通用汽車的資料第1頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage2BillofProcess第2頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage3GlobalBillofProcess(BOP)Globallycommon,balanced,anddocumentedapproachforManufacturingandAssemblingVehiclesBuildsequenceOperationcontentDimensionalstrategySubassemblydesignstrategyMajortoolandequipmentinterfacestotheproductTheBOPimpactsboththeprocessandtheproductandconsistsofthefollowing:TheBOPdoesnotprescribespecificequipment,levelofautomation/manpower,orplantlayout第3頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage4PressandDieBODYPAINTGA(General

Assembly)

GM’sManufacturingSystems:

EachhasaBillofProcess(BOP)Powertrain第4頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage5GlobalBillofProcess(BOP)

CommonBuildSequenceandOperationContent第5頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage6GlobalBillofProcess(BOP)

CommonBuildSequenceandOperationContent第6頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage7GlobalBillofProcess(BOP)

CommonBuildSequenceandOperationContent第7頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage8IntegrateProductRequirementswithManufacturingCapabilitytoProduce:TheRightProductAttheRightTimeAttheRightVolumeAttheRightCostIntheRightPlantGMGoal第8頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage9Acommon,global,world-class,flexiblemanufacturingsystemtodeliverhighqualityatcompetitivecostexceedingcustomerexpectationsBOPVisionGuidingPrinciples第9頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage10ProtectManufacturingPortfolioFlexibilityCommonFlexibleMainLineProcessDrivenProductDesignRequirementsOptimizeManufacturingEfficiencyProductDifferentiationandDifferencesinContentLevelareDriventoSubassembliesorModulesoffoftheMainLineRegionalRequirementsDetermineAutomationLevelOn-LinePilotwithZeroLostUnitsPhasedImplementationBOPCompatibleBOMComponentsConcurrentwithProductArchitectureChangesGlobalBOPObjectives第10頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage11BOPGuidingPrinciples-DevelopmentProtectthehealthandsafetyofoperatorsDevelopproductandprocessattributeswhichensurehighqualityvehiclesareprovidedtothecustomerProvideacommonmainlinemanufacturingsystem*thatsupportstheBFIandBOFproductportfoliobandwidthProvideacommonprocessframeworkforsubassemblies/modulesthatsupportscustomerDifferentiators* Mainlineisdefinedasproductstraightlineflowfromstartofmotorcompartmentassembly(BIW)tothe“CARE”process.* Manufacturingsystemincludesoperationsequence,operation/modulecontent,dimensionalstrategy,andmajortool/equipmentinterfaces.** Regionalmanufacturingrequirementsintermsoflinerates,automationlevels,ergonomic/safetyrequirementsandvehicleflexcapacity.*** Withinmanufacturingportfoliodesignatedflexcapacity.第11頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage12BOPGuidingPrinciples-DevelopmentProvideproductrequirementsthatenablethecommonmanufacturingsystemProvidecommonBOPsolutionsforthebandwidthofregionalproduct&manufacturingrequirements**Enablenewvehiclelauncheswithzerolostunitsthroughcapabilityforon-linepilotandaccelerationofnewmodelsconcurrentwithexistingproduction***Enableinnovationandcontinuousimprovementthroughapprovalofappropriatecouncils* Mainlineisdefinedasproductstraightlineflowfromstartofmotorcompartmentassembly(BIW)tothe“CARE”process.* Manufacturingsystemincludesoperationsequence,operation/modulecontent,dimensionalstrategy,andmajortool/equipmentinterfaces.** Regionalmanufacturingrequirementsintermsoflinerates,automationlevels,ergonomic/safetyrequirementsandvehicleflexcapacity.*** Withinmanufacturingportfoliodesignatedflexcapacity.第12頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage132/2/2000BOPGuidingPrinciples-ImplementationProductcompliancetotheBOPistobeexecutedonallnewproductdesignsBOPcompliantproductscanbebuiltinanyBOPcompliantplantanywhereNewPlant(Greenfield)processcompliancetotheBOPwillbe100percentExistingPlant(Brownfield)processmigrationcompliancetotheBOPwillbeexecutedconcurrentwithplantequipmentreplacementBOPcompliantplantscanbuildanyBOPproductfromanywhere第13頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage14BOPManufacturingProcessBOPProductArchitectureBOPImplementationStrategyMigratetoBOPCompatibleProductArchitecturesConvertUncommon,InflexibleManufacturingSystemstoCommon,FlexibleManufacturingFootprint(BOP)

-BUT-SpendMoneytoImplementBOPOnlyWhenProduct&ManufacturingSystemsMUSTBeChangedNewProductandNew“Greenfield”Plant:BOPCompliant第14頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage15Compliancevs.CompatibilityCompliance: Thisspecificproductorprocessmeets100%oftheapplicableBOPrequirements.Compatibility: Thisspecificproductdoesnotmeet100%oftheapplicableBOPrequirements,butitcanbeprocessedonaBOPcompliantprocess -OR-

Thisspecificprocessdoesnotmeet100%oftheapplicableBOPrequirements,butitcanaccommodateaBOPcompliantproduct.第15頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage16ManufacturingRequirementsProcessCompliancevs.Compatibility第16頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage17WhatDoWeMeanby“ManufacturingRequirements(MR)”?Global,CommonMethodtoBringBOPDirectlyIntoVehicleDevelopmentandManageProgramManufacturingRequirementsInitialListBroughtinFromtheBOPTargetedBOPImplementationBasedonProgramSpecificsImplementBOPWhenMoneyIsSpentonProductorProcessCriteriaThatEnableaVehicletoBeBuiltinGMPlants,Comprehending:Assembly&BuildSequenceEquipmentVehicleSizeEnvelopeEfficiency,Ergonomics,etc.TwoTypes: 1.Product(a.k.a.PDPD,orProcessDrivenProductDesign) 2.Process第17頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage18MRExample

SubassemblyDesignStrategy:103Product1.7Aspidersubassemblywillconsistof:arightandleftmotorcompartmentlowerrailsubassembly,a#1barsubassembly,andabumperbeamorrigidcrossmembertotietherightandleftrailstogetheratthefront.203

Product1.9Frontwheelhouseassemblyisbroughttothe

motorcompartmentmainlineas

acompletedsubassembly/module.StationLevelManufacturingRequirementType第18頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage19MRObjectivesEstablishLean,GloballyCommonProcess&ToolsIntegratedwithExistingCorporateProcessesImproveCommunicationBetweenProductandManufacturingEngineeringStrengthenVoiceofManufacturinginVehicleLineTeams(VLTs)ImplementProcessDrivenProductDesigns(PDPD)FacilitateEngineeringtoRequirementsDriveBOPImplementationEnableCapitalReuse第19頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage20

70

3

Product1.30Thecowlmusthavefore-aftandcross

carsliptothedashsubassembly.

Station

Level

AddressManufacturingRequirement

MRExample

DimensionalStrategy-Body第20頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage21MRGuidingPrinciplesProgramMRsincludebothBOPandnon-BOPrequirements.TheMRprocessbeginsintheAdvancedVehicleDevelopmentprocessAllprogramsshallstartwiththelatestversionoftheBOP.InitialMRsareloadedwellbeforeVPI.AdditionalMRsmaybeaddedatanytimepriortodesignexecution.ReusestrategytakesprecedenceoverBOPmigration.第21頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage22543Product543Product3Product543Product541.20(SeedrawingItemA)Designofmotorcompartment

lowersiderailsR/Lincludesatoolingdatumlocatorfor

F/AandC/C,consistingofa40.1+0.1/-0.0mmhole,

piercedandflangedupward.(NOA001)1.20.2(SeedrawingItemC).Designofmotorcompartment

lowersiderailsR/LincludesprincipalU/Dlocators

carriedthroughoutthemotorcompartmentand

underbodybuildprocess.Heightisheldasapattern

fortargetedplantsandissymmetricallefttoright.

(NOA001)1.20.1(SeedrawingItemB)Designofmotorcompartment

lowersiderailsR/Lincludes40.1+0.1/-0.0mmcarrier

hole,piercedandflangedatthesametimeasholesat

“A”,piercedandflangedupward,located

15.5mmforwardoflocation“A”.(NOA001)MRExampleMajorToolandEquipmentInterfaces-Body

第22頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage23MRConnections-Examples

RegionalDifferencesApplyPSSDeliverablesTrackingG/APaintBodyBOPReq'tsBOPBOPDeviationsBOPChangesVPPSVDPDesRelProgressionLean/ISODREPortal/ProdDesKitMfgRRProcessVTS/SSTS/ICDMfgWallProcessBOM/TechMemModPlanMfgDesKitSORsEWOsCR/DN第23頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage24AgreementMilestonesPre-VPIRequirementsArchitecture-InitialBOMRowSelectionConceptPartsStructurePartsIntegrationPartsForprogramswithmultiplepartgroupreleases(ConceptParts,StructureParts,andIntegrationParts)MRcompletiondatesmaybephasedbasedonpart/processreleaseneeds第24頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage25ManufacturingRequirements

ProcessFlow-ExampleMVNSxx/xx/xxxx/xx/xxEOASFSOPCSOG/APaintBodyBOPReq'tsLoadMRDBCompleteBOP&BOETargetsMRGamePlanMRGamePlanMRRMRRAVDRVPIRManagementApprovalsVDPExecutionWorkBoundaryConditionsDesignIntentAlternativesDevelopmentDesignThemeAlternativeVPIPrepGMNAOnlyCSPRVPIDSI-164-145-131-117-106+26-176-158AddAdditionalProgramMRsPre-VPIAgreesExecuteProductVerifyT2ArchBOMAgreesBodyArchBOMAgreesProcessVerifyIntegrationAgrees(SOR’s)IntegrationAgrees(others)ExecuteT2ProductVerifyProcessVerifyStructureAgrees(SOR’s)StructureAgrees(others)ExecuteT2ProductVerifyProcessVerifyConceptAgrees(SOR’s)ConceptAgrees(others)ExecuteT2ProductVerifyProcessVerify第25頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage26MRTrackingSheetExample第26頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage27AgreementAnindicationofacceptanceofadesignintentforeithertheproductorprocessdiscussedinthemanufacturingrequirement.Theownerisagreeingtoandwillsupportthewordsintheprogramrequirementtextofamanufacturingrequirement.Itisnotnecessarythattheowner(s)ofamanufacturingrequirementhaveeverythingfinalized,merelythattheyagreeonwhattheyshouldbedesigningto.Whentheownersagree,themanufacturingrequirementbecomeslocked.第27頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage28MRTrackingSheetExample第28頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage29ExecutionIncorporateagreedmanufacturingrequirementsintotheproductandprocessdesignsThisistheresponsibilityofeachManufacturingEngineerandProductEngineerProgramVehicleDesignProgramManufacturingSystemDesign第29頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage30GBIST9/18/01VerificationWhatisVerification?AconfirmationofwhattheprogramexecutedrelativetotheagreedManufacturingRequirementsWhyPerformVerification?Havewecreatedpotentialproblems/costfortheprogram(orthenextoffthisdesign)?Didwedowhatwesaidwewoulddo?Arewedrivingtothecommonmanufacturingsystem(BOP)?第30頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage31MRTrackingSheetExample第31頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage32MEResponsibilitiesReviewinitialBOPrequirementsWrite/modifyprogramrequirementtextEstablishallPROCESSrequirementsEvaluateandsetBOPTargetandStatusEnterMEAgreementStatusonallrequirementsWorkwiththePEownertoestablishallPRODUCTrequirementsPromptlyelevateallrequirementsthatarenotcomingtoagreementUserequirementsasinputtodesignsandSORsVerifyrequirementwasimplementedAddnewnon-BOPrequirementswhennecessaryKeepMEownername/phonenumberup-to-dateandincludeadditionalMEownersasnecessary第32頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage33NoMore...NowICan..EasilyLocateAllMyRequirementsDocumentAgreementsSeeWhatOtherEngineersAgreedTo,IncludingThoseUpstreamPeopleSayWhatWeReallyNeedonaProgram,IncludingNon-BOPItemsCommunicateOurRequirementsEasilytoPEsSearchingforApplicableBOPRequirementsTryingtoFigureOutHowtoCommunicateNewRequirementstotheProgramBOPComplianceChecklistFillingOutBOPComplianceChecksheetsMultipleTimesWonderingWhatWasAgreedtobyEngineersUpstreamWhat’sInItforaMEOwner?第33頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage34PEResponsibilitiesWorkwiththeMEtoestablishallPRODUCTrequirementsEnterPEAgreementStatusforeachrequirementPromptlyelevateallrequirementsthatarenotcomingtoagreementUserequirementsasinputtodesignsandSORsKeepPEownername/phonenumberup-to-dateandincludeadditionalPEownersasnecessary第34頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage35What’sInItforaPEOwner?ProductDesignKit

ChecklistItems1-3415.BOP18.MfgProcess30.ToolClearanceProductDesignKitChecklistItems1-3215.MRDatabaseBOPsonBody,PaintandGAWebsites.Nowwhat?MFDPEDMfgprocessisinhere...Whatarethetoolclearancerequirements?Onestopshoppingformanufacturingrequirements!VTSMTSMfgICDWhoistheMEonthisrequirement?PastNow第35頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage36ManagementRole"AsktheRightQuestions"

toDriveMRProcessActivelySupportUseofGMCommonMRProcess-IncorporateinPerformanceMetricsMonitorStatusofMRDeliverables-IncludeinStaffMeetings/ScheduledProgramReviewsAssistinIssueResolution-BreakRoadblocksChallengeDecisionsNottoMeetBOPTargetsorExistingAgreements第36頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage37GlobalBillofEquipment(BOE)第37頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage38GlobalBillofEquipment(BOE)

BOEcomparedtoBOPBOP(BillofProcess)documentsacommonsequenceonhowtoputvehiclestogetherBOE(BillofEquipment)documentstheequipmentandtoolingusedtoputthevehiclestogether第38頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage39CommonBuildSequenceandOperationContentGlobalBillofProcess(BOP)第39頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage40

TheBOPdoesnotprescribespecificequipment, levelofautomation/manpower,orplantlayout, i.e.,“theBOEdoesthat”?Buildsequence?Operationcontent?Dimensionalstrategy?Subassemblydesignstrategy?MajortoolandequipmentinterfacestotheproductTheBOPimpactsboththeprocessandtheproductandcontainsthePRODUCTelementsof………

TheBOPisGloballyCommonanddoesnotchange!GlobalBillofEquipment(BOE)

BOEcomparedtoBOP第40頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage41GlobalBillofEquipment(BOE)

BOEcomparedtoBOPTheBOEdescribesninedifferentyetsimilarequipmentsetsincludinglevelofautomationormanpower,systemorcelllayoutandmake-up,conveyancetype,etc.forninedifferentscenariosorcellsdependingonlaborratesandproductionvolume.ThisCorporatestrategyallowsustohaveagloballycommonBOPwithninedifferentmanufacturingsolutions,i.e.,BOE’sthatallowGeneralMotorstobecompetitiveinALLGlobalregions.第41頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage42BlendingofHighTechnology&simplelowcostsolutionswillenableallofGMtobecomethe“BestoftheBest”.GlobalBillofEquipment

第42頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage43GlobalBillofEquipmentProductionRate(NWR)LaborRateLow(<$15US)Medium($15-35US)High(>$35US)Low(<15JPH)Medium(15-40JPH)High(>40JPH)LansingCraftCenterSGMWSparkYantaiTolucaJinBeiVietnam/IndiaTrollhatenEisenachCAMILutonIBCSpringHill1Flint1&2LGRSpringHill2BowlingGreenSGMWEastSaoCaetano

ShanghaiBupyung2Gravatai/RosarioGliwiceThailandAzambujaSaoJoseGunsanBupyung1RamosChangwonSilaoAntwerpBochumRusselsheimEllesmerePortZaragozaElizabethOshawa1Oshawa2OshawaTruckLordstownDoravilleMoraineOrionFortWayneD-HamtramckShreveportWilmingtonJanesvilleFairfaxPontiacLansingMLindenLansingCArlingtonBaltimoreWentzvilleOKCNUMMINALAAMGMEAPMishawaka124365896第43頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage44Identicalforcells1through9Maybedifferentforcells1through9GlobalBOPKeyElementsBuildsequenceOperationcontentDimensionalstrategySubassemblydesignstrategyMajortoolandequipmentinterfacestotheproductGlobalBOEKeyElementsTooling/Machineryand

equipmenttypeAutomaticvs.manualoperationsConveyancestrategyandtypeOperationlayoutMaterialhandling

andpresentationBOPisidenticalforallproductionandlaborrates,whiletheBOEcanvaryGlobalBOPvs.GlobalBOE!

第44頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage45FramerSpecificationsBodySideInners&OutersLoadedinSequenceonMainlineUnderbodyMasterLocatingHolesRoofLoadAfterOuterFramingFramerBrandOvalvs.DiamondPinsProduct&ProcessRoofAssemblyAutomatedExtr.PaintApplication10ExteriorColorsRobotvs.RecipSprayEquip.ColorPenetrationLevelDoorsOffProcessingVerticalFasteningatMarriageDesignEnablesManualGlassLoadConveyor/BankingDesignHexvs.Torx,ThreadManualvs.AutoGlassLoadSinglevs.Multi-PieceDoorRingBOPisaboutPortfolioFlexibility

BOE

isaboutResourceUtilizationBodyAssemblyBOPandBOEExamples第45頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage46GlobalBillofEquipmentDevelopment

GlobalBillofEquipment(BOE)ProductionRate(NWR)LaborRateLowMediumHighLowMediumHighGMAPGMNAGMNAGMNAGMNAGMEGMELAAMLAAM123654789WithRegionalAssignmentsEachBOECellwasassignedtothemostappropriateglobalregionforinitialBOEdraftdevelopment第46頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage47GlobalBillofEquipmentDevelopment

GLOBALBILLOFEQUIPMENTBODYSHOPGENERALASSEMBLYPAINTSHOP“BOE’sonaPage”arebeingdevelopedforeachofthe9cells–ineachofthethreeareas(Body,Paint,andGeneralAssembly).第47頁(yè)/共54頁(yè)BOP-MRtrainingclass4.pptPage48Withineachfunctionalarea,theBillofEquipmentmaybeappropriateformorethanoneproduction/laborratecombinationandspecificequipmentcanalso