TABLE OF CONTENTS

Title Page 1 (Start here, fill in shutdown dates and team members)

Required Documentation:

Audit Instructions 2 Follow through the worksheets in order to develop your plan and an understanding
of your customer requirements
Shutdown Audit 3 Involve the affected departments as necessary to complete their sections
Meet regularly beginning 6 - 8 weeks before shutdown to revise and review
GP12 Audit 4 Prepare for the audits by developing a comprehensive plan to protect your customers
Distribute this document within your organization for full understanding
GP12 Start / Stop Matrix (by Part Number and Destination) 5 Save this document for review of lessons learned after startup
Review this document as a starting point for the next shutdown period
Master contact list (by department) 6

Backup Support: The following sections are used to support the "Required Documentation". Alternate formats are also acceptable.

Shutdown FMEA 7

Shutdown Team Meeting Schedule 8

Production Plan (with Customer Requirements) 9

Shutdown Percentage Data 10

Shutdown Percentage Charts 11

Employee Information (Who is working when) 12

Shutdown Checklist 13

Maintenance Plan (for shutdown period) 14

Startup Checklist 15

Facility Checklist 16
 SHUTDOWN PLAN / AUDIT FOR: (Your Company Name Here)

GM Shutdown Period Starts 06/27/03 (Date Only) Company Address:

GM Shutdown Period Ends 07/13/03 (Date Only)

Issue Date: DUNS Code

Last Updated: (name) (telephone)
Plant Manager
Created By: Quality Manager
(Team Names) Operations Manager
Production Manager
Shipping Manager
Purchasing Manager

DISTRIBUTION :
 SUPPLIER EXTENDED SHUTDOWN/START-UP AUDIT
Audit Question Requirements and Documentation
Management
Item # Requirements and documentation
1 Does Management have a documented Shutdown/Startup Plan with timing for each A written plan with detail for specific areas. Responsibilities should be
major department/area that will protect the customer, tooling, machinery, and defined and timing outlined.
facilities?

2 Has Management reviewed all GM Bulletins on Supply Power and incorporated them Evidence that GM Bulletins have been received and information
into the Shutdown / Startup Plan? communicated to appropriate people
3 Has a high risk list been generated by management identifying areas of major Actual list of high risk areas or issues.
concern?
4 Does the Management Team formally review the status of these plans at timely Minutes of review meeting or other documentation showing formal
intervals before the shutdown? reviews held.
5 Does Management do a documented floor walk to review details of plan? Evidence that a floor walk was done by the Management Team.
6 Have specific people been designated to perform a final check in each area at the stop of Checklist showing specifics to be checked. Ask for previous checks
operations? from earlier shutdowns if they have been done.
7 Have specific people been designated to check each area, as well as the overall facility Look for evidence of assigned responsibility with required deliverables.
during the shutdown?
8 If any manufacturing or maintenance is planned during the shutdown, is salaried/hourly Look at certification documentation as well as how the assigned
staffing certified to perform required functions? people have been checked against it.
9 Has Management taken the initiative to restrict personnel moves the week prior to and after Look for postings, general policy, or their written documentation that
the startup? movement has been restricted.
10 If personnel moves can't be restricted, has a training plan been incorporated for initial startup, Look for written detail of start up training and acceleration of
including reduced production rates, until quality and proficiency are validated? production in areas affected by personnel movement.
11 If there are significant changes to tools, machinery, processes, or new additions for startup, is Look for detail of what is required in areas impacted by
there a documented approval plan? significant changes.
12 Is there a documented communication distribution of significant product and process changes Look for written letters, postings, or electronic communication.
to all departments?
13 Is there a published and distributed contact list in case of emergency during the shutdown Copy of contact list for Shutdown.
period?
14 Have champions been designated to perform pre-startup activities? List with names of champions.
15 Is there a "Lessons Learned" review conducted after startup to drive change to the Look for evidence that a review was held after prior shutdowns
Shutdown/Startup Plan? and that lessons learned were captured.

Rating % = Red = < 75%

Total yes responses/ total questions. Yellow = 76% - 90%, 3
Revised 5-11-04 Green = 91 - 100%, bolded items must be yes.
 SUPPLIER EXTENDED SHUTDOWN/START-UP AUDIT

QUALITY
Item #
1 Are plans in place for increased in-process quality checks the week that shutdown occurs and Written direction requiring added in-process checks.
during the week of startup?
2 Is GP-12 planned during the week of startup for any new parts, parts with changes, Written documentation showing that GP-12 is to be done.
PRRs, or major disruptions in the past 12 months?
3 If manufacturing is scheduled during the shutdown, has salaried/hourly staffing been audited Evidence supporting that checks have been made to check
to ensure that certified personnel are scheduled, including the quality department and support qualifications of assigned personnel.
organizations?

4 If any significant tooling, machinery, or process changes are to be made, is there a plan for List of planned changes with the level of approval required.
PPAP approval and PTR
5 Has the Quality Department championed a recent cross functional PFMEA review of the Copy of PFMEA methodology.
shutdown/startup process on product quality?

Materials
Item #
1 Are raw materials and purchased parts at the required inventory levels? Evidence of a review of inventory levels vs. required levels.
2 If not, what is the a plan to get up to schedule? Evidence that plans are in place to get inventory to required leve
3 Are raw material and purchased parts stored to prevent damage/deterioration during Walk the floor where parts are stored to look for potential
the shutdown? problems. Ask what they think could go wrong.
4 Is in-process material stored to protect it from the environment and stacking distortion Walk the floor and review in-process areas looking for
during the shutdown? potential issues. Ask what they think could cause a problem.
5 Are process materials and wet chemicals stored to protect them during the shutdown Check storage areas for potential problems. Request proof of
and is shelf life checked? shelf life checks to see if there are concerns.
6 Are raw materials, process materials, in-process stock, and partial packs of finished goods Look for written requirements for identification of materials to
checked at shutdown for identification of each container? be done at the end of production.
7 Has the Materials Department participated in a shutdown/startup PFMEA contemplating Evidence of PFMEA participation.
impact on materials?
8 Have you verified that your tiered suppliers have shutdown/startup plans in place to support Evidence of communication with suppliers regarding their
your schedule shutdown plans.

Rating % = Red = < 75%

Total yes responses/ total questions. Yellow = 76% - 90%, 4
Revised 5-11-04 Green = 91 - 100%, bolded items must be yes.
 SUPPLIER EXTENDED SHUTDOWN/START-UP AUDIT

Machinery/Tooling
Item #
1 If PM is scheduled for Tooling, Machinery, or Processes during the shutdown, is there Look for a list of PM activities with validation steps.
a plan with defined requirements and validation steps for checking the PM?
2 Are spare parts at the required inventory levels? Evidence that spare parts for equipment being PM'd is
3 Is there additional validation required on startup of the above that has been communicated to available
Evidence of validation plans.
the quality department and manufacturing personnel?
4 Is there a plan to tryout other high risk machinery, tooling, or processes? Listing of high risk issues that must be tried out prior to start-
5 Is there a published list of do's and don'ts for protection of tools and equipment during the up.
Posted listing of "do's and Don’t's" for high risk equipment and
down period, such as lubrication or preservatives? tooling.
6 If the environment will change during the shutdown (heat/cold), is there a plan to normalize List of early startup tooling/equipment.
the tooling/equipment prior to startup?
7 Look for specific plans requiring recalibration and propoer
Do you have a written plan to recalibrate and verify proper operation of all automated
checks? (ie - Electrical verification station, part presence probes) orientation of automated checks after all shutdown periods
8
Torque Specific - Do you have a written plan to recalibrate all torque monitoring systems after Look for specific plans and documentation related to
extended shutdown period? recalibration of torque monitoring equipment.
9 Look for specific plans and documentation (I.e.- weld
Welding Specific - Do you have a written plan to verify weld integrity after extended shutdown schedules verification, pry check results)
period?

Facilities
Item #
1 Have significant facility/layout changes been reviewed with all departments to prevent Evidence that information of planned changes has been
disruption at startup? communicated across the organization.

Rating % = Red = < 75%

Total yes responses/ total questions. Yellow = 76% - 90%, 5
Revised 5-11-04 Green = 91 - 100%, bolded items must be yes.
 SUPPLIER EXTENDED SHUTDOWN/START-UP AUDIT
2 Have guidelines been established for safe shutdown and startup of of heating, cooling, and/or List of guidelines and/or requirements..
water flow for all the facility, with a list of do's and don'ts?
3 Is there a champion identified to check the facility daily during the shutdown? Names and schedule.
4 Is an early startup of normalized heating and cooling planned? Evidence of the plan with responsibility and timing.

Major Changes
Item #
If you plan any tooling and/or equipment rebuilds, replacements, relocations, or new List Specific issues.
startups for this period, proceed with this section.

1 Has this information been shared with GM purchasing, Supplier Quality, and the Evidence of communication.
affected assembly plants?
2 Have sufficient banks been built with appropriate safety stock and appropriate level of audit Evidence of a bank build plan with added quality requirements.
depending on the risk?
3 Have bank quantities been reviewed with GM Purchasing, Supplier Quality, and the affected Evidence of communication with assembly plants.
assembly plants?
4 Is there an acceleration plan that contemplates minor problems? Evidence of startup acceleration ahead of customer requirement
5 Is there a contingency plan developed in event of a failure of the plan, with appropriate Written contingency plan and communication list.
levels of immediate communication to the customer?
6 Is there a well defined part approval plan? List of required steps or statement requiring full PPAP .
7 Has the responsible PPAP SQE. been contacted to define if PPAP is required with the level Evidence of communication.
and timing of submission?
8 Has the supplier contacted the Reliability Engineer at the assembly plant to determine Evidence of communication.
if a PTR is required?
9 Is an extended GP-12 plan communicated, understood, and organized for flawless Evidence that GP-12 is more than minimum and suitable for
execution? the magnitude of the change.
10 Is feedback from the GP-12 planned to be driven upstream for immediate countermeasures? Evidence that this has been done for prior major changes.

11 Have alarms been established at GP-12 to trigger an additional level of containment for Evidence of alarm level and required action.
customer protection?

Rating % = Red = < 75%

Total yes responses/ total questions. Yellow = 76% - 90%, 6
Revised 5-11-04 Green = 91 - 100%, bolded items must be yes.
 SUPPLIER EXTENDED SHUTDOWN/START-UP AUDIT
12 Tier 2/3 Impact - Are there any plans related to tool moves or supplier changes at the tier 2/3 List Specific issues.
supplier level?
13 Has this information been shared with GM purchasing, Supplier Quality, and the affected Evidence of communication.
assembly plants?
14 Have plans for PPAP and PTRs been developed and communicated to the appropriate GM Evidence of plan.
personnel?

Rating % = Red = < 75%

Total yes responses/ total questions. Yellow = 76% - 90%, 7
Revised 5-11-04 Green = 91 - 100%, bolded items must be yes.
 SUPPLIER EXTENDED SHUTDOWN AUDIT 2003
Supplier Name: Bopp-Busch Mfg. Co. DUNS: 021093638 Date: 4/30/2020
Supplier Location: Au Gres & Tawas City, MI Audit Completed by (Name):
Yes No N/A Score Status Joe Oswald
26 2 27 93% G GM SQE Name: James Collins
G
Management
Item # YES NO N/A COMMENTS

Does Management have a documented Shutdown/Startup Plan with timing for each
1
major department/area that will protect the customer, tooling, machinery, and facilities?
X

Has Management reviewed all GM Bulletins on Supply Power and incorporated them
2
into the Shutdown/Startup Plan.
X

3 Has a high risk list been generated by management identifying areas of major concern? X
Does the Management Team formally review the status of these plans at timely
4
intervals before the shutdown? X The shutdoen plan is reviewed annually but no plans for a COVID19
or pandemic shutdown existed

5 Does Management do a documented floor walk to review details of plan? X This is tied to the LPA floor review
Have specific people been designated to perform a final check in each area at the stop
6
of operations?
X The shutdown provided limited notification to check each area
prior to shutdown
Have specific people been designated to check each area, as well as the overall facility
7
during the shutdown? X

If any manufacturing or maintenance is planned during the shutdown, is salaried/hourly

8
staffing certified to perform required functions? X Government restrictions do not allow non-essential activities of
this nature

Has Management taken the initiative to restrict personnel moves the week prior to and The shutdown provided limited notification to verify movement
9
after the startup?
X before the shutdown, returning personnel will be reviewed during
startup

If personnel moves can't be restricted, has a training plan been incorporated for initial
10
startup, including reduced production rates, until quality and proficiency are validated?
X
The training plan will be reviewed during startup

If there are significant changes to tools, machinery, processes, or new additions for
11
startup, is there a documented approval plan?
X
No significant changes

Is there a documented communication distribution of significant product and process

12
changes to all departments?
X
No significant changes

Is there a published and distributed contact list in case of emergency during the
13
shutdown period?
X
14 Have champions been designated to perform pre-startup activities? x

Red=<75%, Yellow = 76%-90%, Green= 91%-100% 8 of 5

Process Performance Group-Current SQ (248 528 5398)
 SUPPLIER EXTENDED SHUTDOWN AUDIT 2003
Is there a "Lessons Learned" review conducted after startup to drive change to the
15
Shutdown/Startup Plan?
X continuous improvement during the management meeting
Score 9 0 6

QUALITY
Item # YES NO N/A COMMENTS
Are plans in place for increased in-process quality checks the week that shutdown
1
occurs and during the week of startup? X
Increased inspection frequency during start up will occur

Is GP-12 planned during the week of startup for any new parts, parts with changes,
2
PRRs, or major disruptions in the past 12 months?
X

If manufacturing is scheduled during the shutdown, has salaried/hourly staffing been

3 audited to ensure that certified personnel are scheduled, including the quality X
department and support organizations? Government restrictions do not allow non-essential activities of
this nature

If any significant tooling, machinery, or process changes are to be made, is there a plan
4
for PPAP approval and PTR X
No significant changes

Has the Quality Department championed a recent cross functional PFMEA review of the
5
shutdown/startup process on product quality? X
Score 3 0 2

Materials
Item # YES NO N/A COMMENTS

1 Are raw materials and purchased parts at the required inventory levels? X Due to the rapid nature of the shutdown excessive inventory levels
are on hand
2 If not, what is the a plan to get up to schedule? X
Are raw material and purchased parts stored to prevent damage/deterioration during
3
the shutdown?
X
Is in-process material stored to protect it from the environment and stacking distortion
4
during the shutdown?
X

Are process materials and wet chemicals stored to protect them during the shutdown
5
and is shelf life checked?
X

Are raw materials, process materials, in-process stock, and partial packs of finished
6
goods checked at shutdown for identification of each container?
X

Has the Materials Department participated in a shutdown/startup PFMEA contemplating

7
impact on materials? X
Have you verified that your tiered suppliers have shutdown/startup plans in place to
8
support your schedule X
Red=<75%, Yellow = 76%-90%, Green= 91%-100% 9 of 5
Process Performance Group-Current SQ (248 528 5398)
 SUPPLIER EXTENDED SHUTDOWN AUDIT 2003
Score 7 1 0

Machinery/Tooling
Item # YES NO N/A COMMENTS

If PM is scheduled for Tooling, Machinery, or Processes during the shutdown, is there a

1
plan with defined requirements and validation steps for checking the PM?
X
Government restrictions do not allow non-essential activities of
this nature

2 Are spare parts at the required inventory levels? X

Is there additional validation required on startup of the above that has been
3
communicated to the quality department and manufacturing personnel?
X

4 Is there a plan to tryout other high risk machinery, tooling, or processes? X

Is there a published list of do's and don'ts for protection of tools and equipment during
5
the down period, such as lubrication or preservatives?
X

If the environment will change during the shutdown (heat/cold), is there a plan to
6
normalize the tooling/equipment prior to startup? X

Do you have a written plan to recalibrate and verify proper operation of all automated
7
checks? (ie - Electrical verification station, part presence probes)
X

Torque Specific - Do you have a written plan to recalibrate all torque monitoring
8
systems after extended shutdown period?
X
Welding Specific - Do you have a written plan to verify weld integrity after extended
9
shutdown period?
X
Score 5 1 3

Facilities
Item # YES NO N/A COMMENTS
Have significant facility/layout changes been reviewed with all departments to prevent
1
disruption at startup? X
No facility changes

Have guidelines been established for safe shutdown and startup of of heating, cooling,
2
and/or water flow for all the facility, with a list of do's and don'ts? X

3 Is there a champion identified to check the facility daily during the shutdown? X Government restrictions do not allow non-essential activities of
this nature

Red=<75%, Yellow = 76%-90%, Green= 91%-100% 10 of 5

Process Performance Group-Current SQ (248 528 5398)
 SUPPLIER EXTENDED SHUTDOWN AUDIT 2003
4 Is an early startup of normalized heating and cooling planned? X
Score 2 0 2

Major Changes
Item # YES NO N/A COMMENTS

If you plan any tooling and/or equipment rebuilds, replacements, relocations, or new
startups for this period, proceed with this section.
X
No major changes are considered and Government restrictions do
not allow non-essential activities of this nature

Has this information been shared with GM purchasing, Supplier Quality, and the
1
affected assembly plants?
X
No major changes are considered

Have sufficient banks been built with appropriate safety stock and appropriate level of
2
audit depending on the risk? X
No major changes are considered

Have bank quantities been reviewed with GM Purchasing, Supplier Quality, and the
3
affected assembly plants? X
No major changes are considered

4 Is there an acceleration plan that contemplates minor problems? X No major changes are considered

Is there a contingency plan developed in event of a failure of the plan, with appropriate
5
levels of immediate communication to the customer?
X
No major changes are considered

6 Is there a well defined part approval plan? X

Has the responsible PPAP SQE been contacted to define if PPAP is required with the
7
level and timing of submission?
X
No major changes are considered

Has the supplier contacted The Reliability Engineer at the assembly plant to determine
8
if a PTR is required?
X
No major changes are considered

Is an extended GP-12 plan communicated, understood, and organized for flawless

9
execution?
X
No major changes are considered

Is feedback from the GP-12 planned to be driven upstream for immediate

10
countermeasures?
X
No major changes are considered

Have alarms been established at GP-12 to trigger an additional level of containment for
11
customer protection?
X
No major changes are considered

Tier 2/3 Impact - Are there any plans related to tool moves or supplier changes at the
12
tier 2/3 supplier level?
X
No major changes are considered

Red=<75%, Yellow = 76%-90%, Green= 91%-100% 11 of 5

Process Performance Group-Current SQ (248 528 5398)
 SUPPLIER EXTENDED SHUTDOWN AUDIT 2003
Has this information been shared with GM purchasing, Supplier Quality, and the
13
affected assembly plants?
X
No major changes are considered

Have plans for PPAP and PTRs been developed and communicated to the appropriate
14
GM personnel?
X

Score 0 0 14

Red=<75%, Yellow = 76%-90%, Green= 91%-100% 12 of 5

Process Performance Group-Current SQ (248 528 5398)
 GP 12 SUPPLIER AUDIT

SUPPLIER NAME: Bopp-Busch Mfg. Co. DUNS #: '021093638 LOCATION: Au Gres & Tawas City, MI Escalation Required?
(Yes / No)
GM PROGRAM NAME: Various SQE NAME: James Collins

AUDIT DATE: 4/30/2020 PHONE NUMBER: STATUS: R / Y / G

PART NUMBER(S) AUDITED: Various PART DESCRIPTION(S): Various
Yes No Score
GP-12
14 1 93%

ITEM # YES NO COMMENTS

1 Does the supplier have an acceptable GP-12 Plan? X

2 Is the GP-12 Plan being followed? X

Does the GP-12 Plan include an Extra 100% check for all known customer
3 X
defects from PRR's, Disruptions, High Non Conforming Parts, etc?
Does the GP-12 Plan specify at least a doubled frequency of all in process
4 X
checks, SPC checks, error proofing validations, and dock audits?
Does the GP-12 Plan incorporate risk areas such high RPN's, First Time
5 X
Quality, PRR's, pre-production problems, lessons learned, warranty, …)?
Is GP-12 data being collected, analyzed, and used to drive improvements?
6 X
(Look for I Charts, scheduled reviews, Action Plans, Fast Responses, etc.)
7 Have action plans been developed and monitored to correct GP-12 problems? X

8 Have operators been adequately trained regarding the GP-12 Plan? X

9 Are the layered audits (including plant leadership) to monitor the GP-12 plan? X

Is there a reaction plan based upon "single defect" occurrences detected during
10 X
GP-12 (andon type system)?
Does the GP-12 duration comply with the duration requirements specified in
11 X
GM Supply Power Bulletins issued for 2003?
Has a method been established and in use to clearly identify shipments of GP-
12 X
12 material?
Does the supplier understand the process for exiting GP-12? (including
13 X
notification of customer plants)

14 Does the tier one manage tier two APQP activity including GP-12? X

Has the supplier notified the Tier 2 suppliers of the shutdown schedules and
15 X
requirements and verified the Tier 2 plans meet the supplier needs?
14 1

REV 2
 Shutdown Production Plan As of (Date): 4/1/2020

The GM Part Number, Description, and Destination columns will be filled in automatically based on information from the "Production Plan" sheet. Based on GM
memos and plant requirements, complete the GP12 Start and Stop Dates for each part.
For parts that you ship to more than one GM plant, use the earliest start date and the latest stop date as communicated in GM Supply Power memos for all
destinations.
Instructions For any parts that have received a quality PRR in the past 12 months, highlight the part number cell background in RED. For your 5 "worst" parts OTHER than the
ones with PRR history, based on internal quality data (ie scrap, yield, FTQ) highlight the cell background in YELLOW.
Complete the "GP12 Documents Complete" column with the Date when the GP12 Process Control Plan, Operator Instructions, AND Inspection Data Sheets, as well
as your GP12 Response Plan / Tracking Charts are Completed. Do not enter Target Dates, only Complete Dates
Complete the GP12 Operators Trained Date only after all operators are trained on the part specific GP12 instructions. Do not enter Target Dates.

GP12 GP12
GP12 End Running during
GM Part Destination GP12 Start Documents Operators
Part Description Date (if no Shutdown? Comments
Number Plant Date Complete Trained
findings) (Yes / No)
(Date) (Date)
0 0 0
0 0 0
New Parts 0 0 0
0 0 0
0 0 0
0 0 0
Carryover parts with 0 0 0
Engineering / 0 0 0
Process changes /
0 0 0
New GM destination
plants 0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
All Other GM parts 0 0 0
including SPO
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
including SPO

0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
 Shutdown Contacts and Support Plan

Instructions: Enter the Name and Contact Telephone Number for the assigned department manager for each day of shutdown

Date 30-Mar-20 4/6 4/13 4/20 4/27 5/4 5/11 5/18 5/25

Senior Management Michael Busch Michael Busch Michael Busch Michael Busch Michael Busch Michael Busch Michael Busch Michael Busch Michael Busch

Quality Joe Oswald Joe Oswald Joe Oswald Joe Oswald Joe Oswald Joe Oswald Joe Oswald Joe Oswald Joe Oswald

Production Greg VanderVeen Greg VanderVeen Greg VanderVeen Greg VanderVeen Greg VanderVeen Greg VanderVeen Greg VanderVeen Greg VanderVeen Greg VanderVeen

Shipping Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar

Scheduling Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar

Purchasing Jeff Hayes Jeff Hayes Jeff Hayes Jeff Hayes Jeff Hayes Jeff Hayes Jeff Hayes Jeff Hayes Jeff Hayes

IT (incl EDI support) August Busch August Busch August Busch August Busch August Busch August Busch August Busch August Busch August Busch

Engineering Steve Look Steve Look Steve Look Steve Look Steve Look Steve Look Steve Look Steve Look Steve Look

Maintenance Greg VanderVeen Greg VanderVeen Greg VanderVeen Greg VanderVeen Greg VanderVeen Greg VanderVeen Greg VanderVeen Greg VanderVeen Greg VanderVeen

Tooling Steve Look Steve Look Steve Look Steve Look Steve Look Steve Look Steve Look Steve Look Steve Look

Finance Deborah Norton Deborah Norton Deborah Norton Deborah Norton Deborah Norton Deborah Norton Deborah Norton Deborah Norton Deborah Norton

Human Resources Greg VanderVeen Greg VanderVeen Greg VanderVeen Greg VanderVeen Greg VanderVeen Greg VanderVeen Greg VanderVeen Greg VanderVeen Greg VanderVeen

Customer Service Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar

Other (Specify)

Other (Specify)

Date 6/1 6/8 6/15 6/22 6/29 7/6 7/13 7/20 7/27

Senior Management Michael Busch Michael Busch Michael Busch Michael Busch Michael Busch Michael Busch Michael Busch Michael Busch Michael Busch

Quality Joe Oswald Joe Oswald Joe Oswald Joe Oswald Joe Oswald Joe Oswald Joe Oswald Joe Oswald Joe Oswald

Production Greg VanderVeen Greg VanderVeen Greg VanderVeen Greg VanderVeen Greg VanderVeen Greg VanderVeen Greg VanderVeen Greg VanderVeen Greg VanderVeen

Shipping Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar

Scheduling Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar

Purchasing Jeff Hayes Jeff Hayes Jeff Hayes Jeff Hayes Jeff Hayes Jeff Hayes Jeff Hayes Jeff Hayes Jeff Hayes

IT (incl EDI support) August Busch August Busch August Busch August Busch August Busch August Busch August Busch August Busch August Busch

Engineering Steve Look Steve Look Steve Look Steve Look Steve Look Steve Look Steve Look Steve Look Steve Look
 Maintenance Greg VanderVeen Greg VanderVeen Greg VanderVeen Greg VanderVeen Greg VanderVeen Greg VanderVeen Greg VanderVeen Greg VanderVeen Greg VanderVeen

Tooling Steve Look Steve Look Steve Look Steve Look Steve Look Steve Look Steve Look Steve Look Steve Look

Finance Deborah Norton Deborah Norton Deborah Norton Deborah Norton Deborah Norton Deborah Norton Deborah Norton Deborah Norton Deborah Norton

Human Resources Greg VanderVeen Greg VanderVeen Greg VanderVeen Greg VanderVeen Greg VanderVeen Greg VanderVeen Greg VanderVeen Greg VanderVeen Greg VanderVeen

Customer Service Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar Cheryle Leinaar

Other (Specify)

Other (Specify)
 Shutdown FMEA

Instructions: Insert your Shutdown FMEA on this page. It should be formatted to AIAG standards with RPN's assigned compliant with Rev 3 requirements.
Note: this is an EVENT FMEA, specific to the activities and risks associated with shutting down and starting up equipment, not a part FMEA.
Your "backup", "recovery" or "prevention" plan should be described for each risk element in the "Actions Taken" section of the FMEA.
Use the information included in the other pages of this workbook, especially the maintenance items, to determine your risk elements.
Shutdown Team Planning Meetings
Meeting Date: April 28, 2020 @ 1:00PM Location: WebEx
Meeting Date: May 1, 2020 @ 12:00 PM Location: WebEx
Meeting Date: May 15, 2020 @ 12:00 PM Location: On-site Au Gres MI

Meeting Champion :

Agenda

- review customer schedules

- review Shutdown plan forms for completion and acceptability

- review production needs / bank build status prior to shutdown

- review maintenace projects, timeline, contractors, skilled trade manning, service shutdowns

- review engineering projects, timelines, contractors, skilled trade manning, service shutdowns
 Shutdown Production Plan As of (Date):

Enter all of your GM part numbers, names and destination locations in Column B in the appropriate section. Enter a new line for each of multiple destinations. These will
be copied to the GP12 matrix sheet found in this workbook. Insert rows as needed to include all of your GM parts. Include GM Tier 2 parts
Based on current releases and plant memos, fill in the requirements and past due information as of the date shown above. Update this information weekly or as required
Instructions by your GM SQE.
Fill in whether your current production schedule reflects extra production for any parts for which you do not have a bank meeting the shutdown requirements; add details
(ie extra shift scheduled, added daily production) of how you will meet the delivery requirements
Complete the column Yes or No for whether you intend at this time to run production for these parts during the GM shutdown period.

Bank build
Requirements Past due Inventory Running during
GM Part Destination plan on
Part Description during Shutdown today on hand Shutdown? Comments
Number Plant Schedule?
(pieces) (pieces) (Today) (Yes / No)
(Yes / No)

New Parts

Carryover parts with

Engineering /
Process changes /
New GM destination
plants

All Other GM parts

including SPO
 Shutdown Percentages Table

Instructions: Based on your Production Plan, complete the table below. The data will be transferred to the charts on the next sheet.
Compare the planned numbers with your actual "normal" performance; ie if you normally run 2 shifts, but will only run 1 full shift, use 50%
Date 27-Jun-03 6/28 6/29 6/30 7/1 7/2 7/3 7/4 7/5 7/6 7/7 7/8 7/9 7/10 7/11 7/12 7/13 7/14
Percentage of Normal
Hourly Production
Manpower Expected to
work

Percentage of Machines
Running

Percentage of normal
Production Volume (Parts
Per Day)

1
 Shutdown Manpower Plan

12
10
8
6
4
2
0
06/27/03 06/28/03 06/29/03 06/30/03 07/01/03 07/02/03 07/03/03 07/04/03 07/05/03 07/06/03 07/07/03 07/08/03 07/09/03 07/10/03 07/11/03 07/12/03 07/13/03
Date

Percentage of Normal Hourly Production Manpower Expected to work

Shutdown Machinery Plan

100
80
60
40
20
0
03 03 03 03 03 03 03 03 03 03 03 03 03 03 03 03 03
7/ 8/ 9/ 0/ 1/ 2/ 3/ 4/ 5/ 6/ 7/ 8/ 9/ 0/ 1/ 2/ 3/
/2 /2 /2 /3 /0 /0 /0 /0 /0 /0 /0 /0 /0 /1 /1 /1 /1
06 06 06 06 07 07 07 07 07 07 07 07 07 07 07 07 07

Percentage of MachinesDate
Running

Shutdown Production Plan

100
80
60
40
20
0
03 03 03 03 03 03 03 03 03 03 03 03 03 03 03 03 03
7/ 8/ 9/ 0/ 1/ 2/ 3/ 4/ 5/ 6/ 7/ 8/ 9/ 0/ 1/ 2/ 3/
/2 /2 /2 /3 /0 /0 /0 /0 /0 /0 /0 /0 /0 /1 /1 /1 /1
06 06 06 06 07 07 07 07 07 07 07 07 07 07 07 07 07

Percentage of normal Production Volume

Date (Parts Per Day)
EMPLOYEE INFORMATION
First Name Last Name Area Phone Number Emergency Phone Number w/o 7/1 w/o 7/8
Administration Off Vacation Off Vacation
Corporate HR Working Working
Engineering Off Vacation Off Vacation
Elngineering Off Vacation Off Vacation
Engineering Off Vacation Working
Engineering Off Vacation Working
Engineering Working Working
Engineering Working Working
Finance Working-off Monday Working
Finance Working-off Monday Working
Finance Working-off Monday Working
Finance Working Working
Health & Safety Off Vacation Off Vacation
HR In Monday only In Monday only
HR Off Vacation Off Vacation
HR Off Vacation Off Vacation
HR Off Vacation Off Vacation
ISO Off Vacation Off Vacation
IS Working Working
IS Working Working
Maintenance Working Working
Maintenance Working Working
Maintenance Working Working
Maintenance Working Working
Materials Off Vacation Off Vacation
Materials Off Vacation Off Vacation
Materials Off Vacation Off Vacation
Materials Off Vacation Off Vacation
Production Working Working
Production Off Vacation Working
Production Off Vacation Off Vacation
Production Off Vacation Off Vacation
Production Working Working
Production Off Vacation Off Vacation
Production Off Vacation Working
Production Off Vacation Off Vacation
Production Off Vacation Off Vacation
Production Off Vacation Off Vacation
Operations Off Vacation Off Vacation
Production Off Vacation Working
Production Off Vacation Off Vacation
Production Off Vacation Working
Quality On call On call
Quality Off Vacation Off Vacation
Quality Off Vacation Off Vacation
Quality Off Vacation Off Vacation
Quality Off Vacation Off Vacation
Shipping Off Vacation Working
Shipping Working Off Vacation
Shipping Working Working
Shipping Off Vacation Off Vacation
Tooling Working Working
Tooling Working Working
 SHUTDOWN CHECK LIST
Instructions: Identify all Shutdown Activities and detail them on this sheet

Systems Champion Timing Initial Comments

Server Tape Backups Daily
User and system support Daily
Perform upgrades and maintenance 27-Jun

Maintenance Champion Timing Initial Comments

Shut down press main motors 27-Jun
Shutdown scrap conveyors 27-Jun
Turn off all but 1 compressor 27-Jun
Shutdown GMT 800 27-Jun
Shutdown Berg chiller system 27-Jun
Close all outside doors 27-Jun
Verify Spare parts inventory 27-Jun

Quality Champion Timing Initial Comments

Verify last off from press lines 27-Jun
Conduct Part and Fixture audit 27-Jun
Audit all material for proper tag 27-Jun Plant wide

Materials Champion Timing Initial Comments

Communicate shutdown and start-up 17-Jun
dates as per 862 and 830 releases
Review daily 862 and 830 releases Daily
Customers that are NOT shutting down Daily
verify Bank Builds
Ensure manpower & Supervision to 17-Jun
ship to customers
Check for degradation of process 17-Jun
materials and wet chemicals

Note: Bold items must be executed

PAGE 29
 Production Champion Timing Initial Comments
Empty presses of production parts 27-Jun
Empty 2 zinc line tanks 27-Jun

Clean zinc pit for repairs and inspection 08-15-Jun

Control panel shut-off in PPO booth. 27-Jun

Exhaust fan control panel shutoff. 27-Jun
Pre-treatment control panel shutoff. 27-Jun
Shutoff post rinse 1,2,3 e-coat panel. 27-Jun
Shutoff blow off fan on e-coat panel. 27-Jun
Shutdown zinc line filters. 27-Jun

Shutdown recirc pumps in zinc booth. 27-Jun

Shutdown DI system. 27-Jun
Shutdown waste treatment control
panel. 27-Jun
Pump out e-coat tank. 1-Jul
Pump e-coat tank back. 2-Jul
Flush out UF system. 3-Jul
Put UF system back on-line. 4-Jul
Check chemistry of e-coat tank. 2-Jul

Note: Bold items must be executed

PAGE 29
 Maintenance Shutdown Plan

Item (ie PM, Move, Clean,

Plan Start Plan Finish
Machine / Equipment Department Replace, Overhaul, Install On FMEA? RPN Comments
Date Date
New Equipment)
 START- UP CHECK LIST
Instructions: Identify all pre-start up activities and detail them on this sheet

Systems Champion Timing Initial Comments

Resume support of returning staff 12-Jul

Maintenance Champion Timing Initial Comments

Power up presses 12-Jul
Start press lube pumps 12-Jul
Check scrap conveyor system 12-Jul
Test 2 boiler systems 12-Jul
Test Berg Chiller for operation 12-Jul
Fill up all propane cylinders 12-Jul

Quality Champion Timing Initial Comments

Conduct Part and Fixture audit 15-Jul
Verify first off 15-Jul
Initiate GP-12 15-Jul

Materials Champion Timing Initial Comments

Review / verify Customer releases 12-Jul
Review & communicate NEW 12-Jul
schedules as required
Check for degradtion of process 12-Jul
materials and wet chemicals

Note: Bold items must be executed

PAGE 28
 Production Champion Timing Initial Comments
Start scrap conveyors 14-Jul
Fill 2 new zinc tanks 9-Jul
Verify chemistry of zinc tanks. 11-Jul

Turn on control panel in PPO booth. 11-Jul

Turn on exhaust fan control panel. 11-Jul
Turn on pre-treatment system. 11-Jul
Turn on post rinse 1,2,3 e-coat. 11-Jul
Turn on blow-off fan 1,2,3 panel. 11-Jul
Turn on zinc line filters. 11-Jul
Turn on recirc pumps in zinc booth. 11-Jul
Start-up DI system. 11-Jul
Start-up waste water panel. 11-Jul
Check chemistry on e-coat. 11-Jul
Check chemistry on pre-treatment
system. 11-Jul

Note: Bold items must be executed

PAGE 28
 Facility Check During Shutdown
Instructions: Identify all areas to be checked and list in Column A (Examples are given).
Identify person(s) responsible for checking these areas; they are to initial this sheet daily to verify that they have checked and all is OK.

After
Pre
Area Last 6/27/03 6/28/03 6/29/03 6/30/03 7/1/03 7/2/03 7/3/03 7/4/03 7/5/03 7/6/03 7/7/03 7/8/03 7/9/03 7/10/03 7/11/03 7/12/03
Start-Up
Shift
Compressor
Room - Front

Oil Storage Area

Shipping - North

Waste Treatment

Zinc Plating Line

E-coat Filter Pump

E-coat Circulating
Pump

Paint Kitchen

Shipping - South

Compressor
Room - South

Basement