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1、BOP - MR training class4.ppt Page 1 Bill of Process Manufacturing Requirements Process Bill of Equipment MR Manufacturing Requirements BOP - MR training class4.ppt Page 2 Bill of Process BOP - MR training class4.ppt Page 3 Global Bill of Process (BOP) Globally common, balanced, and documented approa

2、ch 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 equipm

3、ent, level of automation/manpower, or plant layout BOP - MR training class4.ppt Page 4 Press and Die BODY PAINT GA (General Assembly) GMs Manufacturing Systems: Each has a Bill of Process (BOP) Powertrain BOP - MR training class4.ppt Page 5 Global Bill of Process (BOP) Common Build Sequence and Oper

4、ation Content BOP - MR training class4.ppt Page 6 G M V OG M V OB OP .p pt r ev . 10F E 03 10 Gen er al A s s em bl y B OP R o o f T r i m F i x e d G l a s s S e a ts F r o n t a n d R e a r E M M o d u l e s B o d y / C h a s s i s M a r r i a g e R e a r S u s p e n s i o n M o d u l e C r a d l

5、e F r o n t S u s p e n s i o n M o d u l e E n g i n e D r e s s I n s t a l l D o o r s C R F M F r o n t a n d R e a r F a s c i a M o d u l e s W h e e l s a n d T i r e s I n t e r i o r H a r d w a r e I n t e r i o r T r i m C a r p e t R e a r C o m p . T r i m E x t e r i o r T r i m C o c

6、k p i t M o d u l e R e m o v e D o o r s M a i n B o d y H a r n e s s G 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 E N A O C A R O N L Y N O T E : E v e n t h o u g h v e h ic le p a r t it io n in g w ill p r o b a b ly b e s im ila r , f u t u r e s e q u e n c e m a y b e r e v is e d

7、s lig h t ly t o r e f le c t in t e g r a t io n o f T r u c k , I O , a n d B O P 2 . 0 . Co mmo n M ain A ss em b l y L i n e Pro d u ct Di ff er en ti ati o n i n S u b as se mb l i es K e y E le m e nt s : C om mo n a s s e mb l y s e qu e nce Of f li ne s ub a s s e mb l y C om mo n s ub a s s

8、 e mb l y c o nt e nt a nd int e rf a c e s t o t he v e hic le Fle x ibl e c on v e y a n c e a nd e qu ipment Global Bill of Process (BOP) Common Build Sequence and Operation Content BOP - MR training class4.ppt Page 7 G M V OG M V OB OP .p pt r ev . 10F E 03 7 B od y S ho p BO P Global Bill of Pr

9、ocess (BOP) Common Build Sequence and Operation Content BOP - MR training class4.ppt Page 9 A common, global, world-class, flexible manufacturing system to deliver high quality at competitive cost exceeding customer expectations BOP Vision Guiding Principles BOP - MR training class4.ppt Page 10 Prot

10、ect 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 Automati

11、on Level On-Line Pilot with Zero Lost Units Phased Implementation BOP Compatible BOM Components Concurrent with Product Architecture Changes Global BOP Objectives BOP - MR training class4.ppt Page 14 BOP Implementation Strategy Migrate to BOP Compatible Product Architectures Convert Uncommon, Inflex

12、ible Manufacturing Systems to Common, Flexible Manufacturing Footprint (BOP) - BUT - Spend Money to Implement BOP Only When Product s im p le ra c k in g (u p t o 6 J P H ) . M a n . t ra n s fe r w it h a s s is t s a s re q d . M a n . lo a d t o ra c k / p u s h c a rt - t u g g e r t o m a in li

13、n e if re q d . L IN E S ID E M IN O R S U B A S S M S (2 ) M a n u a l 6 c la m p a c t io n s - M a n u a l 3 s e q u e n c e s - A u t o m a t ic (P L C ) M a n . U / B u n it s t o b e s im p le c h a n g e a b le d e t a ils fo r fl e x ib ilit y . C a rt w it h d ra g c h a in C a rt w it h d

14、ra g c h a in B S O F R A M IN G S Y S T E M M a n u a l w it h a s s is t 5 c la m p a c t io n s p e r o p e r. - M a n u a l 3 s e q u e n c e s - A u t o m a t ic (P L C ) M a n . fra m in g F lrp a n S k in , S p id e r AE M w ith a u to m a tic h o is t 4 - 1 5 J P H E L P O C o m b in a tio n

15、 o f s p r a y a n d d ip s ta g e s R e la y L o g ic C o n tr o ls , N o H M I, S ta n d - a lo n e L e v e l T e m p e r a tu r e C o n tr o ls , N o Au to m a tic s p r a y v a lv e s M a n u a l p u s h o n K B K r a il w ith h o is t ( s to p AE M w ith a u to m a tic h o is t 4 - 1 5 J P H E

16、L P O B AK E F lo o r le v e l o v e n R e la y L o g ic C o n tr o ls , N o H M I, S ta n d - a lo n e T e m p e r a tu r e A i r o v e r r e f r i d g e r a n t c h a r g e w / m a s s f l o w m e t e r c o n t r o l E n g i n e C o o l a n t - E v a c M a n ., P e d . M a n ., P e d . M a n . / r

17、 o b . l o a d t o r a c k - t u g g e r t o m a i n l i n e . S a m p l i n g - C M M w / h o l d i n g f i x t ./ p a l l e t B O D Y S ID E I N R D e d i c a t e d h e m p r e s s e s f o r e a c h l i n e . R o b o t i c t r a n s f e r L a s e r K i t f o r f i n i s h e d v e h .- g a p F l r

18、p a n S k i n , S p i d e r and manage information through global peer reviews Global Bill of Equipment When 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)

19、 New vehicle programs New vehicle assembly plant BOP - MR training class4.ppt Page 52 Allow a transition from the traditional Design, Build, Install, & Debug to Build & Install on identical systems, and minor Design and Debug on nearly identical systems Bill of Equipment enables Global use of region

20、ally 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 Global Bill of Equipment Benefits BOP - MR training class4.ppt Page 53 Global Bill of Equipment (BOE) Benefits “ BOE” is a tool that will help us Drive Regionally Common . Process & Tooling Strategies Machinery & Equipment Improve BPD Metrics . Cost Manpower Floorspace