1、BOP - MR training class4.ppt Page 1 Bill of Process BOP - MR training class4.ppt Page 2 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 t

2、o the product The 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 layout BOP - MR training class4.ppt Page 3 Press and Die BODYPAINTGA (General Assembly) Powertrain BOP - MR training cla

3、ss4.ppt Page 4 Common Build Sequence and Operation Content BOP - MR training class4.ppt Page 5 GMVOGMVOBOP.ppt rev. 10FE03 10 General Assembly BOP Roof Trim Fixed Glass Seats Front and Rear EM Modules Body / Chassis Marriage Rear Suspension Module Cradle Front Suspension Module Engine Dress Install

4、Doors CRFM Front and Rear Fascia Modules Wheels and Tires Interior Hardware Interior Trim Carpet Rear Comp. Trim Exterior Trim Cockpit Module Remove Doors Main Body Harness GENERAL ASSEMBLY BUILD SEQUENCE NAO CAR ONLY NOTE: Even though vehicle partitioning will probably be similar, future sequence m

5、ay be revised slightly to reflect integration of Truck, IO, and BOP 2.0. Common Main Assembly Line Product Differentiation in Subassemblies Key Elements: Common assembly sequence Off line subassembly Common subassembly content and interfaces to the vehicle Flexible conveyance and equipment Common Bu

6、ild Sequence and Operation Content BOP - MR training class4.ppt Page 6 GMVOGMVOBOP.ppt rev. 10FE03 7 Body Shop BOP Common Build Sequence and Operation Content BOP - MR training class4.ppt Page 7 Integrate Product Requirements with Manufacturing Capability to Produce: The Right Product At the Right T

7、ime At the Right Volume At the Right Cost In the Right Plant BOP - MR training class4.ppt Page 8 A common, global, world-class, flexible manufacturing system to deliver high quality at competitive cost exceeding customer expectations Guiding Principles BOP - MR training class4.ppt Page 9 Protect Man

8、ufacturing Portfolio Flexibility Common Flexible Main Line Process Driven Product Design Requirements Optimize Manufacturing Efficiency Product Differentiation and Differences in Content Level are Driven to Subassemblies or Modules off of the Main Line Regional Requirements Determine Automation Leve

9、l On-Line Pilot with Zero Lost Units Phased Implementation BOP Compatible BOM Components Concurrent with Product Architecture Changes BOP - MR training class4.ppt Page 10 Protect the health and safety of operators Develop product and process attributes which ensure high quality vehicles are provided

10、 to the customer Provide a common mainline manufacturing system* that supports the BFI and BOF product portfolio bandwidth Provide a common process framework for subassemblies / modules that supports customer Differentiators *Mainline is defined as product straight line flow from start of motor comp

11、artment assembly (BIW) to the “CARE” process. *Manufacturing system includes operation sequence, operation/module content, dimensional strategy, and major tool/ equipment interfaces. *Regional manufacturing requirements in terms of line rates, automation levels, ergonomic/safety requirements and veh

12、icle flex capacity. *Within manufacturing portfolio designated flex capacity. BOP - MR training class4.ppt Page 11 Provide product requirements that enable the common manufacturing system Provide common BOP solutions for the bandwidth of regional product simple racking (up to 6 JP H). Man. transfer

13、with assists as reqd. Man. load to rack / push cart - tugger to main line if reqd. LINE SIDE MINOR SUB ASSMS (2) Manual 6 clamp actions - Manual 3 sequences - Automatic (P LC) Man. U/B units to be simple changeable details for flexibility. Cart with drag chain Cart with drag chain BSO FRAMING SYSTEM

14、 Manual with assist 5 clamp actions per oper. - Manual 3 sequences - Automatic (P LC) Man. framing Flrpan Skin, Spider AEM with automatic hoist 4-15 JPH ELPOCombination of spray and dip stagesRelay Logic Controls, No HMI, Stand-alone Level Temperature Controls, No Automatic spray valves Manual push

15、on KBK rail with hoist (stop AEM with automatic hoist 4-15 JPH ELPO BAKEFloor level ovenRelay Logic Controls, No HMI, Stand-alone Temperature and manage information through global peer reviews Body Paint General Assembly Controls Dimensional Control Press & Stamping Normal machinery and equipment re

16、placement Projects (such as capacity increase or new vehicle content) New vehicle programs New vehicle assembly plant BOP - MR training class4.ppt Page 51 Allow a transition from the traditional Design, Build, Install, & Debug to Build & Install on identical systems, and minor Design and Debug on ne

17、arly identical systems Bill 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 initiatives BOP - MR training class4.ppt Page 52 “BOE” is a to

18、ol that will help us Drive Regionally Common. Process & Tooling Strategies Machinery & Equipment Improve BPD Metrics. Cost Manpower Floorspace BOP - MR training class4.ppt Page 53 Protect Manufacturing Portfolio Flexibility Common Flexible Main Line Process Driven Product Design Requirements Optimiz

19、e 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 Units Phased Implementation BOP Compatible BOM Components Concurrent with Prod

20、uct Architecture Changes BOP - MR training class4.ppt Page 54 Manufacturing Requirements Process M R Manufacturing Manufacturing RequirementsRequirements M R Manufacturing Manufacturing RequirementsRequirements BOP - MR training class4.ppt Page 55 Establish Lean, Globally Common Process & Tools Inte

21、grated 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 R

22、euse BOP - MR training class4.ppt Page 56 Dash Panel F/A & C/C Cowl F/A & C/C Panel Dash Extension 4a Section 4a 70 3 Product 1.30 The cowl must have fore-aft and cross car slip to the dash sub assembly. Station Level Address Manufacturing Requirement MR Example Dimensional Strategy - Body BOP - MR training class4.ppt Page 57 Incorporate agreed manufacturing requirements into the product and proces