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During the assembly of a new Corvette, it undergoes a standard quality control (QC) review. Some Corvettes however, are subject to an additional audit called a Global Customer Audit (GCA). This thread describes the GCA process. What is a GCA?
* It is a supplemental quality control audit that a very small percentage of Corvettes produced at BGA experience. While I do not know the exact particulars of how much extra auditing is currently being done, a few years ago it was a team of QC technicians spending many additional hours extra-closely-examining the car’s assembly. They focus on any issues that heretofore had been previously identified as assembly line issues, plus provide additional scrutiny of all exterior and interior panel gaps, and similar QC potential issues. The GCA also includes a typical 8 mile additional road test.
* At every one of GM's 140 vehicle assembly plants throughout the world, after the day's shift is over, the computer randomly selects 2 cars to go through a supplemental quality control audit. This is not something one can buy, but again is computer selected.
* At every one of GM's 140 vehicle assembly plants throughout the world, after the day's shift is over, the computer randomly selects 2 cars to go through a supplemental quality control audit. This is not something one can buy, but again is computer selected.
The current rate of assembly at BGA is 11.5 vehicles per hour, 115 per day, and a minimum of two Corvettes are chosen every production day for a GCA. Sometimes more than that are selected.
* Results of GCA are sent to the Plant Manager (perhaps also to the GM corporate). Most Plant Managers have an every work day, a daily meeting with top staff, going over those GCA results and much more. Represented at that table at BGA at 7:00 AM , is Plant Manager Kai Spande, often Assistant Plant Manager Nora Roper (who is always present if Kai is not available), their Exec. Assistant, and at least the following: top members of the Plant quality control team, managers from the different major plant assembly "lines" (e.g., General Assembly, Paint, Body Shop, Trim 1, Trim 2 and more), the Plant's liaison with all of its suppliers and, at least one representative of the UAW. Often they are around, or even more than 15 present at the meeting.
*The purpose of these meetings is to discuss and problem solve most if not all of the following:
The day before's production schedule; number of cars produced; what percentage which passed the required, end of the assembly line, 800-test, test vehicle booth results; how many cars did not pass and what were the specific amounts for every failure; how many are now in the "re-work" or fix it shop; each/every "line stop" and what caused it; the computer analysis of yesterday's issues; result of the global customer audit teams (more on that below and what those teams did/learned); input by the line managers and the UAW reps as to yesterday's and potentially still current issues; what earlier implemented changes went well vs. what still needs additional attention now; what is the latest data from warranty claims as to failed parts, parts needing adjustment as identified by the dealerships’ service departments; and much more.
*If a car is computer chosen for a Global Customer Audit, it is pulled into a special the "GCA examination room" (my terminology), where a team of up to typical 5 QC engineers/staff spent a total of up to 25 hours on it; it is further subject to an additional 8 mile specialized-course road test and additional QC Reviews. Fit-n-finish is closely checked. Everything not per assembly standards is adjusted and when rarely needed, a part(s) is replaced. That car is "loved and pampered and messaged."
Also checked is what issues were previously found in previous QCA's noted in previous daily plant QC morning meetings, and especially and specifically, all parts which have been recently modified as a result of previous learning, i.e., if it was determined that if the angle of the rear flux capacitor flange should be moved 1/4 of a degree rearward to more easily install the nuclear power plant, once those modified flux capacitor flanges arrive at the Plant, some of those cars automatically go to the GCA area, and that modified part's fix vis-a-vis all parts attached to it are reviewed for hopefully improved fit. AND, critically important, will be the input of the various line supervisors within the plant as to how the new part's install went, answering the critical question of "does installation now go easier,” the purpose of this part change? Not just management's input is considered, but equally considered is the perspective of UAW rep, having been part of previous meetings and knowing this new part is now going in while the line is moving, the rep will have talked with his/her employee about how it went yesterday installing that new part. Was it the improvement that was expected, would a further 1/4 of a degree angle bend help more, etc.
* How can I get my car to be chosen for a GCA? ; Conversely, how do I avoid my car being chosen for the GCA as I do not want to have it arrive with the minimum eight extra miles? However, the latter is a very rare request AND it is very rare that the additional road test exceeds 8 miles, that is unless something needs to be further fixed and tested to insure production standards.
Answer: You can request GM to not have your car be chosen for the GCA. Well, I guess you can tell them, but it is not going to make a difference, for if the computer were to select your VIN out of those two VINS it picks out daily, your car will mandatorily receive a GCA. Plant Managers can not even de-select a car chosen by the computer for a GCA, e.g., it will receive one.
Actually the opposite is what much more often occurs, that folks request a GCA for their car, as they want additional sets of eyes-n-ears, more brains and skilled QC hands to look at their car. That is my strong preference, i.e., to have BGA skilled personnel adjust and/or fix any issues at the plant — where there is the best skilled talent, the best tools, and "spare/replacement parts" immediately on hand to fix your car.
So, you can request your car to be GCA's, but your chances are small, e.g. 2 mandatory and sometimes one or two more out of the 115 Corvettes per day now being produced. But, there is, IMO, one thing you can do that tends to increase your chances of getting a GCA for your baby is to purchase a "Buyers Tour," and at the end of the tour, at the very last station when you are given the opportunity to start your car, given its "Birth Certificate" (it is really named that), ask the end of the line Supervisor for a GCA. Does this always work to getting your GCA? NO. But IMO, it can result in an increased chance of your car being GCA'd.
*The purpose of these meetings is to discuss and problem solve most if not all of the following:
The day before's production schedule; number of cars produced; what percentage which passed the required, end of the assembly line, 800-test, test vehicle booth results; how many cars did not pass and what were the specific amounts for every failure; how many are now in the "re-work" or fix it shop; each/every "line stop" and what caused it; the computer analysis of yesterday's issues; result of the global customer audit teams (more on that below and what those teams did/learned); input by the line managers and the UAW reps as to yesterday's and potentially still current issues; what earlier implemented changes went well vs. what still needs additional attention now; what is the latest data from warranty claims as to failed parts, parts needing adjustment as identified by the dealerships’ service departments; and much more.
*If a car is computer chosen for a Global Customer Audit, it is pulled into a special the "GCA examination room" (my terminology), where a team of up to typical 5 QC engineers/staff spent a total of up to 25 hours on it; it is further subject to an additional 8 mile specialized-course road test and additional QC Reviews. Fit-n-finish is closely checked. Everything not per assembly standards is adjusted and when rarely needed, a part(s) is replaced. That car is "loved and pampered and messaged."
Also checked is what issues were previously found in previous QCA's noted in previous daily plant QC morning meetings, and especially and specifically, all parts which have been recently modified as a result of previous learning, i.e., if it was determined that if the angle of the rear flux capacitor flange should be moved 1/4 of a degree rearward to more easily install the nuclear power plant, once those modified flux capacitor flanges arrive at the Plant, some of those cars automatically go to the GCA area, and that modified part's fix vis-a-vis all parts attached to it are reviewed for hopefully improved fit. AND, critically important, will be the input of the various line supervisors within the plant as to how the new part's install went, answering the critical question of "does installation now go easier,” the purpose of this part change? Not just management's input is considered, but equally considered is the perspective of UAW rep, having been part of previous meetings and knowing this new part is now going in while the line is moving, the rep will have talked with his/her employee about how it went yesterday installing that new part. Was it the improvement that was expected, would a further 1/4 of a degree angle bend help more, etc.
* How can I get my car to be chosen for a GCA? ; Conversely, how do I avoid my car being chosen for the GCA as I do not want to have it arrive with the minimum eight extra miles? However, the latter is a very rare request AND it is very rare that the additional road test exceeds 8 miles, that is unless something needs to be further fixed and tested to insure production standards.
Answer: You can request GM to not have your car be chosen for the GCA. Well, I guess you can tell them, but it is not going to make a difference, for if the computer were to select your VIN out of those two VINS it picks out daily, your car will mandatorily receive a GCA. Plant Managers can not even de-select a car chosen by the computer for a GCA, e.g., it will receive one.
Actually the opposite is what much more often occurs, that folks request a GCA for their car, as they want additional sets of eyes-n-ears, more brains and skilled QC hands to look at their car. That is my strong preference, i.e., to have BGA skilled personnel adjust and/or fix any issues at the plant — where there is the best skilled talent, the best tools, and "spare/replacement parts" immediately on hand to fix your car.
So, you can request your car to be GCA's, but your chances are small, e.g. 2 mandatory and sometimes one or two more out of the 115 Corvettes per day now being produced. But, there is, IMO, one thing you can do that tends to increase your chances of getting a GCA for your baby is to purchase a "Buyers Tour," and at the end of the tour, at the very last station when you are given the opportunity to start your car, given its "Birth Certificate" (it is really named that), ask the end of the line Supervisor for a GCA. Does this always work to getting your GCA? NO. But IMO, it can result in an increased chance of your car being GCA'd.
Should you choose a Buyers Tour for that reason? Again, NO, but that increased GCA change is IMO an added side benefit. I requested that at the end of my C6 Buyers Tour and during my C7 Buyers Tours, both received one. However, I know someone who purchased the Buyers Tour and at its end, asked for a GCA, and his car arrived at his dealer with 4 miles on it, e.g. no GCA happened. BGA simply does not have enough staff with enough time, nor enough testing areas to do anywhere near the percentage of GCA’s requested.
* That there is one additional testing component which every car that is GCA'd receives, an 8-minute water mist test. [Separately, every Corvette’s receives, and must pass a 3 minute, 800 gallon per minute, water deluge test.]
I am fervently hopeful the Buyers Tour option continues, and if it does, I will contact NCM’s Museum Delivery staff and purchase it for my ME.
A separate thread on what is a Buyers’ Tour is under construction this weekend and will be linked inserted here when finished.
* That there is one additional testing component which every car that is GCA'd receives, an 8-minute water mist test. [Separately, every Corvette’s receives, and must pass a 3 minute, 800 gallon per minute, water deluge test.]
I am fervently hopeful the Buyers Tour option continues, and if it does, I will contact NCM’s Museum Delivery staff and purchase it for my ME.
A separate thread on what is a Buyers’ Tour is under construction this weekend and will be linked inserted here when finished.
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