A Step-by-Step Guide to Conducting a GP-12 Inspection (Template Included)
The GP-12 Early Production Containment mandate requires precision and discipline. This 7-step checklist provides a clear, repeatable process for successfully executing a 100% automotive quality inspection and achieving your zero-defect launch.
When a new product launches or a significant process change occurs, GP-12 becomes your most important tool for ensuring product quality. It’s not just a box to check; it’s a temporary, heightened inspection system designed to catch latent issues before they impact the OEM.
Following a rigorous procedure is the only way to generate reliable data and secure the final GP-12 sign-off. Here is the mandatory 7-step process for executing a perfect containment plan.
The 7 Mandatory Steps of a GP-12 Inspection
1. Define the Scope and Inspection Point
Before starting, confirm the **scope** (which characteristics need inspection) and the duration/volume requirement. Crucially, establish a dedicated, **segregated inspection location**. This area must be distinct from the normal production flow to prevent accidental commingling of inspected and un-inspected parts. Staff performing the **100% inspection** must be focused solely on this task.
2. Create and Approve Work Instructions (WIs)
This is the heart of the process. Detailed **GP-12 work instructions** must be created, including visual aids (photos, diagrams) and specific criteria for acceptance and rejection. These WIs, along with **boundary samples** (examples of defects), must be formally reviewed and approved by your Quality Manager and the OEM.
3. Inspector Training and Certification
Whether using in-house personnel or a **third-party quality inspection** team, every inspector must be formally trained and certified on the specific **GP-12 procedure**. This training ensures that complex or subtle defects are caught consistently across all shifts. Document the training records thoroughly for audit purposes.
4. Execution of the 100% Inspection Check
The team performs the **100% inspection** on all parts earmarked for shipment. Parts are then physically segregated: **OK** parts are marked with a unique **GP-12 verification tag** or label, while **Non-Conforming** parts are placed in quarantine. It is essential that the verification mark is unique (e.g., date coded stamp, specific sticker) to prevent tampering.
5. Real-Time Defect Logging and Communication
All defect data—including the time, defect type, and quantity—must be logged immediately. This data is the most critical output of the **GP-12 inspection**. It must be communicated in **daily reports** to the engineering and quality teams to support **root cause analysis (RCA)** and drive **Permanent Corrective Actions (PCA)** within the production process.
6. Inventory Control and Shipping Documentation
Ensure the shipping documentation (e.g., packing slip) explicitly states that the parts have passed **GP-12 containment**. Manage inventory carefully to confirm that only **GP-12 certified** stock is released from the plant. This final layer of confirmation protects you legally and maintains OEM confidence.
7. Formal Exit and Documentation Archival
Once the required time period (e.g., 30 days) or volume has been shipped defect-free, work with the OEM’s Supplier Quality Engineer (SQE) for the formal **GP-12 exit**. Archive all data, training records, daily reports, and final sign-off documentation—this record is essential for future quality audits.
Why Third-Party Execution is Essential for GP-12
While the procedure is straightforward, the execution is demanding. Internal teams often face resource constraints and operator fatigue, which can compromise the integrity of the **100% inspection**. Utilizing a professional partner ensures:
- Unbiased Focus: Dedicated, non-production personnel provide objective **defect detection**.
- Rapid Scalability: Teams can be mobilized and trained quickly to handle high volume without pulling your own staff from key manufacturing roles.
- Credibility: **Third-party verification** strengthens your data and is highly credible to the OEM’s quality team, accelerating the path to **GP-12 sign-off**.
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