通用汽车BOE、BOP

BOP-MRtrainingclass4.pptPage1BillofProcessManufacturingRequirementsProcessBillofEquipmentMRManufacturingRequirementsMRManufacturingRequirementsBOP-MRtrainingclass4.pptPage2BillofProcessBOP-MRtrainingclass4.pptPage3GlobalBillofProcess(BOP)Globallycommon,balanced,anddocumentedapproachforManufacturingandAssemblingVehicles•Buildsequence•Operationcontent•Dimensionalstrategy•Subassemblydesignstrategy•MajortoolandequipmentinterfacestotheproductTheBOPimpactsboththeprocessandtheproductandconsistsofthefollowing:TheBOPdoesnotprescribespecificequipment,levelofautomation/manpower,orplantlayoutBOP-MRtrainingclass4.pptPage4PressandDieBODYPAINTGA(GeneralAssembly)GM’sManufacturingSystems:EachhasaBillofProcess(BOP)PowertrainBOP-MRtrainingclass4.pptPage5GlobalBillofProcess(BOP)CommonBuildSequenceandOperationContentBOP-MRtrainingclass4.pptPage6GMVOGMVOBOP.pptrev.10FE0310GeneralAssemblyBOPRoofTrimFixedGlassSeatsFrontandRearEMModulesBody/ChassisMarriageRearSuspensionModuleCradleFrontSuspensionModuleEngineDressInstallDoorsCRFMFrontandRearFasciaModulesWheelsandTiresInteriorHardwareInteriorTrimCarpetRearComp.TrimExteriorTrimCockpitModuleRemoveDoorsMainBodyHarnessGENERALASSEMBLYBUILDSEQUENCENAOCARONLYNOTE:Eventhoughvehiclepartitioningwillprobablybesimilar,futuresequencemayberevisedslightlytoreflectintegrationofTruck,IO,andBOP2.0.CommonMainAssemblyLineProductDifferentiationinSubassembliesKeyElements:•Commonassemblysequence•Offlinesubassembly•Commonsubassemblycontentandinterfacestothevehicle•FlexibleconveyanceandequipmentGlobalBillofProcess(BOP)CommonBuildSequenceandOperationContentBOP-MRtrainingclass4.pptPage7GMVOGMVOBOP.pptrev.10FE037BodyShopBOPGlobalBillofProcess(BOP)CommonBuildSequenceandOperationContentBOP-MRtrainingclass4.pptPage9Acommon,global,world-class,flexiblemanufacturingsystemtodeliverhighqualityatcompetitivecostexceedingcustomerexpectationsBOPVisionGuidingPrinciplesBOP-MRtrainingclass4.pptPage10ProtectManufacturingPortfolioFlexibility•CommonFlexibleMainLine•ProcessDrivenProductDesignRequirementsOptimizeManufacturingEfficiency•ProductDifferentiationandDifferencesinContentLevelareDriventoSubassembliesorModulesoffoftheMainLine•RegionalRequirementsDetermineAutomationLevel•On-LinePilotwithZeroLostUnitsPhasedImplementation•BOPCompatibleBOMComponents•ConcurrentwithProductArchitectureChangesGlobalBOPObjectivesBOP-MRtrainingclass4.pptPage14BOPImplementationStrategy•MigratetoBOPCompatibleProductArchitectures•ConvertUncommon,InflexibleManufacturingSystemstoCommon,FlexibleManufacturingFootprint(BOP)-BUT-•SpendMoneytoImplementBOPOnlyWhenProduct&ManufacturingSystemsMUSTBeChangedNewProductandNew“Greenfield”Plant:BOPCompliantBOP-MRtrainingclass4.pptPage15Compliancevs.CompatibilityCompliance:Thisspecificproductorprocessmeets100%oftheapplicableBOPrequirements.Compatibility:Thisspecificproductdoesnotmeet100%oftheapplicableBOPrequirements,butitcanbeprocessedonaBOPcompliantprocess-OR-Thisspecificprocessdoesnotmeet100%oftheapplicableBOPrequirements,butitcanaccommodateaBOPcompliantproduct.BOP-MRtrainingclass4.pptPage16ManufacturingRequirementsProcessMRManufacturingRequirementsMRManufacturingRequirementsCompliancevs.CompatibilityBOP-MRtrainingclass4.pptPage17WhatDoWeMeanby“ManufacturingRequirements(MR)”?•Global,CommonMethodtoBringBOPDirectlyIntoVehicleDevelopmentandManageProgramManufacturingRequirements–InitialListBroughtinFromtheBOP–TargetedBOPImplementationBasedonProgramSpecifics–ImplementBOPWhenMoneyIsSpentonProductorProcess•CriteriaThatEnableaVehicletoBeBuiltinGMPlants,Comprehending:–Assembly&BuildSequence–Equipment–VehicleSizeEnvelope–Efficiency,Ergonomics,etc.•TwoTypes:–1.Product(a.k.a.PDPD,orProcessDrivenProductDesign)–2.ProcessBOP-MRtrainingclass4.pptPage18MRExampleSubassemblyDesignStrategy:103Product1.7Aspidersubassemblywillconsistof:•arightandleftmotorcompartmentlowerrailsubassembly,•a#1barsubassembly,and•abumperbeamorrigidcrossmembertotietherightandleftrailstogetheratthefront.203Product1.9Frontwheelhouseassemblyisbroughttothemotorcompartmentmainlineasacompletedsubassembly/module.StationLevelManufacturingRequirementTypeBOP-MRtrainingclass4.pptPage19MRObjectives•EstablishLean,GloballyCommonProcess&ToolsIntegratedwithExistingCorporateProcesses•ImproveCommunicationBetweenProductandManufacturingEngineering•StrengthenVoiceofManufacturinginVehicleLineTeams(VLTs)•ImplementProcessDrivenProductDesigns(PDPD)•FacilitateEngineeringtoRequirements•DriveBOPImplementation•EnableCapitalReuseBOP-MRtrainingclass4.pptPage20DashPanelF/A&C/CCowlF/A&C/CPanelDashExtension4aSection4a703Product1.30Thecowlmusthavefore-aftandcrosscarsliptothedashsubassembly.StationLevelAddressManufacturingRequirementMRExampleDimensionalStrategy-BodyBOP-MRtrainingclass4.pptPage22543Product543Product3Product543Product541.20(SeedrawingItemA)DesignofmotorcompartmentlowersiderailsR/LincludesatoolingdatumlocatorforF/AandC/C,consistingofa40.1+0.1/-0.0mmhole,piercedandflangedupward.(NOA001)1.20.2(SeedrawingItemC).DesignofmotorcompartmentlowersiderailsR/LincludesprincipalU/Dlocatorscarri