Bill of ProcessManufacturing Requirements ProcessBill of EquipmentBill of ProcessGlobal Bill of Process (BOP)Globally common, balanced, and documented approach for Manufacturing and Assembling VehiclesBuild sequenceOperation contentDimensional strategySubassembly design strategyMajor 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 layoutPress and DieBODYPAINTGA(General Assembly) GMs Manufacturing Systems: Each has a Bill of Process (BOP) PowertrainGlobal Bill of Process (BOP)Global Bill of Process (BOP) Common Build Sequence and Operation Common Build Sequence and Operation ContentContentGlobal Bill of Process (BOP)Global Bill of Process (BOP) Common Build Sequence and Common Build Sequence and Operation ContentOperation ContentGlobal Bill of Process (BOP)Global Bill of Process (BOP) Common Build Sequence and Common Build Sequence and Operation ContentOperation ContentA common, global, world-class, flexible manufacturing system to deliver high quality at competitive cost exceeding customer expectationsBOP VisionGuiding PrinciplesProtect Manufacturing Portfolio FlexibilityCommon Flexible Main LineProcess Driven Product Design RequirementsOptimize Manufacturing EfficiencyProduct Differentiation and Differences in Content Level are Driven to Subassemblies or Modules off of the Main LineRegional Requirements Determine Automation LevelOn-Line Pilot with Zero Lost UnitsPhased ImplementationBOP Compatible BOM ComponentsConcurrent with Product Architecture ChangesGlobal BOP ObjectivesBOP Implementation StrategyMigrate to BOP Compatible Product ArchitecturesConvert 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 CompliantCompliance 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.Manufacturing Requirements ProcessCompliance vs. CompatibilityWhat Do We Mean by “Manufacturing Requirements (MR)?Global, Common Method to Bring BOP Directly Into Vehicle Development and Manage Program Manufacturing RequirementsInitial List Brought in From the BOPTargeted BOP Implementation Based on Program SpecificsImplement BOP When Money Is Spent on Product or ProcessCriteria That Enable a Vehicle to Be Built in GM Plants, Comprehending:Assembly & Build SequenceEquipmentVehicle Size EnvelopeEfficiency, Ergonomics, etc.Two Types:1. Product (a.k.a. PDPD, or Process Driven Product Design)2. Process 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 RequirementTypeMR ObjectivesEstablish Lean, Globally Common Process & Tools Integrated with Existing Corporate ProcessesImprove Communication Between Product and Manufacturing EngineeringStrengthen Voice of Manufacturing in Vehicle Line Teams (VLTs)Implement Process Driven Product Designs (PDPD)Facilitate Engineering to RequirementsDrive BOP ImplementationEnable Capital Reuse 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 - Body543Product543 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 Agreement MilestonesPre-VPI RequirementsArchitecture - InitialBOM Row SelectionConcept PartsStructure PartsIntegration PartsManufacturing RequirementsProcess Flow - ExampleMVNSxx/xx/xxxx/xx/xxEOASFSOPCSOG/APaintBodyBOPReqtsLoad 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(SORs)IntegrationAgrees(others)Execute T2ProductVerify ProcessVerify Structure Agrees(SORs)StructureAgrees(others)Execute T2ProductVerify ProcessVerify Concept Agrees(SORs)ConceptAgrees(others)Execute T2ProductVerify ProcessVerify AgreementAn 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.ExecutionIncorporate agreed manufacturing requirements into the product and process designs This is the responsibility of each Manufacturing Engineer and Product EngineerProgram Vehicle DesignProgramManufacturingSystem DesignGBIST 9/18/01VerificationWhat is Verification?A confirmation of what the program executed relative to the agreed Manufacturing RequirementsWhy 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)? ME ResponsibilitiesReview initial BOP requirementsWrite / modify program requirement textEstablish all PROCESS requirements Evaluate and set BOP Target and StatusEnter ME Agreement Status on all requirementsWork with the PE owner to establish all PRODUCT requirements Promptly elevate all requirements that are not coming to agreementUse requirements as input to designs and SORsVerify requirement was implementedAdd new non-BOP requirements when necessaryKeep ME owner name/phone number up-to-date and include additional ME owners as necessaryNo More.Now I Can.Easily Locate All My RequirementsDocument AgreementsSee What Other Engineers Agreed To, Including Those Upstream PeopleSay What We Really Need on a Program, Including Non-BOP ItemsCommunicate 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 UpstreamWhats In It for a ME Owner?PE ResponsibilitiesWork with the ME to establish all PRODUCT requirementsEnter PE Agreement Status for each requirementPromptly elevate all requirements that are not coming to agreementUse requirements as input to designs and SORsKeep PE owner name/phone number up-to-date and include additional PE owners as necessaryWhats 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?PastNowManagement RoleAsk the Right Questions to Drive MR ProcessActively Support Use of GM Common MR Process - Incorporate in Performance MetricsMonitor Status of MR Deliverables - Include in Staff Meetings / Scheduled Program ReviewsAssist in Issue Resolution - Break RoadblocksChallenge Decisions Not to Meet BOP Targets or Existing AgreementsGlobal Bill of Equipment (BOE)Global Bill of Equipment (BOE)Global Bill of Equipment (BOE)Global Bill of Equipment (BOE)BOE compared to BOPBOE compared to BOPBOP (Bill of Process) documents a common sequence on how to put vehicles togetherBOE (Bill of Equipment) documents the equipment and tooling used to put the vehicles togetherCommon Build Sequence and Operation ContentGlobal Bill of Process (BOP)Global Bill of Process (BOP)The BOP does not prescribe specific equipment,level of automation / manpower, or plant layout, i.e., “the BOE does thatBuild sequenceOperation contentDimensional strategySubassembly design strategyMajor 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 BOPGlobal Bill of Equipment (BOE)Global Bill of Equipment (BOE)BOE compared to BOPBOE compared to BOPThe 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., BOEs that allow General Motors to be competitive in ALL Global regions. 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 Global Bill of EquipmentGlobal Bill of EquipmentProduction Rate (NWR)Labor RateLow ($35US)Low(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 CArlingtonBaltimoreWentzvilleOKCNUMMINALAAMGMEAPMishawaka124365896Identical for cells 1 through 9Identical for cells 1 through 9May be different for cells 1 through May be different for cells 1 through 9 9Global BOP Key ElementsBuild sequenceOperation contentDimensional strategySubassembly design strategyMajor tool and equipment interfaces to the productGlobal BOE Key ElementsTooling/Machinery and equipment typeAutomatic vs. manual operationsConveyance strategy and type Operation layoutMaterial handling and presentationBOP is identical for all production and BOP is identical for all production and BOP is identical for all production and BOP is identical for all production and BOP is identical for all production and BOP is identical for all production and labor rates, while the BOE can varylabor rates, while the BOE can varylabor rates, while the BOE can varylabor rates, while the BOE can varylabor rates, while the BOE can varylabor rates, while the BOE can varyGlobal BOP vs. Global BOE !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 BOE is aboutBOE is aboutResource UtilizationResource UtilizationBody Assembly BOP and BOE ExamplesGlobal Bill of Equipment DevelopmentGlobal Bill of Equipment Development Global Bill of Equipment (BOE)Production Rate (NWR)Labor RateLow Medium High LowMedium High GMAPGMAPGMAPGMNAGMNAGMNAGMNAGMNAGMNAGMNAGMNAGMNAGMNAGMNAGMNAGMEGMELAAMLAAM123654789With Regional AssignmentsEach BOE Cell was assigned to the most appropriate global region for initial BOE draft developmentGlobal Bill of Equipment DevelopmentGlobal Bill of Equipment Development GLOBAL BILL GLOBAL BILL GLOBAL BILL OF EQUIPMENTOF EQUIPMENTOF EQUIPMENTBODY BODY BODY SHOPSHOPSHOPGENERAL GENERAL GENERAL ASSEMBLYASSEMBLYASSEMBLYPAINT PAINT PAINT SHOPSHOPSHOP“BOEs on a Page are being developed for each of the 9 cells in each of the three areas (Body, Paint, and General Assembly).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 BOPGlobal Bill of Equipment DevelopmentGlobal Bill of Equipment DevelopmentA Bill of Equipment within a functional area may be shared among multiple production / labor rate combinationsBody Shop BOEBody Shop BOEExampleExampleCell 1Inner & Outer Manual Weld Framing StationLow volume / low labor rate project in LAAMBody Shop BOEBody Shop BOEExampleExampleCell 9 Inner & Outer Robotic Weld Framing StationHigh volume / high labor rate project in NAVehicle 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 BOEBodyPaintGeneral AssemblyControlsDimensional ControlPress & StampingNormal machinery and equipment replacementProjects (such as capacity increase or new vehicle content)New vehicle programsNew vehicle assembly plantAllow a transition from the traditionalDesign, 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 BenefitsBenefitsGlobal Bill of Equipment (BOE)Global Bill of Equipment (BOE)BenefitsBenefits “BOE is a tool that will help us Drive Regionally Common. Process & Tooling Strategies Machinery & Equipment Improve BPD Metrics. Cost Manpower Floorspace