《通用汽车BOEB》PPT课件.ppt

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1、Bill of ProcessManufacturing Requirements ProcessBill of EquipmentBOP-MR training class4.pptPage Bill of ProcessBOP-MR training class4.pptPage Global Bill of Process(BOP)Globally common,balanced,and documented approach for Manufacturing and Assembling VehiclesBuild sequenceOperation contentDimension

2、al strategySubassembly design strategyMajor tool and equipment interfaces to the productThe BOP impacts both the process and the product and consists of the following:The BOP does not prescribe specific equipment,level of automation/manpower,or plant layoutBOP-MR training class4.pptPage Press and Di

3、eBODYPAINTGA(General Assembly)GMs Manufacturing Systems:Each has a Bill of Process(BOP)PowertrainBOP-MR training class4.pptPage Global Bill of Process(BOP)Global Bill of Process(BOP)Common Build Sequence and Operation ContentCommon Build Sequence and Operation ContentBOP-MR training class4.pptPage G

4、lobal Bill of Process(BOP)Global Bill of Process(BOP)Common Build Sequence and Operation ContentCommon Build Sequence and Operation ContentBOP-MR training class4.pptPage Global Bill of Process(BOP)Global Bill of Process(BOP)Common Build Sequence and Operation ContentCommon Build Sequence and Operati

5、on ContentBOP-MR training class4.pptPage A common,global,world-class,flexible manufacturing system to deliver high quality at competitive cost exceeding customer expectationsBOP VisionGuiding PrinciplesBOP-MR training class4.pptPage Protect Manufacturing Portfolio FlexibilityCommon Flexible Main Lin

6、eProcess Driven Product Design RequirementsOptimize Manufacturing EfficiencyProduct Differentiation and Differences in Content Level are Driven to Subassemblies or Modules off of the Main LineRegional Requirements Determine Automation LevelOn-Line Pilot with Zero Lost UnitsPhased ImplementationBOP C

7、ompatible BOM ComponentsConcurrent with Product Architecture ChangesGlobal BOP ObjectivesBOP-MR training class4.pptPage BOP Implementation StrategyMigrate to BOP Compatible Product ArchitecturesConvert Uncommon,Inflexible Manufacturing Systems to Common,Flexible Manufacturing Footprint(BOP)-BUT-Spen

8、d Money to Implement BOP Only When Product&Manufacturing Systems MUST Be ChangedNew Product and New“Greenfield”Plant:BOP CompliantBOP-MR training class4.pptPage Compliance vs.CompatibilityCompliance:This specific product or process meets 100%of the applicable BOP requirements.Compatibility:This spec

9、ific product does not meet 100%of the applicable BOP requirements,but it can be processed on a BOP compliant process-OR-This specific process does not meet 100%of the applicable BOP requirements,but it can accommodate a BOP compliant product.BOP-MR training class4.pptPage Manufacturing Requirements

10、ProcessCompliance vs.CompatibilityBOP-MR training class4.pptPage What Do We Mean by“Manufacturing Requirements(MR)”?Global,Common Method to Bring BOP Directly Into Vehicle Development and Manage Program Manufacturing RequirementsInitial List Brought in From the BOPTargeted BOP Implementation Based o

11、n Program SpecificsImplement BOP When Money Is Spent on Product or ProcessCriteria That Enable a Vehicle to Be Built in GM Plants,Comprehending:Assembly&Build SequenceEquipmentVehicle Size EnvelopeEfficiency,Ergonomics,etc.Two Types:1.Product(a.k.a.PDPD,or Process Driven Product Design)2.Process BOP

12、-MR training class4.pptPage MR Example Subassembly Design Strategy:103Product1.7 A spider subassembly will consist of:a right and left motor compartment lower rail subassembly,a#1 bar subassembly,and a bumper beam or rigid cross member to tie the right and left rails together at the front.203 Produc

13、t 1.9 Front wheel house assembly is brought to the motor compartment main line as a completed subassembly/module.Station LevelManufacturing RequirementTypeBOP-MR training class4.pptPage MR ObjectivesEstablish Lean,Globally Common Process&Tools Integrated with Existing Corporate ProcessesImprove Comm

14、unication Between Product and Manufacturing EngineeringStrengthen Voice of Manufacturing in Vehicle Line Teams(VLTs)Implement Process Driven Product Designs(PDPD)Facilitate Engineering to RequirementsDrive BOP ImplementationEnable Capital ReuseBOP-MR training class4.pptPage 70 3 Product1.30 The cowl

15、 must have fore-aft and cross car slip to the dash sub assembly.Station Level Address Manufacturing Requirement MR Example Dimensional Strategy-BodyBOP-MR training class4.pptPage 543Product543 Product3Product543 Product541.20 (See drawing Item A)Design of motor compartment lower side rails R/L inclu

16、des a tooling datum locator for F/A and C/C,consisting of a 40.1+0.1/-0.0 mm hole,pierced and flanged upward.(NOA 001)1.20.2 (See drawing Item C).Design of motor compartment lower side rails R/L includes principal U/D locators carried throughout the motor compartment and underbody build process.Heig

17、ht is held as a pattern for targeted plants and is symmetrical left to right.(NOA 001)1.20.1 (See drawing Item B)Design of motor compartment lower side rails R/L includes 40.1+0.1/-0.0 mm carrier hole,pierced and flanged at the same time as holes at “A”,pierced and flanged upward,located 15.5 mm for

18、ward of location“A”.(NOA 001)MR ExampleMajor Tool and Equipment Interfaces-Body BOP-MR training class4.pptPage Agreement MilestonesPre-VPI RequirementsArchitecture-InitialBOM Row SelectionConcept PartsStructure PartsIntegration PartsBOP-MR training class4.pptPage Manufacturing RequirementsProcess Fl

19、ow-ExampleMVNSxx/xx/xxxx/xx/xxEOASFSOPCSOG/APaintBodyBOPReqtsLoad MRDBComplete BOP&BOE TargetsMR Game PlanMR Game PlanMRRMRRAVDRVPIRManagement ApprovalsVDP Execution WorkBoundary ConditionsDesign IntentAlternatives DevelopmentDesign Theme AlternativeVPI PrepGMNA OnlyCSPRVPIDSI-164-145-131-117-106+26

20、-176-158Add Additional Program MRsPre-VPI AgreesExecute ProductVerify T2Arch BOM AgreesBody Arch BOM AgreesProcessVerify Integration Agrees(SORs)IntegrationAgrees(others)Execute T2ProductVerify ProcessVerify Structure Agrees(SORs)StructureAgrees(others)Execute T2ProductVerify ProcessVerify Concept A

21、grees(SORs)ConceptAgrees(others)Execute T2ProductVerify ProcessVerify BOP-MR training class4.pptPage BOP-MR training class4.pptPage AgreementAn indication of acceptance of a design intent for either the product or process discussed in the manufacturing requirement.The owner is agreeing to and will s

22、upport the words in the program requirement text of a manufacturing requirement.It is not necessary that the owner(s)of a manufacturing requirement have everything finalized,merely that they agree on what they should be designing to.When the owners agree,the manufacturing requirement becomes locked.

23、BOP-MR training class4.pptPage BOP-MR training class4.pptPage ExecutionIncorporate agreed manufacturing requirements into the product and process designs This is the responsibility of each Manufacturing Engineer and Product EngineerProgram Vehicle DesignProgramManufacturingSystem DesignBOP-MR traini

24、ng class4.pptPage GBIST 9/18/01VerificationWhat is Verification?A confirmation of what the program executed relative to the agreed Manufacturing RequirementsWhy Perform Verification?Have we created potential problems/cost for the program (or the next off this design)?Did we do what we said we would

25、do?Are we driving to the common manufacturing system(BOP)?BOP-MR training class4.pptPage BOP-MR training class4.pptPage ME ResponsibilitiesReview initial BOP requirementsWrite/modify program requirement textEstablish all PROCESS requirements Evaluate and set BOP Target and StatusEnter ME Agreement S

26、tatus on all requirementsWork with the PE owner to establish all PRODUCT requirements Promptly elevate all requirements that are not coming to agreementUse requirements as input to designs and SORsVerify requirement was implementedAdd new non-BOP requirements when necessaryKeep ME owner name/phone n

27、umber up-to-date and include additional ME owners as necessaryBOP-MR training class4.pptPage No More.Now I Can.Easily Locate All My RequirementsDocument AgreementsSee What Other Engineers Agreed To,Including Those Upstream PeopleSay What We Really Need on a Program,Including Non-BOP ItemsCommunicate

28、 Our Requirements Easily to PEsSearching for Applicable BOP RequirementsTrying to Figure Out How to Communicate NewRequirements to the ProgramBOPComplianceChecklistFilling Out BOP Compliance Checksheets Multiple TimesWondering What Was Agreed to by Engineers UpstreamWhats In It for a ME Owner?BOP-MR

29、 training class4.pptPage PE ResponsibilitiesWork with the ME to establish all PRODUCT requirementsEnter PE Agreement Status for each requirementPromptly elevate all requirements that are not coming to agreementUse requirements as input to designs and SORsKeep PE owner name/phone number up-to-date an

30、d include additional PE owners as necessaryBOP-MR training class4.pptPage Whats In It for a PE Owner?Product Design Kit Checklist Items 1-3415.BOP18.Mfg Process30.Tool ClearanceProduct Design Kit Checklist Items 1-3215.MR DatabaseBOPs on Body,Paint and GA Websites.Now what?MFDPEDMfg process is in he

31、re.What are the tool clearance requirements?One stop shopping for manufacturing requirements!VTSMTSMfg ICDWho is the ME on this requirement?PastNowBOP-MR training class4.pptPage Management RoleAsk the Right Questions to Drive MR ProcessActively Support Use of GM Common MR Process-Incorporate in Perf

32、ormance MetricsMonitor Status of MR Deliverables-Include in Staff Meetings/Scheduled Program ReviewsAssist in Issue Resolution-Break RoadblocksChallenge Decisions Not to Meet BOP Targets or Existing AgreementsBOP-MR training class4.pptPage Global Bill of Equipment(BOE)Global Bill of Equipment(BOE)BO

33、P-MR training class4.pptPage Global Bill of Equipment(BOE)Global Bill of Equipment(BOE)BOE compared to BOPBOE compared to BOPBOE compared to BOPBOP(Bill of Process)documents a common sequence on how to put vehicles togetherBOE(Bill of Equipment)documents the equipment and tooling used to put the veh

34、icles togetherBOP-MR training class4.pptPage Common Build Sequence and Operation ContentGlobal Bill of Process(BOP)Global Bill of Process(BOP)BOP-MR training class4.pptPage The BOP does not prescribe specific equipment,level of automation/manpower,or plant layout,i.e.,“the BOE does that”Build sequen

35、ceOperation contentDimensional strategySubassembly design strategyMajor tool and equipment interfaces to the productThe BOP impacts both the process and the product and contains the PRODUCT elements of The BOP is Globally Common and does not change!Global Bill of Equipment(BOE)Global Bill of Equipme

36、nt(BOE)BOE compared to BOPBOE compared to BOPBOE compared to BOPBOP-MR training class4.pptPage Global Bill of Equipment(BOE)Global Bill of Equipment(BOE)BOE compared to BOPBOE compared to BOPBOE compared to BOPThe BOE describes nine different yet similar equipment sets including level of automation

37、or manpower,system or cell layout and make-up,conveyance type,etc.for nine different scenarios or cells depending on labor rates and production volume.This Corporate strategy allows us to have a globally common BOP with nine different manufacturing solutions,i.e.,BOEs that allow General Motors to be

38、 competitive in ALL Global regions.BOP-MR training class4.pptPage Blending of High Technology&simple low cost solutions will enable all of GM to become the“Best of the Best”.Global Bill of Equipment Global Bill of Equipment BOP-MR training class4.pptPage Global Bill of EquipmentGlobal Bill of Equipm

39、entProduction Rate(NWR)Labor RateLow($35US)Low(40JPH)Lansing Craft CenterSGMW SparkYantaiTolucaJin BeiVietnam/IndiaTrollhatenEisenachCAMILuton IBCSpring Hill 1Flint 1&2LGRSpring Hill 2Bowling GreenSGMW EastSao Caetano ShanghaiBupyung 2Gravatai/RosarioGliwiceThailandAzambujaSao JoseGunsanBupyung 1Ram

40、osChangwonSilaoAntwerpBochumRusselsheimEllesmere PortZaragozaElizabethOshawa 1Oshawa 2Oshawa Truck LordstownDoravilleMoraineOrionFort WayneD-Hamtramck ShreveportWilmingtonJanesvilleFairfaxPontiacLansing MLindenLansing CArlingtonBaltimoreWentzvilleOKCNUMMINALAAMGMEAPMishawaka124365896BOP-MR training

41、class4.pptPage Identical for cells 1 through 9Identical for cells 1 through 9May be different for cells 1 through May be different for cells 1 through 9 9Global BOP Key ElementsBuild sequenceOperation contentDimensional strategySubassembly design strategyMajor tool and equipment interfaces to the pr

42、oductGlobal BOE Key ElementsTooling/Machinery and equipment typeAutomatic vs.manual operationsConveyance strategy and type Operation layoutMaterial handling and presentationBOP is identical for all production and BOP is identical for all production and BOP is identical for all production and BOP is

43、identical for all production and labor rates,while the BOE can varylabor rates,while the BOE can varylabor rates,while the BOE can varylabor rates,while the BOE can varyGlobal BOP vs.Global BOE!BOP-MR training class4.pptPage Framer SpecificationsBody Side Inners&OutersLoaded in Sequence on Mainline

44、Underbody Master Locating HolesRoof Load After Outer FramingFramer BrandOval vs.Diamond PinsProduct&Process Roof AssemblyAutomated Extr.Paint Application10 Exterior ColorsRobot vs.Recip Spray Equip.Color Penetration LevelDoors Off ProcessingVertical Fastening at MarriageDesign Enables Manual Glass L

45、oadConveyor/Banking DesignHex vs.Torx,ThreadManual vs.Auto Glass LoadSingle vs.Multi-Piece Door RingBOP is about Portfolio Flexibility BOEBOE is aboutis aboutResource UtilizationBody Assembly BOP and BOE ExamplesBOP-MR training class4.pptPage Global Bill of Equipment Global Bill of Equipment Develop

46、mentDevelopmentDevelopment Global Bill of Equipment(BOE)Production Rate(NWR)Labor RateLow Medium High LowMedium High GMAPGMAPGMNAGMNAGMNAGMNAGMNAGMNAGMNAGMNAGMEGMELAAMLAAM123654789With Regional AssignmentsEach BOE Cell was assigned to the most appropriate global region for initial BOE draft developm

47、entBOP-MR training class4.pptPage Global Bill of Equipment Global Bill of Equipment DevelopmentDevelopmentDevelopment GLOBAL BILL GLOBAL BILL OF EQUIPMENTOF EQUIPMENTBODY BODY SHOPSHOPGENERAL GENERAL ASSEMBLYASSEMBLYPAINT PAINT SHOPSHOP“BOEs on a Page”are being developed for each of the 9 cells in e

48、ach of the three areas(Body,Paint,and General Assembly).BOP-MR training class4.pptPage Within each functional area,the Bill of Equipment may be appropriate for more than one production/labor rate combination and specific equipment can also exist in multiple Bill of EquipmentsProduction RateLabor Rat

49、eProduction RateLabor Rate(charts for illustrative purposes only)Production RateLabor RateBodyPaintGACRWProduction RateLabor RateThe segment of BOE that is often reviewed and confused as being“the BOP”Global Bill of Equipment Global Bill of Equipment DevelopmentDevelopmentDevelopmentA Bill of Equipm

50、ent within a functional area may be shared among multiple production/labor rate combinationsBOP-MR training class4.pptPage Body Shop BOEBody Shop BOEExampleExampleExampleCell 1Inner&Outer Manual Weld Framing StationLow volume/low labor rate project in LAAMBOP-MR training class4.pptPage Body Shop BOE