通用汽车BOE、BOP.ppt

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 Vehicles•Build sequence•Operation content•Dimensional strategy•Subassembly design strategy•Major 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 DieBODYPAINTGA(General Assembly) GM’s 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 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 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 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 Flexibility•Common Flexible Main Line•Process Driven Product Design RequirementsOptimize Manufacturing Efficiency•Product Differentiation and Differences in Content Level are Driven to Subassemblies or Modules off of the Main Line•Regional Requirements Determine Automation Level•On-Line Pilot with Zero Lost UnitsPhased Implementation•BOP Compatible BOM Components•Concurrent with Product Architecture ChangesGlobal BOP ObjectivesBOP - MR training class4.pptPage BOP Implementation Strategy•Migrate to BOP Compatible Product Architectures•Convert Uncommon, Inflexible Manufacturing Systems to Common, Flexible Manufacturing Footprint (BOP)- BUT - •Spend 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 specific 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 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 Requirements–Initial List Brought in From the BOP–Targeted BOP Implementation Based on Program Specifics–Implement BOP When Money Is Spent on Product or Process•Criteria That Enable a Vehicle to Be Built in GM Plants, Comprehending:–Assembly & Build Sequence–Equipment–Vehicle Size Envelope–Efficiency, Ergonomics, etc.•Two Types:–1. Product (a.k.a. PDPD, or Process Driven Product Design)–2. Process BOP - 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 Product 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 Objectives•Establish Lean, Globally Common Process & Tools Integrated with Existing Corporate Processes•Improve Communication Between Product and Manufacturing Engineering•Strengthen Voice of Manufacturing in Vehicle Line Teams (VLTs)•Implement Process Driven Product Designs (PDPD)•Facilitate Engineering to Requirements•Drive BOP Implementation•Enable Capital ReuseBOP - MR training class4.pptPage  70 3 Product1.30 The cowl 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 includes 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. Height 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 forward 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 Flow - ExampleMVNSxx/xx/xxxx/xx/xxEOASFSOPCSOG/APaintBodyBOPReq'tsLoad MRDBComplete BOP & BOE TargetsMR Game PlanMR Game PlanMRRMRRAVDRVPIRManagement ApprovalsVDP Execution WorkBoundary ConditionsDesign IntentAlternatives DevelopmentDesign Theme AlternativeVPI PrepGMNA OnlyCSPRVPIDSI-164-145-131-117-106+26-176-158Add Additional Program MRsPre-VPI AgreesExecute ProductVerify T2Arch BOM AgreesBody Arch BOM AgreesProcessVerify Integration Agrees(SOR’s)IntegrationAgrees(others)Execute T2ProductVerify ProcessVerify Structure Agrees(SOR’s)StructureAgrees(others)Execute T2ProductVerify ProcessVerify Concept Agrees(SOR’s)ConceptAgrees(others)Execute T2ProductVerify ProcessVerify BOP - MR training class4.pptPage BOP - MR training class4.pptPage Agreement•An 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 support 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.BOP - MR training class4.pptPage BOP - MR training class4.pptPage Execution•Incorporate agreed manufacturing requirements into the product and process designs •This is the responsibility of each Manufacturing Engineer and Product EngineerProgram Vehicle DesignProgramManufacturingSystem DesignBOP - MR training class4.pptPage GBIST 9/18/01Verification•What is Verification?–A confirmation of what the program executed relative to the agreed Manufacturing Requirements•Why 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 do? –Are we driving to the common manufacturing system (BOP)? BOP - MR training class4.pptPage BOP - MR training class4.pptPage ME Responsibilities•Review initial BOP requirements•Write / modify program requirement text•Establish all PROCESS requirements •Evaluate and set BOP Target and Status•Enter ME Agreement Status on all requirements•Work with the PE owner to establish all PRODUCT requirements •Promptly elevate all requirements that are not coming to agreement•Use requirements as input to designs and SORs•Verify requirement was implemented•Add new non-BOP requirements when necessary•Keep ME owner name/phone number up-to-date and include additional ME owners as necessaryBOP - MR training class4.pptPage No More...Now I Can..•Easily Locate All My Requirements•Document Agreements•See What Other Engineers Agreed To, Including Those Upstream People•Say What We Really Need on a Program, Including Non-BOP Items•Communicate 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 UpstreamWhat’s In It for a ME Owner?BOP - MR training class4.pptPage PE Responsibilities•Work with the ME to establish all PRODUCT requirements•Enter PE Agreement Status for each requirement•Promptly elevate all requirements that are not coming to agreement•Use requirements as input to designs and SORs•Keep PE owner name/phone number up-to-date and include additional PE owners as necessaryBOP - MR training class4.pptPage What’s 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 here...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 Role•"Ask the Right Questions" to Drive MR Process•Actively Support Use of GM Common MR Process - Incorporate in Performance Metrics•Monitor Status of MR Deliverables - Include in Staff Meetings / Scheduled Program Reviews•Assist in Issue Resolution - Break Roadblocks•Challenge Decisions Not to Meet BOP Targets or Existing AgreementsBOP - MR training class4.pptPage Global Bill of Equipment (BOE)Global Bill of Equipment (BOE)BOP - MR training class4.pptPage Global Bill of Equipment (BOE)Global Bill of Equipment (BOE)BOE compared to BOPBOE compared to BOPBOE compared to BOP•BOP (Bill of Process) documents a common sequence on how to put vehicles together•BOE (Bill of Equipment) documents the equipment and tooling used to put the vehicles 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 sequence•Operation content•Dimensional strategy•Subassembly design strategy•Major 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 Equipment (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 BOP•The BOE describes nine different yet similar equipment sets including level of automation 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., BOE’s that allow General Motors to be 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 EquipmentProduction Rate (NWR)Labor RateLow (<$15US)Medium ($15-35US)High (>$35US)Low(<15 JPH)Medium (15-40 JPH)High (>40JPH)Lansing Craft CenterSGMW SparkYantaiTolucaJin BeiVietnam / IndiaTrollhatenEisenachCAMILuton IBCSpring Hill 1Flint 1 & 2LGRSpring Hill 2Bowling GreenSGMW EastSao Caetano ShanghaiBupyung 2Gravatai / RosarioGliwiceThailandAzambujaSao JoseGunsanBupyung 1RamosChangwonSilaoAntwerpBochumRusselsheimEllesmere PortZaragozaElizabethOshawa 1Oshawa 2Oshawa Truck LordstownDoravilleMoraineOrionFort WayneD-Hamtramck ShreveportWilmingtonJanesvilleFairfaxPontiacLansing MLindenLansing CArlingtonBaltimoreWentzvilleOKCNUMMINALAAMGMEAPMishawaka124365896BOP - MR training class4.pptPage Identical for cells 1 through 9May be different for cells 1 through 9Global BOP Key Elements•Build sequence•Operation content•Dimensional strategy•Subassembly design strategy•Major tool and equipment interfaces to the productGlobal BOE Key Elements•Tooling/Machinery and equipment type•Automatic vs. manual operations•Conveyance strategy and type •Operation layout•Material handling and presentationBOP is identical for all production and labor BOP is identical for all production and labor rates, while the BOE can varyrates, while the BOE can varyGlobal BOP vs. Global BOE !BOP - MR training class4.pptPage Framer SpecificationsBody Side Inners & OutersLoaded in Sequence on Mainline 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 LoadConveyor/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 DevelopmentDevelopmentDevelopment 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 developmentBOP - 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“BOE’s on a Page” are being developed for each of the 9 cells – in each 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 RateProduction 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 Equipment 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 BOEBody Shop BOEExampleExampleExampleCell 9 Inner & Outer Robotic Weld Framing StationHigh volume / high labor rate project in NABOP - MR training class4.pptPage Vehicle AssemblyPlants Select vehicle assembly plant machinery and Equipment from the Global Bill of Equipment; and manage information through global peer reviewsGlobal Bill of Equipment Global Bill of Equipment When to Use the BOEWhen to Use the BOEWhen to Use the BOE•Body•Paint•General Assembly•Controls•Dimensional Control•Press & Stamping•Normal machinery and equipment replacement•Projects (such as capacity increase or new vehicle content)•New vehicle programs•New vehicle assembly plantBOP - MR training class4.pptPage Allow a transition from the traditional…Design, Build, Install, & Debug to Build & Install on identical systems, and minor Design and Debug on nearly identical systemsBill of Equipment enables Global use of regionally common equipment within a given CELL and allows our processes and assembly plants to become the “Best of the Best” through focused long term Continuous Improvement initiativesGlobal Bill of Equipment Global Bill of Equipment BenefitsBenefitsBenefitsBOP - MR training class4.pptPage Global Bill of Equipment (BOE)Global Bill of Equipment (BOE)BenefitsBenefitsBenefits “BOE” is a tool that will help us…• Drive Regionally Common….• Process & Tooling Strategies• Machinery & Equipment • Improve BPD Metrics….• Cost• Manpower• FloorspaceBOP - MR training class4.pptPage 。