Safe Launch Plan (SLP) in Automotive Manufacturing

🚗 What Is a Safe Launch Plan (SLP)?

A Safe Launch Plan (SLP) is a structured, temporary quality control strategy implemented during the early production phase of a new product or process. Its purpose is to protect the customer from potential defects while the manufacturing process stabilizes.

SLP is also known as:

• GP-12 by GM (Early Production Containment)
• Formel Q Capability by Volkswagen
• Launch Readiness Review (LRR) by Ford
• Safe Launch Process by ZF

🎯 Purpose of SLP

• Prevent non-conforming parts from reaching the customer
• Provide documented evidence of process stability
• Establish a baseline for process reliability growth
• Enable early detection and correction of issues
• Support customer confidence during launch

📌 Scope

SLP applies to:

• All new product launches
• All process changes
• All tooling changes
• All supplier changes
• All customer-specific requests

🧩 Key Elements of a Safe Launch Plan

1️⃣ Planning Phase

• Define scope and duration of SLP
• Identify critical characteristics and Customer Interface Characteristics (CICs)
• Develop an SLP Control Plan (enhanced version of the serial Control Plan)
• Align with PFMEA, Process Flow, and Standardized Work

2️⃣ Execution Phase

• Perform 100% inspection or enhanced sampling
• Monitor:
  • Process capability (Cpk/Ppk)
  • Defect rates
  • Scrap and rework
  • Error-proofing device functionality
  • Operator training effectiveness
• Record and analyze data daily
• Implement containment actions for any defects

3️⃣ Reporting Phase

Submit to customer:

• Daily defect summary
• Inspection results
• Process capability data
• Corrective action status
• SLP audit results

Use customer-specific formats (e.g., GM GP-12 forms, Ford LRR checklist)

4️⃣ Exit Criteria

• Minimum number of certified OK shipments (typically 3–5)
• No open issues or recurring defects
• Stable process capability
• Customer approval (written sign-off)
• Internal review and documentation

📊 What to Monitor During SLP

Category	Examples
Product Quality	Defect types, PPM, scrap rate
Process Stability	Cpk/Ppk, cycle time, downtime
Error Proofing	Device verification logs
Operator Performance	Training records, audit results
Customer Feedback	Complaints, returns, audit findings

📁 What to Submit to the Customer

• SLP Control Plan
• Daily inspection logs
• Defect containment reports
• Corrective action status
• Process capability summary
• SLP audit checklist
• SLP exit review documentation

🌐 Integration with AIAG & VDA Standards

✅ AIAG APQP (2024)

• SLP is now a formal phase between Pre-Launch and Production
• Requires linkage to:
  • PFMEA
  • Control Plan
  • Measurement System Analysis (MSA)
  • Error Proofing Verification (GQS 10)

✅ VDA 6.3

• SLP supports Maturity Level Assurance
• Requires:
  • Enhanced monitoring
  • Supplier readiness audits
  • Defect containment and escalation

🌍 Global OEM Requirements

OEM	SLP Equivalent	Key Requirements
GM	GP-12	100% inspection, daily reporting, certified OK shipments
Ford	LRR	Launch audit, defect tracking, customer sign-off
Volkswagen	Formel Q Capability	Process maturity, defect containment
ZF	PCM-SLP	Data recording, performance monitoring, exit review
Stellantis	SLP	Supplier launch readiness, defect tracking
Mercedes-Benz	SLP	Enhanced inspection, launch control

✅ Summary

Implementing a Safe Launch Plan helps suppliers:

• Protect customers during early production
• Build confidence in product and process quality
• Meet global OEM and industry standards
• Drive continuous improvement and defect prevention

📌 Beginner Tip: Think of SLP as your “quality safety net”—it catches issues before they reach your customer.

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KIMEC|Expert Group

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