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GVDP: Global Vehicle Development Process for General Motors
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GVDP Visitor Safety Protocol • In case of emergency (Fire, Tornado, etc.) in this building: An announcement will be made over the public address system to all buildings • To exit this building: Choose the nearest exit and proceed carefully • For emergency shelter: Proceed to the basement, or the nearest designated shelter area • For Emergency Telephone: Contact Security and stay on line until help arrives • Location of the nearest Medical Facility: Contact Building Security • Other Safety Requirements include: If you will be entering a shop area, appropriate safety discussions will be conducted and any appropriate safety equipment will be issued AT GM, SAFETY IS THE OVERRIDING PRIORITY ALL ACCIDENTS CAN BE PREVENTED Agenda Process What it is What it contains Architecture/Program Development Vehicle Development by Sub-Phase Process Measurement Imperatives Metrics Summary Agenda Process What it is What it contains Architecture/Program Development Vehicle Development by Sub-Phase Process Measurement Imperatives Metrics Summary The Vehicle Development Process is: The process for bringing a vehicle to the marketplace from Planning to Production; A plan for General Motors to get common globally while maintaining our focus on speed to market. Common globally means using the same VDP in all regions where General Motors conducts vehicle development activities Process History GVDP was originally developed, and continues to evolve, to respond to a number of corporate strategies including: • Globalization of General Motors • An increased focus on program lead-time reduction • Improved use of limited Product Development resources • Alignment of Corporate Architecture and Program Governance These strategic process imperatives must be met to compete effectively in a global market place. What is the VDP? The process for bringing a vehicle to the marketplace from Planning to Production. A plan for General Motors to get Common Globally while maintaining our focus on speed to market. The Vehicle Development Process defines the “What and When” and the functions define and execute the “How” Defines when Milestone Templates for Vehicle Program Plan Templates Defines what Activities / Deliverables Templates for Defines how Work Instructions Common Globally means using the same VDP in all regions where General Motors conducts vehicle development activities Functional Plans Underlying GVDP Philosophies 1. Early underbody development supports GM’s global architecture sharing strategy 2. Structured decision and release progression enables overlapping vehicle development 3. Early involvement by critical decision makers 4. Earlier product/process learning cycles reduce late changes 5. Integrated virtual learning cycles reduce the need for physical hardware 6. Manufacturing Process driven product design 7. Component and subsystem sourcing tied to design progression 8. Globally common core processes facilitate work sharing GVDP Terminology Milestones indicate the start or the end of some significant period of work. It also indicates the beginning of the next sub phase. DSI -184 Timing of Milestones is indicated in weeks from SORP Timing of GVDP templates are indicated in months PQRR Program Quality Readiness Reviews (PQRR) support the review of Critical to Quality and Critical to Readiness GVDP deliverables Market clinic events to support design and financial assessment GVDP 5.1 PQRR PFI PQRR DSI PQRR PQRR PQRR VPI CSO VDR PQRR SORP 23 Months 35 Months CSO – Contract Sign Off DSI – Document of Strategic Intent SORP – Start of Regular Production VDR – Verified Data Release Link to Templates Slide VPI – Vehicle Program Initiation VTS – Vehicle Technical Specifications Element documentation in GVDP Process: Function / SME / VDP Owner Element Name / Number Deliverable Description Requirements Related links Program: Owner Examples / Templates Activity Description Activity Purpose Deliverable Name Timing (Start / End) GVDP 5.1 Program Templates DSI AFI New 55/48/35/23 Major 48/35/23 AA 56 DSI PFI DSI DSI 24 DSI PFI 31 DSI DSI 24 CSO VPI 36 18 CSO VPI 31 LCI 36 LPI LPE 99 weeks SORP 44 105 weeks LPE 16 29/25/21 SORP VDR VDR LPI Annual 99 weeks 18 16 38/34/24 SORP VDR SORP VDR 20 90 weeks SORP CKDI CKD/SKD 90 weeks 21 N = New AFI or DSI – VPI or LPI Underbody New AFI Major GVDP 5.0 Program Templates M = Modified I = Identical Color Under body Mule Arch. New to Plant N N Yes Yes N N N No Yes M M I M/N No No I I I/M I M/N No No I I I I I I No No I I I I I I No No Elect Powertrain Int/Ext Styling Material N N N N DSI-VPI M N/M N LCI LPI I I Annual (Obsolete after MY14) LPI I Complete Knock-Down (CKD) CKDI Import / SUP SUPIi LP! – Lifecycle Program Initiation CSO – Contract Sign Off DSI – Document of Strategic Intent SORP – Start of Regular Production VDR – Verified Data Release VPI – Vehicle Program Initiation Back GVDP 5.1 Program Template Timing What do the numbers (55/45/35/23) in the template name mean? 55 Months AFI to SORP 45 Months PFI to SORP 35 Months VPI to SORP Architecture Framing Initiation Architecture Approval AFI AA SOP 23 Months VDR to SORP Architecture Development Program Framing Document of Strategic Intent Initiation PFI DSI Program Development Vehicle Program Initiation Styling Freeze Verified Data Release VPI SF VDR Theme Development & Release Engineering Development & Release First Integration Vehicle Complete FIVC Virtual and Physical Validation Powertrain and Calibration Development Manufacturing Tooling & Launch Start Of Regular Production SORP GVDP Templates are primarily based upon allowable content changes Link to Template Guidelines Agenda Process What it is What it contains Architecture/Program Development Vehicle Development by Sub-Phase Process Measurement Imperatives Metrics Summary Global Engineering and Design Centers (11:00 a.m.) (8:00 p.m.) (12:00 noon) (6:00 a.m.) (3:00 a.m.) (7:00 p.m.) (5:00 a.m.) (4:30 p.m.) (9:00 a.m.) (1:00 p.m.) (10:00 p.m.) GVDP 5.1 Framework AFI PFI DSI VPI VDR SORP Architecture Styling Engineering Validation Tool / Launch AFI – Architecture Framing Initiation DSI – Document of Strategic Intent PFI – Program Framing Initiation SORP – Start of Regular Production VDR – Verified Data Release VPI – Vehicle Program Initiation GVDP 5.1 High Level Framework Architecture Framing Initiation AFI Architecture Statement of Strategic Intent Review ASSI Review Architecture Approval Global Vehicle Development Process AA Architecture Development Program Framing Initiation Vehicle Program Initiation Document of Strategic Intent Engrg Contract Verified Sign Styling Sign Data VPI DSI PFI Off Freeze Off Release First ESO SF CSO VDR Integration Vehicle Program Development Complete Single Refine Theme Altern. Single Alt. Theme Theme Release Theme Develop Theme Development & Release FIVC Market Validation Review MVR Engineering Development Engineering Validation Start Of Regular Production SORP Manufacturing Tools & Equipment Launch GVDP 5.1 High Level Framework Architecture Framing Initiation AFI Architecture Statement of Strategic Intent Review ASSI Review Architecture Approval AFI to AA AA Architecture Development Program Framing Initiation PFI to VPI Vehicle Program Initiation Document of Strategic Intent Engrg Contract Verified Sign Styling Sign Data VPI DSI PFI Off Freeze Off Release First ESO SF CSO VDR Integration Vehicle Program Development Complete Single Refine Theme Altern. Single Alt. Theme Theme Release Theme Develop Theme Development & Release FIVC Market Validation Review MVR Engineering Development Engineering Validation Start Of Regular Production SORP Manufacturing Tools & Equipment Launch Product Development Begins with the Portfolio Plan Portfolio Planning Ongoing • Utilize the global portfolio planning matrix to: – Continually monitor and assess the competitiveness of our current portfolio of vehicles – Define a set of proposed future vehicle architectures and product programs providing for: Resource allocations Timing Plant assignment – The plan must be … Compliant Aligned Responsive Robust Integrated Stephen K Carlisle Vice President Global Product Planning What is a Vehicle Architecture? A Vehicle Architecture is the Integration of all five of these elements . . . = Example BOM – Bill of Material BOP – Bill of Process . . . for a family of vehicles to meet customer requirements and maximize profits. What is a Vehicle Architecture? Common Component Families COMMON COMPONENTS (BOM) The common components (Maximize BOM Commonality) (http://qav.gm.com/bom/bomtool.html) The set of architecture components that can be common, shared or substituted within a family of vehicles. The sharing strategy is expressed in the Visual BOM. Engine Transmission Suspension-Front BOM families Suspension-Rear BOM families Max Tire Diameter/Width Subframe (f/r) Steering Sys. (Type/BOM fam.) Ptrain Mount (Type/BOM fam.) Available Options New Option Back BOM – Bill of Material What is a Vehicle Architecture? Functional Ranges PERFORMANCE BANDWIDTH The functional/performance limits (Ensures Functional Ability) The functional and performance limits for vehicles that the architecture can accommodate NCAP Rating LINCAP Rating IIHS Offset Barrier Euro-NCAP Rear Offset Barrier Danner Rating Bumper Barrier Impact Test IIHS Bumper Test 1st Structure Mode All Belts to Seats Adv. Occupt.Restraint Systems Understeer Gradient Max Effec. Ride Travel Max Axle Weight Rating - Front Max Axle Weight Rating - Rear GVW Rating Torsional Stiffness Duty Cycle Towing Capacity Payload Capacity Max Lateral Acceleration EPA Test Weight CG Height @ Curb Current Range Proposed Expansion Back What is a Vehicle Architecture? Common Interfaces Body Side to Rocker & Frt Body Hinge Pillar In Floor Pan to Rear Pan Floor Pan to Toe Pan Dash Panel to Toe Pan Mid Rail to Toe Pan & Floor Pan Floor Pan to Rocker Frt Body Hinge Pillar Inner to Rocker & Toe Pa Bumper Beam to Mid Rails (f/r) COMMON INTERFACES A set of common interfaces The set of key physical (e.g. bolt pattern) and functional (e.g. load capacity) interfaces that are required to support the architecture component sharing strategy, the body clip sharing strategy, the dimensional strategy and the manufacturing strategy. Cow l Plenum to Frt Body Hinge Pillar Inner Body to Ladder Frame Mounting Points Front Row Seat Frame to Floor Pan Front Underbody Package Rear Underbody Package FOD/Cowl Area Package Seat Mounting/Storage Pkg Common (y-n) / Pkg. Data Loc Proposed Change Back What is a Vehicle Architecture? Common Manufacturing I-Shaft Conn (Motor Compt/Pass Compt) COMMON MANUFACTURING SYSTEM (BOP) The common manufacturing system (Maximize Implementation of BOP) The manufacturing strategy that supports process driven design, plant chaining, BOP, specific plant constraints and the Corporate goal to migrate to a common manufacturing system. Form & Pierce Operations (Y/N) Main Line Seq. (BA,Paint,GA) Hemming of Wheelhouse (Y/N) Framing Type & Logic (modul/layered) Laser Welding (Y/N) Locating/Tranfer Hole Size & Loc. Com (Y/ Door Hinges (Welded/Bolted) Brake System Processing (Closed/Open Silicon-Bronze Joints (Y/N) Flanges According to Weld Stand-WSI (Y/N Description Proposed Change Back BOP – Bill of Process What is a Vehicle Architecture? Dimensional Flexibility The range of dimensional flexibility The dimensional range or bandwidth for vehicles that the architecture can accommodate, including strategies to vary length, width, cowl position, etc. DIMENSIONAL BANDWIDTH Wheelbase Vehicle Length Vehicle Width Tread-Front Tread-Rear Turn Diameter - curb to curb (TD1) Ball of Foot to Front Axle SgRP to Heel Point (Chair Hgt) SgRP to Ground Cargo Volume Couple Distance Ctrline. Occ. to Ctrline, Veh. Windshield DLO Location Front Overhang Rear Overhang Nominal BIW CG Max BIW Lgth/Width/Hgt Fuel Capacity Step Height Current Range Proposed Expansion Back Architecture Content - Example Epsilon & Software Architecture Content - Example Current Epsilon These are examples of the range of products that can be built from one architecture Global Portfolio Decision Tree Look Share / Follower Program Opel GT and Daewoo G2X Program Framing Initiation PFI Architecture Modifications within bandwidth Saturn Sky Program Framing Initiation PFI No Portfolio Development Arch. Mods? Pontiac Solstice Ongoing Yes Architecture Framing Initiation AFI PFI Example: Kappa AFI – Architecture Framing Initiation New/Modified Architecture PFI – Program Framing Initiation Pre-DSI GVDP – Overview Architecture Modifications Program Framing Initiation PFI (within bandwidth) Portfolio Development VPI DSI 5.5 Mo. Program 1 mth Framing No Vehicle Program Initiation Document of Strategic Intent 7 Mo. Program Development Arch. Mods? Arch. Framing Initiation Ongoing Yes Architecture Statement of Strategic Intent Review ASSI AFI AA Review Architecture Framing New/Modified Architecture Architectural Approval Engineering & Execution 6 Mo. 7 Mo. PFI Lead Program VPI DSI 5.5 Mo. 7 Mo. Program 1 mth Framing Program Development Follower Program(s) AA – Architecture Approval AFI – Architecture Framing Initiation ASSI – Architecture Statement of Strategic Intent DSI – Document of Strategic Intent PFI – Program Framing Initiation VPI – Vehicle Program Initiation Summary: GVDP AFI-AA – Key Architecture Deliverables Initial Architecture objectives identified AFI Inputs • ‘Big Idea’ and Strategic Role of Architecture • Architecture Opportunity (Volumes, Target Segment Sizes) • Architecture Scope (Brands, Body Styles, Regions Participating, Markets of Sale) – w/ Managing Director Engagement • Initial Engineering Strategy (Reuse, dimensions, vehicle types, bandwidths, PT and Drive Configurations) • Competitive Information – Vehicle and Objective Performance Data, Teardown Results (Cost, Mass, Design Solutions, Performance) • Target ASSI and Lead Program SORP • Competitive PT Landscape and Guiding Principles • JV and AP Identification • Initial Architecture Quality Targets AFI Capability of Architecture & bandwidths defined ASSI Review Architecture Framing • Global Market & Arch. Requirements • High Level ‘Go to Market’ Strategy – by brand, bodystyle & region • Portfolio Business Case Assessments and Financial Targets • Architecture Design Direction Reviews • Architecture Trade-offs • Coarse Architecture Business Case • Bandwidth of physical dimensions/proportions • Arch. Boundary Conditions (Material Cost & Investment) • Architecture Imperatives • Architectural Concept Technical Descriptors (CTDs) & Requirements • Initial Quality targets (allocated to architecture BOM Rows) • Quality Lessons Learned & Sufficiency Plan • Mainstream Architecture Concept/Packaging • Load Path Strategy • Virtual Architecture Assessment • Key Architectural BOM Rows Selected • Baseline Powertrain Plan (Engine/Trans. Families, Drive Types) • Proportional Model(s) • Manufacturing Strategy Architecture solution defined AA Engineering & Execution • Architecture Cost Status • Initiate the Design Concept Sheets • Virtual Architecture Assessment • Proportions / Integrated Packaging • Systems & Component Concept Solutions • Architecture Quality Sufficiency Process Status • Early Supplier Involvement (if needed) • Manufacturing Concept • Architecture Learning ADV Plan (starts preASSI) Examples Architecture Development – Front Suspension Example Initial arch. objectives identified AFI Inputs AFI Capability of arch. & bandwidths defined Architecture Framing PQRR ASSI ASSI Review PFI Architecture solution defined Engineering & Execution AA DSI Program Framing Architecture Capability confirmed virtually VPI Program Development GM CONFIDENTIAL • Coarse component package • Suspension geometry roughly defined – Suspension type selected – Ride travels established – Key IDSRs defined – … – ASSI requirements have been met – Preliminary loads estimated –… • Multiple design solutions for some components • Coarse tire flops • Only one side of vehicle generated defined – Above + Min Wheel & Max Tire • Package Corporate Common – Coarse packaging study to determine component locations Components • All components meet Mass targets • All parts meet FEA targets – Requires accurate Loads • Component designs are manufacturable • All Fasteners sized and shown in math PFI Program Framing DSI 1 m t h ? The purpose of Program Framing: • Develop common program vision and objectives with Leadership • Translate customer & corporate requirements into technical requirements • Understand the engineering solutions within the existing architecture Modifications as required within existing bandwidths • Develop the compatible boundary conditions and Balanced Business Case captured in the DSI No Architecture Modifications (outside of bandwidth) Program Framing Initiation PFI Portfolio Development Ongoing Arch. Mods? 5.5 Mo. DSI Program 1 mth Framing No Vehicle Program Initiation Document of Strategic Intent VPI 7 Mo. Program Development Architecture Statement of Strategic Intent Review Arch. Framing Initiation ASSI Review AFI Yes Architecture Framing New/Modified Architecture Architectural Approval 6 Mo. AA Engineering & Execution PFI 7 Mo. Lead Program Follower Program(s) 5.5 Mo. DSI Program 1 mth Framing VPI 7 Mo. Program Development VPI Summary: GVDP PFI-VPI – Key Program Deliverables Initial program objectives identified PFI PFI Inputs • • • • • • • • • • • • • • • • • • • • Program Profile Architecture Initial lifecycle and scope Initial Body Style and Brand Assumptions Preliminary Powertrain Plan Initial Capital assumptions and Engineering Workload Affordable Spending Targets Preliminary Global Volumes Countries of Sale - Initial Consumer Insights Brief Innovation Workshop Results - Initial Global Product Research Plan – Init. Initial Program Quality Targets Joint Venture / Alliance Partner Key issues Approved NoD and SORP date Proposed Program Plan GVLE & Program Team Identified Competitive Information – Vehicle and Objective Performance Data, Teardown Results (Cost, Mass, Design Solutions, Performance) Regulatory Check List Product and program boundary conditions defined DSI Program Framing • Program Vision & Key Objectives • Target Market/Target Competitor • Program & Financial Boundary Conditions • Balanced Business Case • Vision/Proportional Model • Modifications within Architectural Bandwidth • Virtual Vehicle Assessment • Powertrain Plan • Program BOM • Study Plant(s) Identified and Investment Range • Design Center Operating Plan • Vehicle Pricing • Program Quality Sufficiency Process Status • Preliminary Program Plan • PDT Plans • Preliminary Product Content • Technology Plan • Design Concept Sheets • Countries of Sale • Pre-DSI Clinic • Program Comparison and Positioning • Commodity Strategy • Design Direction Reviews PFI ? Winning theme with engineering solutions that meets business case Program Development • Program Charter • Program Vision • Business Case • Single Theme Direction – Full Scale Themes • Clinic Results • Engineering Solutions • Virtual Vehicle Assessment • Manufacturing Strategy/Investment • Approved Program Plan • Product Program Content • Develop Quality Assessment DSI 1 m t h VPI VPI GVDP PFI to DSI - Design DSI PFI VPI Program Program Framing Development “Demonstrate capability of architecture/proportions to enable styling theme” Scale Models Full Scale Model Alias Posters/Sketches Math Models DSI – Document of Strategic Intent STD – Single Theme Direction VPI – Vehicle Program Initiation AD – Alternatives Development DTA – Design Theme Alternatives GVDP 5.1 High Level Framework Architecture Framing Initiation AFI Architecture Statement of Strategic Intent Review ASSI Review Architecture Approval DSI to VPI AA Architecture Development Program Framing Initiation Vehicle Program Initiation Document of Strategic Intent Engrg Contract Verified Sign Styling Sign Data VPI DSI PFI Off Freeze Off Release First ESO SF CSO VDR Integration Vehicle Program Development Complete Single Refine Theme Altern. Single Alt. Theme Theme Release Theme Develop Theme Development & Release FIVC Market Validation Review MVR Engineering Development Engineering Validation Start Of Regular Production SORP Manufacturing Tools & Equipment Launch DSI to VPI Summary Design Theme Alternatives FEW Alternatives Development DTA AD DSI PFI Program Framing Design Theme Alternatives Development 9 weeks 11 weeks Alternatives Theme Vehicle Program Selection Initiation Clinic STD VPI Design Intent Verified Data Release Start of Regular Production VDR SORP Program Execution 11 weeks 31 weeks • Explore the full range of styling themes • Continue Cost Management Process (CMP) • Initiate SOR process on long-lead commodities • Update BOM subsystem proposals • Establish high level vehicle requirements and initial allocation of imperatives • Continue full size clay development • Update engineering solutions, program requirements, and initial business case • Update BOM subsystem proposals • Identify issues and resolution plans • Develop the Charter • Ensure mainstream Design solution is “balanced & feasible” to meet the program BOM & manufacturing regmts. • Develop High-level tradeoff decisions and balanced business case • Clearly understand issues and their resolution plans • Finalize cross-functional program activities for program execution The Styling Process– Exterior This slide describes the typical process. The actual number of physical properties is a function of the product opportunity and resource constraints. Full Size Proportion Model with Strong Theme PFI DSI DTA STD AD VPI clinic 31 weeks Note: 2D Exterior theme images may be used for Clinic (3D is optional). Full-Size Clay Proportion Model (no hard parts) ? wks ? weeks Sketches Single Theme Refinement 1/3 Scale Clay Models 1/3 Scale Clay Models Full Size Clay Models MATH DEVELOPMENT PFI – Program Framing Initiation DSI – Document of Strategic Intent DTA – Design Theme Alternatives Single Theme: EXTERIOR VPI – Vehicle Program Initiation STD – Single Theme Direction Single Theme Math Data (VPI+4) The Styling Process - Interior This slide describes the typical process. The actual number of physical properties is a function of the product opportunity and resource constraints. PFI DSI DTA STD AD VPI clinic clinic 31 weeks Full Size Clay Proportion Model (no hard parts) Sketches Full Size Model w/hard parts Single Theme Refinement Single Theme: INTERIOR 1/2 Scale Clay Models MATH DEVELOPMENT Single Theme Math Data (VPI+4) Package Buck (Eng. deliverable) DTA – Design Theme Alternatives VPI – Vehicle Program Initiation AD – Alternatives Development DSI – Document of Strategic Intent PFI – Program Framing Initiation STD – Single Theme Direction Vehicle Program Initiation - Main Deliverables PFI DSI VPI VDR GPDC SORP PURPOSE : Single Theme Selected, Business Case Balanced Develop Initial Program Quality Plan Quality Assessments Design/Static Perceptual Quality Charter-Level Balanced Business Case Confirm Complexity Targets Virtual Architecture Vehicle Assessment Product Profile Status Complete Engineering Theme Surface Assessment Engineering Program Risk Assessment Vehicle Bill of Material (BOM) Develop Design for Six Sigma Assessment Vehicle-Level Concept Model(s) Develop Program Manufacturing Requirements-Product Engineering Intend to Execute-VPI Manufacturing Strategy Document Manufacturing at Program Quality Readiness Review Develop Product Program Content Approved Program Plan Balanced Program Imperatives Program Charter Conduct Pre-VPI Theme Study Clinic and Compile Design Clinic Results Staffing Assessment Complete Supplier Selection Decision for Production Parts Develop Single Theme Alternatives Performance Assessment Reports Program Quality and Readiness Review Status: Vehicle Program Initiation. Dimensional Technical Specification (DTS). Type Insurance Class Evaluation Complete Product Statement of Requirements for Mules Develop Consumer Reports Program Status Delivery Concepts for Sourcing Parts After Sales Engineering Plan Agree on Delivery Strategy Based on Total Supply Chain Cost Develop Subassembly Plan Production Launch Performance Targets Program Executive Reviews PFI Program Framing Initiation is an approval that the Program as described in its Strategic Role in the Portfolio is ready to initiate the Program Framing portion (PFI to DSI) of the GVDP. PFI reflects the start of the GVDP ‘clock’ leading up to SORP/SOS and also authorizes the engagement of functional resources GPDC DSI Document of Strategic Intent is an agreement on Program Vision/Objectives/Scope, Key Customer Driven Wins & Target Competitor, Architecture/BOM/Technology solutions, Design Enablers, Powertrain Plan, Content/PPC-lite, and Balanced Business Case/Boundary Conditions GPDC VPI Vehicle Program Initiation / Approved Program Charter determines if a program team should pass VPI and have Charter approved. Implies a Winning Single Theme that is supported by Engineering and Manufacturing solutions that are reflected in a Business case that meets Profitability, Key “Go/No Go”, and other Program Imperative requirements. GPDC CSO Contract Sign Off formally approves the Program Contract where all responsible parties formally commit to the agreed upon program Imperatives and Targets. Also includes an update on the progress toward meeting a program’s Imperatives, including a detailed financial status, a forecast of completion for Key CSO Go/No Go requirements, and a review of significant program issues and action plans. In addition, the AR, as approved after CSO HC, is assessed to determine is it is still inline with the programs allocation within the approved Capital Plan GPDC MVR Market Validation Review will assess whether the program is meeting market requirements, review the high level market launch plan, and identify changes to the business case that have occurred since Contract Signoff (CSO) Regional Marketing Forum PR Performance Review assesses the actual performance of the product against the Program Contract commitments (Capital/Resource Program Imperatives and Functional Targets & Profitability Program Imperatives and Functional Targets). Any next steps or opportunities for Profit Recovery are also reviewed. Also, the status to commitment as described in the program’s Appropriation Request, as reported to the BOD, is reviewed VP-GPO + Exec. Dir.-GPM + Group VLE/VCEs Link to Charter / Contract Template GVDP 5.1 High Level Framework Architecture Framing Initiation AFI Architecture Statement of Strategic Intent Review ASSI Review Architecture Approval VPI to SORP AA Architecture Development Program Framing Initiation Vehicle Program Initiation Document of Strategic Intent Engrg Contract Verified Sign Styling Sign Data VPI DSI PFI Off Freeze Off Release First ESO SF CSO VDR Integration Vehicle Program Development Complete Single Refine Theme Altern. Single Alt. Theme Theme Release Theme Develop Theme Development & Release FIVC Market Validation Review MVR Engineering Development Engineering Validation Start Of Regular Production SORP Manufacturing Tools & Equipment Launch GVDP 5.1 High Level Framework Architecture Framing Initiation AFI Architecture Statement of Strategic Intent Review ASSI Review Architecture Approval Styling Design and Release VPI to VDR AA Architecture Development Program Framing Initiation Vehicle Program Initiation Document of Strategic Intent Engrg Contract Verified Sign Styling Sign Data VPI DSI PFI Off Freeze Off Release First ESO SF CSO VDR Integration Vehicle Program Development Complete Single Refine Theme Altern. Single Alt. Theme Theme Release Theme Develop Theme Development & Release FIVC Market Validation Review MVR Engineering Development Engineering Validation Start Of Regular Production SORP Manufacturing Tools & Equipment Launch Styling in the GVDP DSI PFI VPI DTA Theme Alternatives AD STD Develop Single Theme Alternatives Alternatives -115 CSO VDR Ext clinic clinic clinic Program Framing DSO STMD Single Theme SF ESO Refine Theme IDR IDR VDR VDR int sm VDR Engineering Sign Off (ESO) - A point in time to assess readiness to proceed to Design Sign-Off and identify risk to the styling freeze data release Design Sign Off - A point in time when Styling Management has assessed the readiness of the exterior and interior elements of the program to proceed to Styling Freeze (SF) ESO – Engineering Sign-Off AD – Alternatives Development CSO – Contract Sign-Off DSI – Document of Strategic Intent DSO – Design Sign-Off DTA – Design Theme Alternatives IDR – Initial Data Release STMD –Single Theme Math Data PFI – Program Framing Initiation SF – Styling Freeze STD – Single Theme Direction VDR Ext– Verified Data Release Ext Components VDR I – Verified Data Release – Interior VDR sm – Verified Data Release – Sheet Metal VPI – Vehicle Program Initiation Styling in the GVDP – Math Flow PFI clinic Program Framing -115 clinic DTA Theme Alternatives AD – Alternatives Development CSO – Contract Sign-Off DSI – Document of Strategic Intent DSO – Design Sign-Off DTA – Design Theme Alternatives AD VDR Ext clinic STD Develop Single Theme Alternatives Alternatives CSO DSO VPI DSI STMD Single Theme ESO – Engineering Sign-Off IDR – Initial Data Release STMD – Single Theme Math Data PFI – Program Framing Initiation SF – Styling Freeze SF ESO Refine Theme IDR IDR VDR VDR VDR sm int I VDR STD – Single Theme Direction VDR Ext– Verified Data Release Ext. Components VDR Int - Verified Data Release - Interior VDR sm – Verified Data Release – Sheet Metal VPI – Vehicle Program Initiation Styling in the GVDP – Math Flow PFI clinic Proportions & Interfaces Theme Alternatives Design Center Math Releases Virtual Assm’ts -115 clinic DTA AD Theme Math Data VVA DSI clinic STD Develop Single Theme Alternatives Alternatives VDR Ext CSO DSO VPI DSI STMD Single Theme Theme Math Data SF ESO IDR Refine Theme SF MD STD STMD MD VVA VPI IDR VDR VDR sm int VDR IDR VDR E VDR VDR sm I IVER (updated ABIW) VMVA ABIW VVA DSO VSVA VCVA VIVA Sync Points Level 1 Math Releases Manufacturable Math Releases CVER Lvl 1 SVER Lvl 1 IVER Lvl 1 Concept Struct Int MMR MMR MMR Note: VMVA & VCVA (Virtual Mule & Concept Vehicle Assessment) is available for new or heavily modified architecture programs only Styled Surface Development - IDR/VDR Process SF Baseline Release 2 wks. IDR VDR VDR sm ext VDR int Baseline Release • The data/surface: - release represents a timestamp as the part evolves through the development and/or verification process. - content could be incomplete, or could be different than a previous version. IDR* = Initial Data Release • A Unigraphics part file released into TcC (TeamCenter Community). • The data/surface release (UGNX sewn sheets) that represents an unverified surface release of a completed part • The data will meet criteria and will be Data Creation Standards (DCS) compliant. VDR* = Verified Data Release • Audits and verification models have been completed. • This represents final release of styled surfaces. * For additional detail, please refer to the Design Center Math Release Document and the Global Technical Requirements for Styled Surfaces. DCS – Data Creation Standards IDR – Initial Data Release SF – Styling Freeze TcC – TeamCenter Community UG – Unigraphics VDR – Verified Data Release GVDP 5.1 High Level Framework Architecture Framing Initiation AFI Architecture Statement of Strategic Intent Review ASSI Review Engineering Development and Validation VPI to SORP Architecture Approval AA Architecture Development Program Framing Initiation Vehicle Program Initiation Document of Strategic Intent Engrg Contract Verified Sign Styling Sign Data VPI DSI PFI Off Freeze Off Release First ESO SF CSO VDR Integration Vehicle Program Development Complete Single Refine Theme Altern. Single Alt. Theme Theme Release Theme Develop Theme Development & Release FIVC Market Validation Review MVR Engineering Development Engineering Validation Start Of Regular Production SORP Manufacturing Tools & Equipment Launch Test/Simulation/Release Process DSI VPI ESO DSO SF VDR VDR int sm IDR Virtual Assessments VVA-DSI VVA-VPI VMVA VVA-DSO VCVA VIVA VPVA IVER Mule CVER FMC Program to decide Mule Requirements Ped Pro Non-Runner Runner Etc. VSVA SVER IVBR IVER LL Release Progression Prod. Tool Construction Tool / Build Critical Tests FIVC Virtual Assessments precede each Physical Hardware step and Engineering Release Tool / Build Vehicle Validation Integration Vehicle CVER – Concept Vehicle Engineering Release DSI – Document of Strategic Intent DSO – Design Sign-Off ESO – Engineering Sign-Off FIVC – First Integration vehicle Complete FMC – First Mule Complete IDR – Initial Data Release IVER – Integration Vehicle Engineering Release LL – Long Lead SF – Styling Freeze SORP – Start of Regular Production SVER – Structure Vehicle Engineering Release VCVA – Virtual Concept Vehicle Assessment VDR – Verified Data Release VDR I – Verified Data Release – Interior VDR sm – Verified Data Release – Sheet Metal VIVA – Virtual Integration Vehicle Assessment VPI – Vehicle Program Initiation VPVA – Virtual Product/Process Validation Veh. Assess. VSVA – Virtual Structure Vehicle Assessment VVA – Virtual Vehicle Assessment Production Design Release Schedule Concept Design Structure Design Integration Design CVER Concept Vehicle Engineering Release Architecture Underbody Structure SVER Structure Vehicle Engineering Release Remaining Architecture Subsystems IVER Integration Vehicle Engineering Release Styled Surface Related Sheet Metal & Interior Trim Virtual Activity Overview DSI VVA DSI VPI VVA VPI DSO VVA DSO VMVA CSO VCVA VSVA 100% VDR VIVA SORP VPVA Virtual Assessments Sync Points VR IV VR PPV Virtual Reviews • In addition to the physical build and test stages, a series of Virtual events (Assessments and Reviews) are included in GVDP. • Virtual Assessments focus on resolving physical, performance and manufacturing integration issues prior to Hardware Release and are timed to support the progression of the design. • Virtual Reviews focus on resolving BOM, build and part design interface issues prior to building IVs and PPVs. • Additionally, Manufacturing uses Virtual Tryouts to validate the vehicle assembly process prior to launch. These activities are not shown in GVDP. Balance & Validate the Note: VMVAPerformance & VCVA (Virtual Mule & Concept Vehicle Assessment) are available for new or heavily to Requirements modified architecture programs only BOM – Bill of Material CSO – Contract Sign-Off DSI – Document of Strategic Intent DSO – Design Sign-Off SORP – Start of Regular Production VDR – Verified Data Release VPI – Vehicle Program Initiation V*VA – Virtual Vehicle Assessment (A – Architecture / C – Concept / DSO – Design Sign-Off / I – Integration / Ini – Initial / P – Product/Process / S – Structure) Virtual Advanced Body-in-White DSI VDR VPI ABIW “Mule” Tool/Build/Test Integration Vehicle SORP PPV – An early virtual build that represents the integrated body solution – The body represented in math reflects intended panel breaks, part shingling, section size, gauge, and assembly sequence – Intent is to discover problems early and develop solutions prior to production release ABIW – Advanced Body in White Mules DSI ABIW VDR VPI “Mule” Tool/Build/Test SORP Integration Vehicle PPV Two approved types of engineering uses-Bandwidth* and Subsystem*: Bandwidth Mules are to be used by the LEAD PROGRAM off a new architecture for the purpose of assessing or developing bandwidth capability (when analytical methods are insufficient). Subsystem Mules are to be used by FOLLOWER PROGRAMS (when necessary) to develop and validate subsystems. (Example: Powertrain or Chassis) and are to be built off donor properties. Soft tooled * Note: All PPO Mule classifications (running, non-running, BIW, etc.) are still available and were not affected by ELT NoA 350 BIW – Body in White DSI – Document of Strategic Intent HVAC – Heating Ventilation Air Conditioning PPV – Product/Process Validation Vehicle SORP – Start of Regular Production VDR – Verified Data Release VPI – Vehicle Program Initiation VTS – Vehicle Technical Specification Fabricated CARRYOVER Integration Vehicle DSI VPI Purpose: ABIW VDR “Mule” Tool/Build/Test Integration Vehicle SORP PPV • Complete development, optimization, calibration & validation to vehicle related SSTS & VTS requirements by VTC. • Engineering demonstration of compliance to Type Approval regulatory requirements (Not actual Type Approval/Witness Testing) • Validation to Self-certification Regulatory Requirements (e.g. MVSS, Emissions, Fuel Economy & Diagnostics) • Support the 65%, 80% (if required) and 99% Vehicle Buy-Off Rides • Issue identification and resolution • Hoist or line build process used for validation of assembly plant build sequence. • Marketing Show Cars for world premieres and photo shoots Content: • Integration Property has the following MINIMUM part characteristics (fidelity): – Parts must be “production intent”* and may be either prototype or production tooled (Exceptions--headlamps, etc.) – CVER & SVER P2 Released components – IVBR (U1 & IDR Styled Surface)--Includes only those components (parts) and systems required for the IV Build per the Program LADV plan – PPQP (Pre-Production Part Quality Process) Status (formerly GP-11) - High-fidelity, high-quality parts • IV Builds may be “ground up” or from another process that results in “production intent” content – Parts may be carryover from another program. (This includes all BOM “re-use” parts, corporate common components, slave or donor underbodies, etc.) – IVs may be “ground-up”, 100% production-tooled or some combination of prototype and production parts based upon program classification (e.g. MCE, Major, New) and needs to support the Program LADV Plan. Production Intent --- Part meets all physical & functional requirements (fit, form & function) and has been produced off production representative tooling*. Materials must be approved to the applicable material specifications, including appearance (style, construction, finish) requirements and procured from the production intent material supplier. Program specific color, gloss or grain approval is not required. *Note: “Production representative tooling” means that a stamped part should be stamped not “hammer-formed” or an injection molded part should not be vacuum-formed. Tooling can be either prototype or production. The Integration Vehicle build is based on the following data maturity: CVER – P2 SVER – P2 IVBR – U1 (based on IDR) Product and Process Validation Vehicle PPV DSI Purpose: VDR VPI “Mule” Tool/Build/Test Integration Vehicle FPPVC SORP PPV • • • • • • • • • Post-Validation Audits 100% Vehicle Buy-Off Rides Final software verification/validation for Electrical & Powertrain Fuel Economy certification VTS Validation for Electromagnetic Compatibility MVSS 201 U Validation (Current state...not acceptable in Future state) Type Approval (Global process required TBD--Brian Latouf) Manufacturing system validation, production tool tuning, plant personnel training. After-Sales support (e.g. Owner’s Manual, Dealer Training) (ONLY--If MVBns or MVBs timing cannot support) • Marketing Show Cars for world premieres and photo shoots (ONLY--If MVB-ns timing cannot support) • Confirmation of Consumer Metrics Content: • 100% Production tooled parts exceptions will need to be evaluated for impact • Assembly Plant built using production tooling (per the PPV Manual agreements) • Dimensionally, material, functionally correct Sheet Metal & General Assembly parts in accordance with GVDP timing • General Assembly Matching 2 parts • PPAP Status available with a minimum Non-Salable Status and timing in place to support following builds • MGO responsible for ordering material GVDP 5.1 High Level Framework Architecture Framing Initiation AFI Architecture Statement of Strategic Intent Review ASSI Review Architecture Approval Manufacturing Development and Launch VPI to SORP AA Architecture Development Program Framing Initiation Vehicle Program Initiation Document of Strategic Intent Engrg Contract Verified Sign Styling Sign Data VPI DSI PFI Off Freeze Off Release First ESO SF CSO VDR Integration Vehicle Program Development Complete Single Refine Theme Altern. Single Alt. Theme Theme Release Theme Develop Theme Development & Release FIVC Market Validation Review MVR Engineering Development Engineering Validation Start Of Regular Production SORP Manufacturing Tools & Equipment Launch Manufacture Vehicle DSI CSO VPI Launch Red Zone VDR SORP Manufacture Manufacturing Requirements MMR Concept Dies MMR Structure Dies MMR The staggered design, construction, integration and test of: • Sheet Metal Fabricating Dies and Body Shop Tools • Assembly Plant Tooling and conveyance systems • Integration Dies / Body Shop Tools Matching MCB PPV GA MVB Manufacturing Launch Process Paint Shop Equipment CSO – Contract Sign Off DSI – Document of Strategic Intent GA – General Assembly MCB – Manufacturing Confirmation Build MMR – Manufacturable Math Release MVB – Manufacturing Validation Build PPV – Product/Process Validation Vehicle SORP – Start of Regular Production VDR – Verified Data Release VPI – Vehicle Program Initiation Die Development Work Stream IDR SVER IVBR IVER Lvl 1 LL IVER Complete Vehicle Validation SORP IVER MMR Create MMR PPV Process/ Formability Die Design FIVC – First Integration Vehicle Complete GA – General Assembly IDR – Initial Data Release IVBR – Integration Vehicle Build Release IVER – Integration Vehicle Engineering Release GA BUILD VDR sm FIVC Die Construction LL – Long Lead MMR – Manufacturable Math Release MVBns – Manufacturing Validation Build Non Salable MVBs – Manufacturing Validation Build Salable PPV – Product/Process Validation Vehicle Verification, Iteration & Eng Changes MVBns MVBs T1-T8 & Iteration SORP – Start of Regular Production SVER – Structure Vehicle Engineering Release VDR – Verified Data Release VDR sm – Verified Data Release Sheet Metal 110 Body Shop Tooling Work Stream IDR SVER IVBR IVER Lvl 1 IVER MMR LL IVER PPV Body Tool Design Body Tool Processing IDR – Initial Data Release IVBR – Integration Vehicle Build Release IVER – Integration Vehicle Engineering Release FIVC – First Integration Vehicle Complete SORP 0 FIVC Integration Tool Const. Body Try Out Iterative Matching Installation LL – Long Lead MMR – Manufacturable Math Release MVBns – Manufacturing Validation Build Non Saleable MVBs – Manufacturing Validation Build Saleable MVBns MVBs PPV – Product/Process Validation Vehicle SORP – Start of Regular Production SVER – Structure Vehicle Engineering Release Matching Process PPAP Gate 2 -2 PPAP Gate 1 -15 PPAP Status -35 Conduct Iterative Matching Body M1 GA M2 GA M 3 SORP M 4 0 The Matching process relies upon early GM and supplier interaction to increase vehicle Perceived Quality. The Body Shop basically utilizes a continuous Matching process and provides a vehicle body for GA Matching 2. The following four physical vehicle builds focus on gaps, fits, finishes, and material usages for hundreds of aesthetic interior and body parts: • Matching 1: To start fitting/evaluating initial GA parts off of production tools to the Interior Total Assembly Checking fixture and the Exterior Total Assembly Checking Fixture • Matching 2: To validate Matching 1 decisions/fixes were effective and to make decisions on further fit refinements using updated material • Matching 3: To validate refined Matching Body/GA Matching 2 decisions/fixes were effective and continue to finesse fits throughout MVBNS • Matching 4: To validate fine-tuned Matching 3 decisions/fixes were effective and to make decisions on final fit enhancements throughout MVBS Iterative Matching • A process to drive the dimensional quality of production body parts to nominal • Evaluation of production die-struck body parts relative to each other and to locating datums in body assembly tools • Driven primarily by die tryout and BIW tool timing – Best opportunity to influence & tune in the part in a timely manner is prior to shipping dies to home line – Small batch quantities of parts enable quick turnaround of improvements (real iterations!) Ext. Fitting Fixture (EFF) Total Assembly Check (TAC) Fixture Ext. Environmental Cubing Fixture Additional Information: Product and Process Validation Link BIW – Body in White EFF – Exterior Fitting Fixture MVB – Manufacturing Validation Build TAC – Total Assembly Check Global Launch Process The Global Launch Process is the GM common process to plan and deliver vehicles to meet program quality and throughput requirements with minimum production loss during acceleration at maximum profit. Launch Team: Core members • Key members of Mfg & Vehicle Engineering • Quality, Facilities, Training, Communications, MFD, Powertrain • Manufacturing Supply Operations • Purchasing • Marketing • Union (U.S./Canada) • Financial • IS&S (Membership is based on launch program complexity) Primary Focus: Issue Resolution Process (IRP) • Identify Issues • Root Cause • Resolve IRP – Issue Resolution Process Link to GLP MFD – Metal Fabricating Division Manufacturing Confirmation Build CSO Launch Red Zone 100% VDR FIVC Integration Vehicle Procure Parts Build Critical Testing Conduct Manufacturing Confirmation Build MCB PPV GA SORP MVBns MVBs 6 weeks • This build is a training and preparation event, using Integration Build materials which are shipped to the assembly plant. • Vehicles will run through the assembly plant systems and will be exposed to assembly plant personnel. • They are intended to provide a product/process learning opportunity for the assembly plant personnel. • This will facilitate operator training, assembly tooling tune-in, and assembly process validation in preparation for the Product/Process Validation and Manufacturing Validation Build activities. • Early identifier for plant issues prior to MVB events CSO – Contract Sign-Off FIVC – First Integration Vehicle Complete GA – General Assembly MCB – Manufacturing Confirmation Build MVBns – Mfg Validation Build Non Saleable MVBs – Manufacturing Validation Build Saleable PPV – Product/Process Validation Vehicle SORP – Start of Regular Production VDR – Verified Data Release Link to Master Product/Process Validation Vehicle Launch Red Zone 100% VDR CSO FPPVC FIVC Integration Vehicle Procure Parts SORP PPV Vehicle Build Build Critical Testing MCB VTC VDC PPV GA MVBns MVBs 11 weeks What Is The PPV Build? PPV Units are used to complete VTS Validation/Verification/Final Calibration in areas where production tooled parts & production assembly process are required and for training assembly plant personnel When And Where Is The PPV Build Conducted? The PPV units are built at the production assembly plant on mainline tooling & equipment Who Is Involved? PPV event is owned by the launch team and led by the PEM & MLM. Who Is the Customer? The customer is Product Engineering Why do a PPV? • • • To improve the launch (Makes MV-ns and MV-s “real” launch events) The production system is exercised earlier (esp. material ordering) Higher probability of Validation Test Complete (VTC) being completed on-time (production representative properties vs. IV builds) FBIW – First Body-in-White Complete FIVC – First IV Complete GA – General Assembly IV – Integration Vehicle MCB – Manufacturing Confirmation Build MLM – Manufacturing Launch Manager MVBns – Manufacturing Validation Build Nonsalable MVBs – Manufacturing Validation Build Salable PEM – Program Engineering Manager PPV – Product/Process Validation Vehicle SORP – Start of Regular Production VTC – Validation Testing Complete VTS – Vehicle Technical Specification FPPVC- 1st PPV Complete VDC – Vehicle Documentation Complete Link to Master End of Line Testing (EOLT) 100% Veh Cal 99% Veh Cal 65% Veh Cal Int Develop IV IV Cal RPR Veh Cal SORP 0 RPR Cal Develop 100% Cal FIVC G A Complete Vehicle Validation FPPVC Paint MCB PPV GA IV EOLT PPV EOLT MVBns MVBs MVBns EOLT Final Elect Bench Bld End of line testing was added as a GVDP process with GVDP 5.0. This process synchronizes the development of software for equipment used during end-of-line testing and the development of software used in-vehicle. 65% Veh Cal – 65% Vehicle Calibration 99% Veh Cal – 99% Vehicle Calibration 100% Veh Cal – 100% Vehicle Calibration CRFM – Cooling Radiator Fan Module EOLT – End of Line Testing FIVC – First Integration Veh. Complete FPPVC – First Product/Process Val. Vehicle Complete GA – General Assembly IV – Integration Vehicle MCB – Manufacturing Confirmation Build MVBns – Mfg Validation Build Nonsalable MVBs – Manufacturing Validation Build Salable PPV – Product/Process Validation Vehicle RPR Veh Cal – Rapid Probl. Resolution Veh Cal. SORP – Start of Regular Production Manufacturing Validation Build Events CSO Launch Red Zone 100% VDR VTC VDC FIVC Integration Vehicle Procure Parts Build Critical Testing SORP Manufacturing Validation Builds MCB PPV GA MVB MVBs ns 10 weeks 13 weeks What Is a Manufacturing Validation Build? • MVB is a Manufacturing event (NOT a Product Design Validation event) Why do Manufacturing Validation Builds? • Provides an earlier and more structured approach to identify, resolve and validate issues • Allows opportunity for operator training and certification • Provides Captured Test Fleet CTF are MVB vehicles given to company car drivers for the purpose of providing early identification of unknown problems (250 vehicles max) What is the difference between MVBns & MVBs? VTC: VDC: All vehicle, subsystem, and component validation and testing is completed so that the MVBns can begin. Completion of all validation testing at VTC is the goal but is not a requirement to stat MVBns Documented confirmation of status and commitment to action plans documented in VTC review. VDC is a prerequisite for PPAP. CSO – Contract Sign-Off CTF – Captured Test Fleet FIVC – First IV Complete GA – General Assembly IV – Integration Vehicle MCB – Manufacturing Confirmation Build MVBns – Manufacturing Validation Build Nonsalable MVBs – Manufacturing Validation Build Salable PPV – Product/Process Validation Vehicle SORP – Start of Regular Production VDC – Validation Documentation Complete VDR – Verified Data Release VTC – Validation Testing Complete Link to Master Global Manufacturing Validation Build (General Assembly) New/Major Template - GVDP 5.1 MRD 0 MRD 1 BSVal/Iter Match Body & GA PPV 7 calendar days prior to build event on a Monday For GM stamped parts, 7 calendar days on a Monday prior to the build event; for MGO parts, 10 calendar days on a Friday prior to the build event Notes: 1) Any deviations to these MRD requirements will be directed by the assembly plant Material Department (e.g. GM stamped parts, sequenced parts, bulk parts, etc.). Body parts required per program’s Body build cadence. 2) See MFD/SQA Tier2 Agreements for Stamping PPAP timing 3) Any changes to the template, including MRDs, require approval of the GM Global Production Launch Process Team MRD 2 MRD 3 Body & GA MVBNS Body & GA PPV PQRR Wk -35 MRD 4 MRD 5 MRD 6 Body & GA MVBS Body & GA Body & GA 10 calendar days on a Friday prior to the build event MVBns PQRR Wk -24 PPV Vehicles FATG -28 MVBs PQRR Wk -15 PQRR SORP Wk 0 NonSalable Vehicles Salable Vehicles RPR CEC VTC -24 SORP STC PQRR Wk1 LTR PQRR Wk 12 VDC -15 Body Shop Validation/Iterative Matching MRD 4 MRD 4 MRD 3 MRD 3 MRD 3 MRD 2 MRD 2 Manufacturing Confirmation MRD 5 PPV Build - Body and GA MRD 5 -41 Plant Purge -16 M2 MRD 6 M1 MRD 6 -56 55 54 53 52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 PPAP Matching Wk -48 Production Launch Milestones 46 PPAP NonSalable Wk -38 EWO SOP Effective Point Wk -35 Red Zones PPAP Gate Wk -15 SSF SORP NO MORE PRODUCT ENGINEERING CHANGE REQUESTS EXCEPT FOR THOSE APPROVED BY THE PRODUCTION LAUNCH TEAM NO MORE PROCESS CHANGE REQUESTS GVDP 5.1 High Level Framework Architecture Framing Initiation AFI Architecture Statement of Strategic Intent Review ASSI Review Architecture Approval AA Summary Architecture Development Program Framing Initiation Vehicle Program Initiation Document of Strategic Intent Engrg Contract Verified Sign Styling Sign Data VPI DSI PFI Off Freeze Off Release First ESO SF CSO VDR Integration Vehicle Program Development Complete Single Refine Theme Altern. Single Alt. Theme Theme Release Theme Develop Theme Development & Release FIVC Market Validation Review MVR Engineering Development Engineering Validation Start Of Regular Production SORP Manufacturing Tools & Equipment Launch Agenda Process What it is What it contains Architecture/Program Development Vehicle Development by Sub-Phase Process Measurement Imperatives Metrics Summary A balanced set of imperatives utilizing scarce resources to achieve corporate objectives, while maximizing profitability Corporate Imperative Corporate Capital / Resource Objectives Corporate Product Objectives Product Complexity* IPTV (12 MIS) * A “Functional Target” for some programs • External Surveys (e.g., JD Power) • Design / Static Perceptual Quality Profitability Objectives Total Investment • Internal Rate of Return (IRR) Program Imperative Direct Engineering Expense Supporting Functional Targets • Engineering Workload (SUWs) • BOM Reuse • Product Complexity Base Engineered Content (BEC) • Hours per Vehicle (HPV) Global Customer Audit (GCA) Direct EBIT • MEMO EBIT Contribution Margin • Net Sale • Material Cost • Lifecycle Policy & Warranty Total LCA Volume • Volume breakdown by Region Fuel Economy / Consumption • Mass Program “Wins” Product Profile Conformance Timing (SORP) Key Distinction: Functional Targets can be traded off by the team (without senior management approval) to balance the Program Imperatives and the business case. Trading off a Program Imperative requires senior management approval. BEC – Base Engineered Content BOM – Bill of Material CPV – Cost Per Vehicle EBIT – Earnings before Interest and Taxes GCA – Global Customer Audit HPV – Hours Per Vehicle IPTV – Incidents Per Thousand Vehicles IRR – Internal Rate of Return LCA – Life Cycle Average MIS – Months in Service SORP – Start of Regular Production SUW – Standard Unit of Work Program Metric Template DSI Decision Fixed Point Product Program Content Status Statement Of Requirements Supplier Selection Vehicle Performance Status Summary Program VPP Summary ADV Activity Throughput Initial Release Level 2 Math Tooling P.O. (Spot Buy) Issued Production Tooling Construction Powertrain Calibration / Software Release Integration Builds Bodyshop Readiness Paint Shop Readiness General Assembly Readiness PRTS Average Age Of Issues VTS Validation Throughput VPI CSO VPI VDR SORP Example of the SOR Metric An example of an excel workbook for the T745 program…note the names of the available metrics on the tabs at the bottom Definition Sheet provides the metric definition along with the subject matter expert contact info and data sources Agenda Process What it is What it contains Architecture/Program Development Vehicle Development by Sub-Phase Process Measurement Imperatives Metrics Summary Course Summary • Global VDP is GM’s process for bringing new vehicles to Market • It is composed of three major elements: – Architecture/Program Development – Vehicle Development • The Global Vehicle Development Process is a multi-functional process • GVDP has three major elements: – Style – Engineer – Manufacture • All vehicle programs are measured according to their achievement of program imperatives and track performance using program metrics GVDP Web Site – https://gmweb.gm.com/sites/GVDP/Pages/gvdp.aspx GVDP Contacts Bernd Schmedding (GME Ruesselsheim) + 49(0) 6142 7 53092 Don Smith (GMNA Warren) + 1 (586) 940 8996 Luciana Haddad (GM Brasil, Sao Paulo) + 55 11 4234 7013 Hoki Yi (GM DAT Bupyeong ) + 82-32-520-2087 Marco Paglia (GM Holden Melbourne) Juhan Kim (GM China Shanghai) Olga Agalakova (GM Powertrain Pontiac) Charnsak Laicharoenchokchai (GM Thailand) +613 9647 2628 + 86-(0)21-2891-7953 + 1 (248) 752-5296 + 66 38 667093 Questions?
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