I GM WORKSHOP REPORT Production Innovations... People, Processes and Systems At General Motors' largest car assembly facility in America, state-of-the-art manufacturing processes and relentless improvement efforts lead to gains in product quality, productivity, and employee job satisfaction. By Lea Tonkin. contribuling editor No longer will past performance in manufacturing chassis assembly plants less than two miles away," quality be acceptable to the restless executives and Downie said. "It's an 'all under one roof concept plant workers at the Buick·Oldsmobile·Cadiliac (B·O·C) called integrated manufacturing that contributes plants in Lansing, MI. They have seen what a total significantly to the basic quality of the GM20 cars." commitment to product and production excellence Downie cited a direct relationship between this new can do for the current lineup of GM20 cars. Now manufacturing concept and the advantages of Just·ln· they're combining efforts to make sure that the Time (JIT) inventory management. "Materials move revolution continues. As General Motors executives shorter distances and in smaller quantities between explained to participants in AME's workshop at B·O·C the various operations that are required to work on Lansing in October, 1985, the importance of a new them. In addition, people involved in GM20 are technology and work ethic and commitment to excel· located in close proximity with each other and func· lence cannot be underestimated. The automaker's tion much more effectively as a coordinated team," future, and their jobs, depend on quality and cost he said. competitiveness in tough world markets. The follow· More robots are used in the GM20 program than in ing report reflects workshop presentations, any other GM location in this country. Body assembly uses 220 robots in its operations, and chassis has What GM20 is all about another 7 for a total of 227. Uniformity in assembly "GM20 was a major General Motors undertaking," processes is boosted by these robots. explained Donald R. Downie, Director of Planning and A unique automatic guided vehicle system (AGVS) Industrial Engineering at B·O·C Lansing. "On June at B-O·C Lansing's chassis assembly allows assembly 18, 1984... the first of the 1985 model GM20 cars techniques unmatched elsewhere in North America, ... the Oldsmobile Calais, Pontiac Grand Am and the executive continued. "The AGV's will allow major Buick Somerset Regal ... came off our assembly lines. portions of our GM20 cars to be built in station," Millions of dollars in investment and many hours of Downie said. "Each operator is able to stop the prod­ work by thousands of hourly and salaried employees uct if difficulties arise and is able to take the time at both (Lansing) locations took form and came alive necessary to make corrections. This technique adds to in new processes and equipment." Innovation is not the quality of our cars." new to Lansing, Downie said. Yet B·O-C Lansing's Vendor relationships are essential to the success of combined efforts reflect a revolutionary way to build the GM20 project. "From the beginning of this proj­ and bring new cars to the marketplace. ect, we have met with and involved our suppliers to For more than 85 years, Lansing has been a car­ be certain they will be able to produce high·quality building town. Now the long-standing association with parts and components all the time, just-in-time ... Oldsmobile production has been extended to Buick Our vendors ship 100 percent to specification, and and Pontiac as well. Another change: A single line of we do not have receiving inspection." Downie stated. cars will be built here, compared to the variety of cars "Ninety percent of B-O-C Lansing's suppliers are turned out simultaneously in past years, within 250 miles, permitting truck shipment to our Key points of the GM20 program outlined by build schedule. Downie are: "Finally, and perhaps most important, B-O-C Lans· All major sheet metal parts are made at B-O-C ing has involved our people ... hourly and salaried Lansing's stamping plants and sent next door to ... in all of the details of the GM20 program from the B-O·C Lansing body assembly facilities. "At body very beginning. Our employees are highly trained. assembly, sheet metal parts are assembled into They are committed to producing a quality product," bodies, painted, trimmed, and sent immediately to the said Downie. 10 planners: converting two 60·job-per-hour production Quality strategies lines under one roof to new assembly technology, The real power of the new Oldsmobile Calais, for with no more than four and a half months' downtime example, lies in quality concepts in its design and in any area. manufacture, according to the B·O·C executive. "Our Each production line has three major departments: quality strategies for GM20 were built around four body, which produces the metal shell: paint: and trim. basic elements in product development ... product Changes in these areas include: design, people, manufacturing processes, and parts Installation of underbody press lines, body framing sourcing," he said, adding: equipment, and other equipment began in February Design: "Our design had to be right for the features 1983-after previous modifications such as excava· our market was looking for, and at the same time, tion, structural changes, and floor resurfacing. All provide for top quality in assembly operations." major automated systems needed to build pilot People: "Our people had to believe in our quality vehicles were ready to run by November 1983. objectives and be thoroughly trained in their respon­ "It is in the body shop that automation and other sibilities, many of them different from anything they technological developments are most evident," Mattis had done before," said. "One hundred and sixty hydraulic and electrical Manufacturing processes: Our manufacturing proc­ robots perform spotwelding, migwelding, screwdriving, esses had to take full advantage of promising new and part handling operations. By comparison, we utilized concepts such as 'team build,' ergonomics, 'socio­ only six robots in 1984 model production," Body shop technical systems planning,' and of course, our whole systems also include 18 presswelders to assemble approach to quality of work life and participative GM20 underbodies, more than 60 non-robotic auto­ management." matic welders, 50 mechanical handling devices, and Parts sourcing: "Our parts sourcing had to be based two precision stop-and-go conveyor systems. on doing business with quality vendors and on Several subassemblies for the GM20 program are allbwing them to participate in the entire program." produced in tooling that is unique among GM plants Close cooperation between engineering, manufac­ and in some cases unique in the industry_ Example: turing, materials management, and reliability staffers Each body side assembly is buill in a fourteen-stage drove the basic GM20 design effort. Studies of exist­ automatic shuttle line, Mattis said. "Once parts are ing cars and their field experience resulted in an loaded into this shuttle system, a body side assembly action plan to assure that GM20 would be an even is untouched by human hands," he said. "It is better car. Sixty-one test vehicles, some built with automatically transferred to a delivery conveyor that the help of assembly plant hourly personnel, were carries it to the framing line. From there, another assembled. "This is double innovation. Sixty-one is a automatic system places it onto the underbody, and large number of vehicles, and prototypes are usually bends down the metal tabs which hold it in place on built by engineers, not by assembly plant people," its way to the automatic framing operation." Downie said. Automation also plays a key role in the production of underbody and motor compartment components, Evolution and innovation: rear wheel housings, and roof and shelf subassem­ People, facilities, and materials blies. Approximately 77 percent of the 1660 spot­ Thorough preparation is essential to the success of welds required to build a GM20 body shell are done the new GM20 era, according to Herbert T. Mattis, by robots or other automatic welding equipment. Superintendent, LCA-Body (Lansing Car Assembly), at Lansing is the first GM facility in which automatic B-O-C Lansing. Changes in people, facilities, and body framing stations are an integral part of the stop­ materials are needed as well, he said. For example, a and-go conveyor system. Reduced equipment cost series of training and development programs "informed, and decreased potential downtime associated with prepared, and motivated our first-class workforce transfers to and from the framing station are among for the changes that would be coming with the new benefits. product," Mattis said. The assembly of door glass frames, or headers, to "In the materials category, special events and com· the lower door in the assembly plant is another munication systems were created to get our suppliers significant process innovation_ This operation tradi­ on the GM20 team with uS as partners in the process tionally took place in a metal fabrication plant, far of building a total vehicle, not just a part," he from the point where doors are assembled to the body. continued. Mattis also described facilities changes "of "For GM20, a five-stage automatic shuttle system formidable proportions." probe-checks the lower doors and headers for incom­ Conversion to GM20 body assembly reflects the in· ing quality, assembles the headers to the doors, bolts vestment of millions of dollars at the Lansing body hinges to the door, trims flanges, migwelds the plant. Included are 25 buildings, housing 2.6 million headers, and probe-checks the finished assembly," square feet of floor area, on 75 acres of land. Much of Mattis said. "All coupe doors for both production the revamping process took place during the 1984 lines come from a single shuttle system, which is model year.