1 1
194 1 1 1 1
195 1 1 1 1
196 1 1 1 1
197 1 1 1 1
198 1 1 1 1
199 1 1 1 1
200 1 1 1 1

Total 0 DFMEA PFMEA

Severity DFMEA DET DET
10 0 10 0 10 0
9 0 9 0 9 0
7 0 8 0 8 0
7 0 7 0 7 0
6 0 6 0 6 0
5 0 5 0 5 0
4 0 4 0 4 0
3 0 3 0 3 0
2 0 2 0 2 0
1 0 1 0 1 0

CRV 4 GAP Analysis 897621592.xlsx Revision: 03/10/17

GM Confidential 14 Issue Date: 03/23/17
 Risk Mitigation Action Plan
Commodity/Program: Design Responsible: DRE: To Auto-Populate from previous Analysis
Gap Analysis Date: SQE: Place an "X" in the box
DFMEA PFMEA DFMEA PFMEA
Failure Line Line Actual Req D to P DET Complete Line Line Actual Req D to P DET
Mode No XXX SEV. No XXX SEV. DET. DET. GAP GAP Action / Item Date No XXX SEV. No XXX SEV. DET. DET. GAP GAP
1 1 1 1 1
2 1 1 1 1
3 1 1 1 1
4 1 1 1 1
5 1 1 1 1
6 1 1 1 1
7 1 1 1 1
8 1 1 1 1
9 1 1 1 1
10 1 1 1 1
11 1 1 1 1
12 1 1 1 1
13 1 1 1 1
14 1 1 1 1
15 1 1 1 1
16 1 1 1 1
17 1 1 1 1
18 1 1 1 1
19 1 1 1 1
20 1 1 1 1
21 1 1 1 1
22 1 1 1 1
23 1 1 1 1
24 1 1 1 1
25 1 1 1 1
26 1 1 1 1
27 1 1 1 1
28 1 1 1 1
29 1 1 1 1
30 1 1 1 1
31 1 1 1 1
32 1 1 1 1
33 1 1 1 1
34 1 1 1 1
35 1 1 1 1
36 1 1 1 1
37 1 1 1 1
38 1 1 1 1
39 1 1 1 1
40 1 1 1 1
41 1 1 1 1
42 1 1 1 1
43 1 1 1 1
44 1 1 1 1
45 1 1 1 1
46 1 1 1 1
47 1 1 1 1
48 1 1 1 1
49 1 1 1 1
50 1 1 1 1
51 1 1 1 1
52 1 1 1 1
53 1 1 1 1
54 1 1 1 1
55 1 1 1 1
56 1 1 1 1
57 1 1 1 1
58 1 1 1 1
59 1 1 1 1
60 1 1 1 1
61 1 1 1 1
62 1 1 1 1
63 1 1 1 1
64 1 1 1 1
65 1 1 1 1
66 1 1 1 1
67 1 1 1 1
68 1 1 1 1
69 1 1 1 1
70 1 1 1 1
71 1 1 1 1
72 1 1 1 1
73 1 1 1 1
74 1 1 1 1
75 1 1 1 1
76 1 1 1 1
77 1 1 1 1
78 1 1 1 1
79 1 1 1 1
80 1 1 1 1
81 1 1 1 1
82 1 1 1 1
83 1 1 1 1
84 1 1 1 1
85 1 1 1 1
86 1 1 1 1
87 1 1 1 1
88 1 1 1 1
89 1 1 1 1
90 1 1 1 1
91 1 1 1 1
92 1 1 1 1
93 1 1 1 1
94 1 1 1 1
95 1 1 1 1
96 1 1 1 1
97 1 1 1 1
98 1 1 1 1
99 1 1 1 1
100 1 1 1 1
101 1 1 1 1
102 1 1 1 1
103 1 1 1 1
104 1 1 1 1
105 1 1 1 1
106 1 1 1 1
107 1 1 1 1
108 1 1 1 1
109 1 1 1 1
110 1 1 1 1
111 1 1 1 1
112 1 1 1 1
113 1 1 1 1
114 1 1 1 1
115 1 1 1 1
116 1 1 1 1
117 1 1 1 1
118 1 1 1 1
119 1 1 1 1
120 1 1 1 1
121 1 1 1 1
122 1 1 1 1
123 1 1 1 1
124 1 1 1 1
125 1 1 1 1
126 1 1 1 1
127 1 1 1 1
128 1 1 1 1
129 1 1 1 1
130 1 1 1 1
131 1 1 1 1
132 1 1 1 1
133 1 1 1 1
134 1 1 1 1
135 1 1 1 1
136 1 1 1 1
137 1 1 1 1
138 1 1 1 1
139 1 1 1 1
140 1 1 1 1
141 1 1 1 1
142 1 1 1 1
143 1 1 1 1
144 1 1 1 1
145 1 1 1 1
146 1 1 1 1
147 1 1 1 1
148 1 1 1 1
149 1 1 1 1
150 1 1 1 1
151 1 1 1 1
152 1 1 1 1
153 1 1 1 1
154 1 1 1 1
155 1 1 1 1
156 1 1 1 1
157 1 1 1 1
158 1 1 1 1
159 1 1 1 1
160 1 1 1 1
161 1 1 1 1
162 1 1 1 1
163 1 1 1 1
164 1 1 1 1
165 1 1 1 1
166 1 1 1 1
167 1 1 1 1
168 1 1 1 1
169 1 1 1 1
170 1 1 1 1
171 1 1 1 1
172 1 1 1 1
173 1 1 1 1
174 1 1 1 1
175 1 1 1 1
176 1 1 1 1
177 1 1 1 1
178 1 1 1 1
179 1 1 1 1
180 1 1 1 1
181 1 1 1 1
182 1 1 1 1
183 1 1 1 1
184 1 1 1 1
185 1 1 1 1
186 1 1 1 1
187 1 1 1 1
188 1 1 1 1
189 1 1 1 1
190 1 1 1 1
191 1 1 1 1
192 1 1 1 1
193 1 1 1 1
194 1 1 1 1
195 1 1 1 1
196 1 1 1 1
197 1 1 1 1
198 1 1 1 1
199 1 1 1 1
200 1 1 1 1

Total 0 DFMEA PFMEA

Severity DFMEA DET DET
10 0 10 0 10 0
9 0 9 0 9 0
8 0 8 0 8 0
7 0 7 0 7 0
6 0 6 0 6 0
5 0 5 0 5 0
4 0 4 0 4 0
3 0 3 0 3 0
2 0 2 0 2 0
1 0 1 0 1 0

CRV 5 GAP Analysis 897621592.xlsx Revision: 03/10/17

GM Confidential 15 Issue Date: 03/23/17
 Tech Review - Status Quo CRV 3 - Status Quo CRV 4 CRV 5 or Continuous Improvement DFMEA to PFMEA DFMEA to PFMEA DFMEA to PFMEA DFMEA to PFMEA
Severity Severity Severity Severity Tech Review Gap Assessment SRV 1 Gap Assessment SRV 2 Gap Assessment SRV 3 Gap Assessment
DFMEA Data PFMEA Data DFMEA Data PFMEA Data DFMEA Data PFMEA Data DFMEA Data PFMEA Data 10/30/2021
CRV 3 or Status Quo CRV 3 or Status Quo CRV 3 or Status Quo CRV 3 or Status Quo CRV 4 CRV 4 CRV 5 or Improvement CRV 5 or Improvement Confirmed Misaligned Confirmed Misaligned Confirmed Misaligned Confirmed Misaligned
10 0 10 0 10 0 10 0 10 0 10 0 10 0 10 0 10 0 10 0 10 0 10 0
9 0 9 0 9 0 9 0 9 0 9 0 9 0 9 0 9 0 9 0 9 0 9 0
0
0
0
0
0
0
0
0
0
Sum 0 Sum 0 Sum 0 Sum 0 Sum 0 Sum 0 Sum 0 Sum 0 0 0 0 0 0 0 0 0

CRV 1 - Status Quo CRV 3 - Status Quo CRV 4 CRV 5 or Continuous Improvement
Detection Detection Detection
DFMEA Data PFMEA Data DFMEA Data PFMEA Data DFMEA Data PFMEA Data DFMEA Data PFMEA Data
Detection Detection Detection Detection CRV 3 or Status Quo CRV 3 or Status Quo CRV 5 or Improvment CRV 5 or Improvement
10 0 10 0 10 0 10 0 10 0 10 0 10 0 10 0
9 0 9 0 9 0 9 0 9 0 9 0 9 0 9 0
8 0 8 0 8 0 8 0 8 0 8 0 8 0 8 0
7 0 7 0 7 0 7 0 7 0 7 0 7 0 7 0
6 0 6 0 6 0 6 0 6 0 6 0 6 0 6 0
5 0 5 0 5 0 5 0 5 0 5 0 5 0 5 0
4 0 4 0 4 0 4 0 4 0 4 0 4 0 4 0
3 0 3 0 3 0 3 0 3 0 3 0 3 0 3 0
2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0
1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0

Sum 0 Sum 0 Sum 0 Sum 0 Sum 0 Sum 0 Sum 0 Sum 0

Failure Modes

Graph Data 897621592.xlsx Revision: 03/10/17

GM Confidential 16 Issue Date: 03/23/17
Original date:
Rev Date:
Revision:
Responsible:
Number: Characteristic Matrix
Page:
Department:
Customer: Model/Project: Drawing Ref. No: Spec.Ref. No: Part/Process Description: Line:

Process Number

KEY /

FRQ
DET
SEV
No. Product Characteristic Description Process Characteristic Description Spec or Parameter

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

C = Critical Characteristic O-Operation for clamping or locating

S = Significant Feature L-Operation affect later charac.
X-Operation reflect charac. Directly

Characteristic Matrix 897621592.xlsx Revision: 03/10/17

GM Confidential 17 Issue Date: 03/23/17
GM 1927 21 Severity and Detection Transition Form To be completed by the supplier or GM

This form is required to grant full PPAP approval in the event that the supplier cannot meet GM detection requirements for
Severity 9's and 10's, as outlined in the Supplier Quality's Part/Process Specific CG.
Year and Program: SMT:
PPAP Gate Date: Part Number(s) OR
Supplier: Process:
DUNS: Creativity Team:
SQE: DRE:
Issue Description Severity Occurrence Detection

Is the detection gap because technology does not exist to detect the defect?
Is the downstream detection the best in the industry? Attached Supporting
Is there another reason why requirements can't be met? Documentation
Explain the use of current technology and/or provide reasoning on why requirements can't be met:

Provide data (warranty, plant, SPC, Cpk, etc.) and controls/frequency that are in place to reduce/eliminate risk?

Supplier's Approval
Supplier's Plant
Manager Signature
(INSERT NAME HERE) Date
Nothing in the document supersedes, amends, or limits Supplier's responsibilities and obligations relating to the delivery of conforming
parts under the applicable purchase contract, including, without limitation, any quality or warranty obligations

FOR GM USE ONLY: Automated Per S.O.D. Rankings Required Required

Approvers Approvers
Above
Design Change - Current Program
PRTS#/EWO#:______________________________ SQ Manager, EGM,
(For Info Only, SQ
SQ Director, PE
Director,
Owner: Director and PE (For Info Only: GFL,
Director) EGM, SQ Manager)
Design Change - Future Program PRTS#/Owner:

SQ Director, PE
CG(s): SQ Manager
Director,
(For Info Only, SQ
SQ CG Update Director and SQ
(For Info Only: GFL,
EGM, SQ Manager,
______________________ GPM)
SQ GPM)

SQ Manager, EGM, SQ Director, PE

No Design Change (For Info Only, SQ Director,
e-approval #: _________________
or SQ CG Update Director and PE (For Info Only: GFL,
Director) EGM, SQ Manager)

GM's Decision
Explanation:

GM Confidential
GM 1927 21 Severity and Detection Transition Form To be completed by the supplier or GM

GM Confidential
 GM 1927 21 Severity and Detection Transition Form To be completed by the supplier or GM

GM Confidential
GM 1927 21 DFMEA PFMEA Gap Analysis Process and Transition Form To be completed by the supplier or GM

This form is required to grant full PPAP approval in the event that the supplier cannot meet GM detection requirements for
Severity 9's and 10's, as outlined in the Supplier Quality's Part/Process Specific SOR.
Year and Program: 2019 T1CXF SMT: Chassis 1. Base information for GM approvers to review.
PPAP Gate Date: 2/5/2020 Part Number(s) OR 12345678, 87654321 2. "Part Number(s) OR Process:"
A. Use part number(s) if a Part Specific CG is affected.
Supplier: Matic Process: B. Use a process title is a Process Specific CG is affected. i.e. "Welding"
DUNS: 1234567 Creativity Team: Control Arm 3. "Creativity Team" and "SMT" are drop down lists.
SQE: Joseph Thomas DRE: Edward James
Issue Description Severity Occurrence Detection 1. "Issue Description" - Be very clear on the reason for the deviation and explain the detection ranking.
We can't meet GM's detection requirements of a detection of a 3 for weld penetration. The 2. For "Severity", "Occurrence", and "Detection", input only a number that is on the supplier's PFMEA and
best we can do is a detection of 7 for this severity 9 item. is aligned to AIAG.
10 3 7 3. Use "Attached Supporting Documentation" if more information is requested by the GM assessors to
make a decision. Or, if the supplier/SQE run out of room.
Is the detection gap because technology does not exist to detect the defect? Yes
Is the current detection/prevention technology the best in the industry? Yes Attached Supporting 4. It is understood that, depending on the SMT/CT, technology might not exist to meet PFMEA detection
Is there another reason why requirements can't be met? No Documentation requirements. There might also be additional reasons. Either way, clearly explain why so that the
Explain the use of current technology and provide reasoning on why requirements can't be met: document stands alone for the assessor to review. The assessor will also have to know if the supplier has
We have purchased a vision system to check for other welding defects, but the system does not check for weld penetration. To the the best detection/prevention equipment in the industry. SQE's must be pushing for the best equipment.
best of our knowledge, no such technology exists at our vendors. To check 100%, we would have to perform cut and etch, which would 5. Since the PFMEA detection requirements can't be achieved, list all additional applicable controls and
scrap 100% of the parts. data that aid in reducing/eliminating risk. Think about the assessors and what they would want to see.
Examples include, but not limited to: Cpk, Warranty on previous program, Standardized Work, Multiple
100% visual/tactile inspections, etc.
Provide data (warranty data, plant data, SPC, etc) and list controls that will be put in place to reduce/eliminate risk?
We have installed processing controllers to operate to validated parameters. We have two 100% visual weld inspection, on top of the
vision system. In steady state, we will be performing cut and etch testing on a daily basis. On the previous generation truck and
through builds on this program, we have not had any warranty or plant disruptions for this issue.

Supplier's Approval
1. The supplier shall sign this form for GM to process the transition request.
Supplier's Plant
Manager Signature 2. "(INSERT NAME HERE)" shall be the Supplier's Plant Manager or high level of senior leadership.
(INSERT NAME HERE) Date
Nothing in the document supersedes, amends, or limits Supplier's responsibilities and obligations relating to the delivery of conforming
parts under the applicable purchase contract, including, without limitation, any quality or warranty obligations

FOR GM USE ONLY: Required Required 1. This section will be filled in by hand or PDF Editor, by the SQE, once the supplier has signed. Please see
Approvers Approvers PowerPoint presentation for example of PDF Editor.
Design Change - Current Program 2. Example: "PRTS#/EWO#" - 123456789/ABCED - "Owner" - Edward James - Only use for "Design Change -
PRTS#/EWO#:______________________________ SQ Manager, EGM, SQ Director, PE Current Program"
(For Info Only, SQ Director,
Owner: Director and PE (For Info Only: GFL, 3. Example: 123456789/Edward James - Only use for "Design Change - Future Program"
Director) EGM, SQ Manager)
Design Change - Future Program PRTS#/Owner:
4. Only Use for "CG(s)#" for "Part Specific / Process CG Update"
SQ Director, PE
CG(s): SQ Manager
Director,
SQ CG Update (For Info Only, SQ
(For Info Only: GFL, 6."Required Approvers" automatically highlights, based on Severity, Occurrence, and Detection Rankings.
Director and SQ
______________________ GPM)
EGM, SQ Manager,
SQ GPM)
The other column will "black out" to avoid confusion
7. Enter your e-approval number.
8. "No Design or SQ CG Update" is used if there is agreement for the supplier to not follow our
requirements for only this program and GM is not planning on performing an engineering change.
SQ Manager, EGM, SQ Director, PE
(For Info Only, SQ Director,
e-approval #: _________________ No Design or SQ CG Update Director and PE (For Info Only: GFL, 9. "GM's Decision Explanation" - Document reasoning to why the approval decision was made.
Director) EGM, SQ Manager)

GM's Decision
Explanation:

GM Confidential
GM 1927 21 DFMEA PFMEA Gap Analysis Process and Transition Form To be completed by the supplier or GM

GM Confidential
 Document change record
Title

Document Name Issue Change Description Date Compiler

Interior DFMEA to PFMEA Gap

2 Added learnings from users, accommodated SRV progress tracking 5/13/2015 JR Leonardi
Analysis

Interior DFMEA to PFMEA Gap Added learnings from users, accommodated Tech Review progress
3 10/21/2015 JR Leonardi
Analysis tracking
Interior DFMEA to PFMEA Gap Added learnings from users, DFMEA "DET" cells now hidden, and
Analysis 4 changed PFMEA required DET formula to be derived from DFMEA DET.
2/22/2016 Mark Waligora

Removed "Detection Requirements" tab and added "Transition Form"

and "Transition Form Instructions". "RPLS", "RPL-S Calculation", and
Gap Analysis and Transition Form 5 "Drop Downs" were also added and are "Hidden". Changed header
4/25/2018 Adam Rada
information on the four (4) Tech Review / SRV Gap Analysis tabs.
Replaced SRV with CRV; new RASIC instructions tab; deleted the old
Throughout the document 6 instructions tab; added Gap analysis date on Analysis tabs
3/31/2022 Amarbir Sra
Gap Analysis RASIC Instruction tab updated. Purpose: Amarbir Sra and
Tab 1 7 6/7/2022
added clarification to Item 2 PFMEA Global Team

Change Record 897621592.xlsx Revision: 03/10/17

GM Confidential 23 Issue Date: 03/23/17