基于精益制造开发平台的样车尺寸匹配

基于精益制造开发平台的样车尺寸匹配圣基尚源国际科技2013-07-28制造开发尺寸控制流程WhatistheGVDP?StyleManufactureVPIVDRSORPDSISourcingManageProgramCSRequirementsEngineer•TheGVDPdocumentsprogramlevelactivitiesfromDSItoSORP.ManyfunctionalactivitiesaredocumentedandtrackedatalowerlevelthantheGVDPdocumentation.•Thechartbelowshowswheredocumentationistrackedandamajorityofresourcesarecommittedattheprogramlevel.Shadedbarsindicatealowerlevelofresourcerequirements.PET/VLT/VPRReviews(continuousreviews)Deliverables&MetricsProgramImperativesPETVLTVPRPQRRTimingGVDP4.0Conceptualize/DesignDesign/DevelopLaunchReadinessContinuousImprovementProgramQualityReadinessReviewsPQRRDeliverablesERAparticipationVPIVehicleProgramInitiationDesignSign-OffCSOContractSign-OffVDRVerifiedDataReleaseIntegrationCriticalTeatCompleteValidationDocumentCompleteStartofSystemFillStartofRegularProductionDSOPQRRVPIPQRRDSOPQRRCSOPQRRVDRPQRRINTPQRRMVPQRRPRODPQRRSTCVehicleTestCompleteShiptoCommerceProductionManufacturingValidationProduct/ProcessVehicleValidationIntegrationVerifiedDataReleaseContractSign-OffDesignSign-OffVehicleProgramInitiationSORPSSFVDCVTCINTCritTestPQRRPVVDSI-181DTA-172AD-166VPIVehicleProgramInitiationAlternativesDevelopmentADManufactureVehicleVPIVDRSORPMatchingConceptDiesStructureDiesIntegrationDiesPVVGAManufactureMVB0102030407060508090100110120170160150140130180190200MMRMMRMMRCSDSICraftsmanshipPurposeofEvents-85………-73-65…….-59-48……-42-36……..-30-27…….-15-17……..-10-11………0VerifyDesignCoarsetoFineFinetomicroHighfidelitymathresultingfromdisciplinedvirtualassessmentsIterativefittingofdimensionallyknownGApartstoknownbodies.Agreementtobodyshopset-upandparttuning.Cadencedpartsubmissionstosupportiterativefitting&learningMatchingProcessM#(BorG)–Matching(BIWorG/A)BuildIB/IG/IM–Integration(CraftsmanshiporMatching)BuildMA–MathActivityCSO100%VDRSORP0MAIMBuildatValidationCenterBuildatplantTheMatchingprocessreliesuponearlyGMandsupplierinteractiontoincreasevehiclePerceivedQuality.Thefollowingfourphysicalvehiclebuildsfocusongaps,fits,finishes,andmaterialusagesforhundredsofaestheticinteriorandbodyparts:•Matching1:Usedtostartmakingcoarsebodyfitdecisionsusingfirstshotpartsoffofproductiontools•Matching2:UsedtovalidatethatMatching1decisions/fixeswereeffectiveandtomakedecisionsonfurtherbodyfitrefinementsusingupdatedmaterial.•Matching3:UsedtovalidatethatrefinedMatchingdecisions/fixeswereeffectiveandtoensurethatbodyfititemsarerobusttomanufacturingprocesses.•Matching4:Usedtovalidatethatfine-tunedMatching3decisions/fixeswereeffectiveandtomakedecisionsonfinalfitenhancements.Uponcompletionoftheprocess,partdesignsareupdatedtoreflectthefinalfitenhancements.M1BIWM1BIWM1GAM2BIWM2GAM3M4LowersUppers25242017151114820StartofSystemFill(SSF)23RedZones526MRD2MRD2MRD3MRD4MRD5MRD6MRD6StartofRegularProduction(SORP)NOMOREPRODUCTENGINEERINGCHANGEREQUESTSEXCEPTFORTHOSEAPPROVEDBYTHEPRODUCTIONLAUNCHTEAMNOMOREPROCESSCHANGEREQUESTS.521ProductionLaunchMilestonesBodyTestBodyTryout302223PPAP100%SaleableManufacturingConfirmation15MRD4MRD5M3M43827ManufacturingValidationBuildsSalableVehiclesNon-SalableVehiclesSalableVerificationBuildPVVBuild-Body&GAPPAPStatusAvailableRunatRate36100%ProductionTooledPartsAvailable1-236420piecesprovidedat–39/37usedtoprovidevehiclesin1st3bucketsDimensionallyknownpartsavailableforMVBbuildsEWOSOPEffectivePoint283046PPAP100%Approval•LaunchComplexitydeterminesthelengthofMVB•TheLaunchTeamwilldeterminethenumberofbuckets,quantitiesperbucketanddocumentastheProgramSpecificVehicleBuildPlan.EXAMPLEONLY-QUANTITIESVARYMVB—Non-Salable:Testoutproductiontooling,assemblyprocessandlogisticssystemsCompleteanyremainingvehiclesfortestingandtypeapprovalMVB—Salable:ValidatemanufacturingprocessUsesPPAPsalablepartsManufacturingValidationBuildsProductionPartApprovalProcess(PPAP)CSO100%VDRSORPBodyProductionToolsVTCGAProductionTools–MatchingGAProductionTools–Non-MatchingMatch1Match2M3M4MVB(ns)MVB(ns)PPAPStatusPPAPSaleablePPAPApproval100%R@RPPAPsubmissionby3weekspriorshouldensurestatusisavailableAllpartsshouldbesaleableatthistimeAllpartsshouldbe100%approvedPPAPStatusPPAPSaleablePPAPApproval10PillarDefinitionWeldingEnsuringallvehiclesadheretoproductandmanufacturingspecificationsforweldingSealingEnsuringallvehiclesadheretoproductandmanufacturingspecificationsforapplicationofadhesivesandsealantsDimensionalAchievingandmaintainingalevelofdimensionalperformancethatmeetsorexceedstargetswhilemeetingotherbusinessobjectivesSurfaceQualityAchievingandmaintainingalevelofexteriorsurfacequalitythatmeetsorexceedscustomerexpectationsasdefinedinGCAauditsTorqueThemonitoring,processandproductrequirementstoensurecompliancetothreadedfastenerinstallationspecifications.OptionVerificationEnsuringvehiclecontentmatchesvehicleorder11DimensionalPerformanceDimensionalperformanceisoneofthesix(6)pillarsofqualitythatdrivetheBodyShop•GlobalCustomerAudit(GCA)•DirectRunLoss(DRL)•JDPowers•ABCMetrics(PercentonTarget)•BodyStructureVariation(E31)•EngineeringDimensionalTechnicalSpecifications(DTS)•FeedbackitemsfromGeneralAssembly(GA)andPaint12RedXTeams&VAESuppilerQ