【正文】 BOP MR training Page 1 Bill of Process Manufacturing Requirements Process Bill of Equipment MRManufacturing RequirementsBOP MR training Page 2 Bill of Process BOP MR training Page 3 Global Bill of Process (BOP) Globally mon, 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 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 Page 4 Press and Die BODY PAINT GA (General Assembly) GM’s Manufacturing Systems: Each has a Bill of Process (BOP) Powertrain BOP MR training Page 5 Global Bill of Process (BOP) Common Build Sequence and Operation Content BOP MR training Page 6 G M V OG M V OB O P .p p t r e v . 1 0 F E 0 3 10G e nera l A s s e mb l y BO PR o o f T r i mF i x e d G l a s sS e a t sF r o n t a n d R e a rE M M o d u l e sB o d y / C h a s s i sM a r r i a g eR e a r S u s p e n s i o nM o d u l eC r a d l eF r o n t S u s p e n s i o nM o d u l eE n g i n e D r e s sI n s t a l lD o o r sC R F MF r o n t a n d R e a rF a s c i a M o d u l e sW h e e l s a n d T i r e sI n t e r i o rH a r d w a r eI n t e r i o rT r i mC a r p e tR e a r C o m p .T r i mE x t e r i o rT r i mC o c k p i t M o d u l eR e m o v eD o o r sM a i n B o d yH a r n e s sG E N E R A L A S S E M B L Y B U I L D S E Q U E N C EN A O C A R O N L YN O T E : E v e n t h o u g h v e h i c l e p a r t i t i o n i n g w i l l p r o b a b l y b es i m i l a r , f u t u r e s e q u e n c e m a y b e r e v i s e d s l i g h t l y t o r e f l e c ti n t e g r a t i o n o f T r u c k , I O , a n d B O P 2 . 0 .C om m on M a in A s s e m bl y Li neP r oduc t D iffe r e ntia tio n in S uba s s e m bli e sKe y E l e m e nts :? Com m on a s s e m bl y s e que nc e? O ff l i ne s uba s s e m bl y? Com m on s uba s s e m bl y c o nte nt a nd i nte rfa c e s to the v e hi c l e? Fl e x i bl e c on v e y a n c e a nd e qui pm e ntGlobal Bill of Process (BOP) Common Build Sequence and Operation Content BOP MR training Page 7 G M V OG M V OB O P .p p t r e v . 1 0 F E 0 3 7Bo dy Sh op B O PGlobal Bill of Process (BOP) Common Build Sequence and Operation Content BOP MR training Page 9 A mon, global, worldclass, flexible manufacturing system to deliver high quality at petitive cost exceeding customer expectations BOP Vision Guiding Principles BOP MR training Page 10 Protect Manufacturing 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 Level ? OnLine Pilot with Zero Lost Units Phased Implementation ? BOP Compatible BOM Components ? Concurrent with Product Architecture Changes Global BOP Objectives BOP MR training Page 14 BOP Implementation Strategy ? Migrate to BOP Compatible Product Architectures ? Convert Unmon, Inflexible Manufacturing Systems to Common, Flexible Manufacturing Footprint (BOP) BUT ? Spend Money to Implement BOP Only When Product amp。 Manufacturing Systems MUST Be Changed New Product and New “Greenfield” Plant: BOP Compliant BOP MR training Page 15 Compliance vs. Compatibility Compliance: 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 pliant process OR This specific process does not meet 100% of the applicable BOP requirements, but it can acmodate a BOP pliant product. BOP MR training Page 16 Manufacturing Requirements Process MRManufacturing RequirementsCompliance vs. Compatibility BOP MR training Page 17 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 amp。 Build Sequence – Equipment – Vehicle Size Envelope – Efficiency, Ergonomics, etc. ? Two Types: – 1. Product (. PDPD, or Process Driven Product Design) – 2. Process BOP MR training Page 18 MR Example Subassembly Design Strategy: 10 3 Product A spider subassembly will consist of: ? a right and left motor partment 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. 20 3 Product Front wheel house assembly is brought to the motor partment main line as a pleted subassembly/module. Station Level Manufacturing Requirement Type BOP MR training Page 19 MR Objectives ? Establish Lean, Globally Common Process amp。 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 Reuse BOP MR tra