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1GVDP v5_Upd_trg.ppt/Don Smith/5/22/2006/version 6.0INDEXGVDP v5.0 UpdateDon Smith22MAY06This document is for internal GM use only.Not to be duplicated or disclosed outside GM without approval of Don Smith 586-986-19832GVDP v5_Upd_trg.ppt/Don Smith/5/22/2006/version 6.0INDEXGVDP Post DSI v5.0 Released 06April06(for more information go to:gvdp/asiapacific/index.html)GVDP Pre-VPI Process Documentation v1.0Released 06MAR06(for more information go to:)GVDP Pre-VPI GVDP version 5.03GVDP v5_Upd_trg.ppt/Don Smith/5/22/2006/version 6.0INDEXOutlinePre-VPI and Post-VPIGlobal GVDP 5.0 BackgroundHigh level frameworkProcess AgreementsProcess Agreement detail 5.0 contentProgram FrameworkArchitecture&Program Work StructureGVDP 5.0 Assumptions&EnablersProcess Documentation4GVDP v5_Upd_trg.ppt/Don Smith/5/22/2006/version 6.0INDEXPre-VPI and Post DSI GVDPpre-VPI GVDP“bolts-on to the beginning of the rest of the GVDP for individual programs and supplies needed deliverables at DSIProgram DevelopmentArchitectureFramingArchitectureEngineeringArchitectureRefinementProgram Framing/ArchitectureDevelopmentPortfolio Plan DevelopmentProgram ExecutionCurrent Arch?VPIVDRSORPPFIAFIto ensure quality execution.ASSIAADSIACArchitecture Framing InitiatedArchitecture Statement of Strategic IntentProgram Framing InitiationArchitecture ApprovalDocument of Strategic IntentArchitecture ConfirmationVehicle Program InitationVerified Data ReleaseStart Of Regular Production5GVDP v5_Upd_trg.ppt/Don Smith/5/22/2006/version 6.0INDEXWhat is pre-VPI GVDP?pre-VPI GVDP is GMs integration of architecture development and program developmentpre-VPI GVPDIs GlobalIs a documented processAccommodates multi-market architectural development similar to Global EpsilonAccommodates the newly defined Global Portfolio ProcessProvides timing guidance for architecture and program development(start and end points)Defines required decision points and approval forums(governance)6GVDP v5_Upd_trg.ppt/Don Smith/5/22/2006/version 6.0INDEXPre-VPI GVDP OverviewArchitectural ApprovalDocumentof Strategic IntentArchitecture Statement of Strategic IntentVehicle Program InitiationPFIYesNoArch.Framing InitiationAFIVPI1 mthArch.Mods?Program Framing InitiationPortfolio DevelopmentProgramFramingArchitectureFramingEngineering&ExecutionArchitectureRefinementProgram Development5-6 Mo.6-7 Mo.6-7 Mo.6 Mo.6 Mo.OngoingASSIAAACDSIArchitectural ConfirmationPFIVPI1 mthProgramFramingProgram Development5-6 Mo.6-7 Mo.DSILead Program(e.g.Vectra)Derivative Program(s)(e.g.GMX 353,GMX 354)No ArchitectureModifications(outside of bandwidth)(e.g.GMX211,GMX272,GMX386)New/Modified Architecture(e.g.Epsilon,Gamma,Delta)7GVDP v5_Upd_trg.ppt/Don Smith/5/22/2006/version 6.0INDEXAFI-AC Key Program DeliverablesArchitectureFramingEngineering&ExecutionArchitectureRefinementAFIGlobal Market&Arch.RequirementsBandwidth of physical dimensions/proportionsArch.Boundary Conditions(Material Cost&Investment)Body StylesMainstream Architecture Configuration/PackagingLoad path StrategyKey Architectural BOM Rows SelectedBaseline Powertrain Plan(Engine/Trans.Families,Drive Types)Proportional Model(s)Sourcing StrategyManufacturing StrategyVirtual Performance AssessmentVirtual Package AssessmentUnderbody 3D Math ModelGlobal ADV PlanAllowable Costs SOR Development Sourcing ActivitiesASSIAAAC Architecture Imperatives Architecture Cost Status Virtual Architecture Assessment Proportions/Integrated Packaging Systems&Component Concept Solutions Proportional Model Early Supplier Involvement Manufacturing ConceptCapability of arch.&bandwidths definedArchitectureCapability confirmed virtuallyArchitecturesolutiondefinedInitial Participating Regions and ProgramsInitial Engineering Requirements Regulatory Performance Etc.Initial arch.objectives identified8GVDP v5_Upd_trg.ppt/Don Smith/5/22/2006/version 6.0INDEXProgram FramingThe purpose of Program Framing:Develop common program vision and objectives with Leadership Translate customer and corporate requirements into technical requirements Understand the engineering solutions within the existing architecture Modifications as required within existing bandwidths Develop the compatible boundary conditions captured in the DSI Architectural ApprovalDocumentof Strategic IntentArchitecture Statement of Strategic IntentVehicle Program InitiationPFIYesNoArch.Framing InitiationAFIVPI1 mthArch.Mods?Program Framing InitiationPortfolio DevelopmentProgramFramingArchitectureFramingEngineering&ExecutionArchitectureRefinementProgram Development5-6 Mo.6-7 Mo.6-7 Mo.6 Mo.6 Mo.OngoingASSIAAACDSIArchitectural ConfirmationNo ArchitectureModifications(outside of bandwidth)New/Modified ArchitecturePFIVPI1 mthProgramFramingProgram Development5-6 Mo.6-7 Mo.DSILead ProgramDerivative Program(s)9GVDP v5_Upd_trg.ppt/Don Smith/5/22/2006/version 6.0INDEXProgram Planning/Architecture AdaptationProgram Framing Portfolio DevelopmentTarget Exploration WorkshopProgram Framing KickoffDocument of Strategic IntentProgram Framing CompleteProgram Definition CompleteOngoingProgram Framing InitiationPFIDDDSI DirectionGVDPPFCPDC5-6 monthsDSIApproves“kick-off of program DSI developmentConfirms PFI inputs:“Big Idea and Strategic Role in PortfolioArchitectureProgram scope and timeline Body Style and Brand Assumptions Potential Powertrain Families and Drive ConfigurationsInitial capital and engineering Workload assumptions Primary Region(s)of salePotential issuesAuthorizes resources(Core PET)Regional AVDLT or GPDC (if required)DSIPrep10GVDP v5_Upd_trg.ppt/Don Smith/5/22/2006/version 6.0INDEXProgram FramingProgram Framing KickoffDocument of Strategic IntentProgram Framing CompleteProgram Framing Program Definition CompleteOngoingProgram Framing InitiatedPFIDSI DirectionPFCPDCDDTarget Exploration WorkshopGVDP5-6 monthsDSIPortfolio DevelopmentCreate and assess program alternativesDevelop organizational alignment concerning scope,vision,and key objectives(key wins,price of entry items)Establish program targets and boundary conditionsProgram positioning Preliminary Content(including powertain,key technologies)Financial Boundary ConditionsDesign enablersManufacturing footprintDevelop&verify high level engineering solutions that will meet existing Bill of Architecture(BOA)DSIPrepGlobalPortfolio Planning11GVDP v5_Upd_trg.ppt/Don Smith/5/22/2006/version 6.0INDEXGlobal VDP 5.0 BackgroundProduct development leadership direction to shorten time between VPI and SORPReduction based on GELT led studies of GMDAT and Toyota lead time advantages.Study concluded:GMs global VDP lead times lag Toyotas by several monthsToyotas enablers:decoupled development,overlapping functional work and fast functional processes DSI to SORP advantage of about 4 monthsGMDAT Lean VDP faster for in-country productsActual GVDP 5.0 reduction is 15 weeks(37/20 to 33/20)for New and Major vehicle programs.Reduction moves single theme math 15 weeks closer to the market.GVDP 5.0 was released for programs with a Document of Strategic Intent(DSI)on or after June 1,2006,and for select programs earlierExisting 4.1 programs will not be updated to 5.0 logic or timing.Additional studies are being conducted to develop shorter templates for derivative programsGVDP Pre-VPI Released for use on 06MAR06 creates deliverables important to executing GVDP 5.012GVDP 5.0 Release Announcement 07April 06All,Following an initiative sanctioned by the Global Product Development Council(GPDC),Global Engineering Leadership Team(GELT)and Global Joint Engineering and Manufacturing Staff(GJEMS)to shorten product development lead time,we are pleased to announce the release of the Global Vehicle Development Process(GVDP)5.0.This release improves VPI-SORP timing,for new and major programs,from 37 months to 33 months,and moves styling 15 weeks closer to market introduction.GVDP 5.0 is directed at programs with Document of Strategic Intent(DSI)dates after June 1,2006,and several select(slightly earlier)programs where partial implementation will occur.Regards,Rick SpinaExecutive DirectorGlobal Program Management13GVDP v5_Upd_trg.ppt/Don Smith/5/22/2006/version 6.0INDEXGVDP 5.0 Framework 33/20Theme DevelopmentSORP0IDRVDR-112IDR-106Design ARMSourcingSORBCTProcure PartsSVER-98FGCV Design SolutionFGSV Design SolutionProcess/FormabilityConstruct/Verify Dies IVERMMRBCTProcure Parts FIVC-79100%IVER-83IV Design SolutionFGsmVDR-96100%-90VDRDTA-163AD-155Design DiesSF-116MVBsMVBnsPPVDesign BodyShop ToolsConstruct/VerifyBody Shop Tools-15Ped Pro MuleCVER-109MulesVPI-SORP 15 week reduction from GVDP 4.1PPAPGate 1-15PPAPGate 2-2PPAPGate 3EOAPPAPStatus-35IVPT Cal-69100%PT Cal-21 VTC-21Develop 100%PT CalFATG-25EOLTIterative Matching-148VPI-144DSI-172STDDSI-SORP Overall leadtime is within 6 weeks of ToyotaFunctional processes have been adjusted,added,or refined:Styling&Surfacing Mules Sourcing Dies and Bodyshop Tooling Pedestrian Protection PPAP End-of-Line Test Iterative Matching Etc.DSI-VPI6 week add from GVDP 4.114GVDP v5_Upd_trg.ppt/Don Smith/5/22/2006/version 6.0INDEXDSI-181SORP0VPI-159IDRVDR-112IDR-105Design ARM SourcingSORBCTProcure PartsDesign ANRMSourcingSORBCTProcure PartsTheme DevelopmentCVER-117SVER-100100%IVER-90FGCV Design SolutionFGDesign SolutionIV Design SolutionFGSV Design SolutionProcess/FormabilityDesignDiesConstruction/VerifyDies IVERMMRBCTProcure Parts FIVC-80FGsmVDR-95100%-88VDRSF-116PSD-121DTA-172AD-166GVDP 4.1 Framework 37/20MVBsMVBnsPVVDesign BodyShop ToolsConstruction/VerifyBody Shop Tools StylingMulesIVEngineering DesignManufacturing/LaunchTo show how time was removed for 5.0,lets build the framework starting with 4.115GVDP v5_Upd_trg.ppt/Don Smith/5/22/2006/version 6.0INDEXDSI-166SORP0VPI-144IDRVDR-112IDR-106Design ARM SourcingSORBCTProcure PartsTheme DevelopmentCVER-109SVER-98FGCV Design SolutionFGSV Design SolutionProcess/FormabilityDesignDiesConstruction/VerifyDies BCTProcure Parts FIVC-79smVDR-96100%-90VDRSF-116DTA-157AD-151Design ANRMBCTProcure PartsSourcingSOR100%IVER-83IV Design SolutionFGBuild OneIVERMMRMVBsMVBnsPPVConstruction/VerifyBody Shop Tools Design BodyShop ToolsStylingMulesIVEngineering DesignManufacturing/LaunchDesign work stream reduced a total of 16 weeks from VPI to sm VDR Theme Refinement Process IDR/VDR ProcessStyling&Surfacing Process ChangeEnabled by:Increased sketch work done pre-DSIRevised definition of IDR requirementsEarlier sourcing of DC 12 componentsRevised DFP scheduleSTD-148STD MD-14016GVDP v5_Upd_trg.ppt/Don Smith/5/22/2006/version 6.0INDEXSORP0IDRVDR IDR-106CVER-109SVER-98FGCV Design SolutionFGSV Design SolutionProcess/FormabilityDesignDiesConstruction/VerifyDies BCTProcure Parts FIVC-79smVDR-96100%-90VDR100%IVER-83IV Design SolutionFGBuild TwoIVERMMRDesign ANRMBCTProcure PartsSourcingSORDesign ARM SourcingSORBCTProcure PartsSF-116MVBsMVBnsPPVConstruction/VerifyBody Shop Tools Design BodyShop ToolsStylingMulesIVEngineering DesignManufacturing/LaunchDTA-163AD-155DSI-172Theme DevelopmentSTD-148VPI-144Time between DSI and VPI extended by 6 weeks for more robust theme development before the clinic and Engineering assessment after clinicLengthening of DSI-VPI Process17GVDP v5_Upd_trg.ppt/Don Smith/5/22/2006/version 6.0INDEXSORP0IDRVDR IDR-106Design SourcingSORBCTProcure PartsCVER-109SVER-98FGCV Design SolutionFGSV Design SolutionProcess/FormabilityDesignDiesConstruction/VerifyDies BCTProcure Parts FIVC-79smVDR-96100%-90VDR100%IVER-83IV Design SolutionFGBuild ThreeIVERMMRSF-116MVBsMVBnsPPVConstruction/VerifyBody Shop Tools Design BodyShop ToolsVPIStylingMulesIVEngineering DesignManufacturing/Launch4.1Since the mule stream could not be reduced to match the styling reduction,mule sourcing and design activity starts earlier relative to VPISourcing and engineering requirements have been revised to accommodate this changeMule Stream Pull-AheadDTA-163AD-155DSI-172-112Theme DevelopmentSTD-148VPI-14418GVDP v5_Upd_trg.ppt/Don Smith/5/22/2006/version 6.0INDEXSORP0IDRVDR IDR-106Design SourcingSORBCTProcure PartsCVER-109SVER-98FGCV Design SolutionFGSV Design SolutionProcess/FormabilityDesignDiesConstruction/VerifyDies IVERMMRBCTProcure Parts FIVC-79100%IVER-83IV Design SolutionFGsmVDR-96100%-90VDRBuild FourSF-116MVBsMVBnsPPVDesign BodyShop ToolsConstruction/VerifyBody Shop Tools Overlap of ME Activities with engineering designStylingMulesIVEngineering DesignManufacturing/LaunchOverlap of ME Activities with engineering designME willingness to start dies and body shop tooling with IVER MMR vs LL IVER releaseOverlapping of ME activities with Engineering DesignMust adhere to IDR data approximately 1mm to VDR or as restricted by the Red/Blue ProcessDTA-163AD-155DSI-172-112Theme DevelopmentSTD-148STD MD-140VPI-14419GVDP v5_Upd_trg.ppt/Don Smith/5/22/2006/version 6.0INDEXKey GVDP 5.0 Process AgreementsGVDP 5.0 Assumptions and Enablers(link)GVDP 5.0 Modification Restrictions(link)Lead Time Reduction Changes Lengthening of DSI-VPI Process Styling&Surfacing Process Change Mule Stream Pull-Ahead Relative to VPI Overlapping of ME activities with Engineering DesignProcess Additions/Refinements/Clarifications PPAP Process End of Line Testing Ped Pro Iterative Matching PQRR Process Additional Changes20GVDP v5_Upd_trg.ppt/Don Smith/5/22/2006/version 6.0INDEXLengthening of DSI-VPI ProcessCurrently 22 weeksDSI-172AD-155Theme AlternativesDevelop Single Theme AlternativesDSI-181AD-166DTA-172Theme AlternativesDevelop Single Theme+4+2GVDP 4.1GVDP 5.04 additional weeks to develop themes2 additional weeks for engineering assessment of clinic input(not Design driven)VPI-144DTA-163clinicNEXTSingle ThemeDevelop ThemeSTD-148clinicSTD-161VPI-159DSI Document of Strategic IntentSTD Single Theme Direction DTA Design Theme AlternativesVPI Vehicle Program InitiationAD Alternatives DevelopmentAdded 6 weeks21GVDP v5_Upd_trg.ppt/Don Smith/5/22/2006/version 6.0INDEXLengthening of DSI-VPI ProcessGVDP 5.0What has changed?4 weeks added between DTA and the STD2 weeks added between STD and VPIWhy has it changed?4 weeks,enables a more robust design styling process by allowing additional time to create and optimize multiple themes to a given set of architectural criteria with increased fidelity of the design surfaces.2 weeks,for engineering assessment of the single theme decision outcome and to allow for management reviews(Engineering and Program Management Driven)What does this mean to Program Teams?Clinic properties will have the benefit of a more robust and comprehensive theme development processHigher fidelity theme at Single Theme DirectionAdditional time to complete business case and Charter document at VPIAdditional time for management reviewsDSI-172AD-155Theme AlternativesDevelop Single Theme AlternativesAdded 6 weeks+4+2VPI-144DTA-163Single ThemeSTD-148clinicDSI Document of Strategic Intent STD Single Theme Direction DTA Design Theme Alternatives VPI Vehicle Program InitiationAD Alternatives Development22GVDP v5_Upd_trg.ppt/Don Smith/5/22/2006/version 6.0INDEX15 weeks closer to MarketStyling&Surfacing Process ChangeIDRVDR InteriorUppersDoorsFenders&Quarter PanelsHood&DecklidFascias/Lamps/Grilles/MoldingsDevelop Theme100%VDR-88VDRsm-95IDR-105PSD-121ESO-132VPI-159-113-105-88-121-113-101-119-117-117-115-110-106-106-102-97-98-98-98GVDP 4.1SF-113CSO-113DSO-125NEXTIDRVDR Single ThemeVDRsm-96ESO-127SF-116100%VDR-90GVDP 5.0IDR-106-116-106-90Interior-116-106-96Metal-116-106-94VPI-144DSO-120CSO-108Fascias/Lamps/Grilles/MoldingsDSI-172Theme AlternativesDevelop Single Theme AlternativesDTA-163STD-148AD-166Theme AlternativesDevelop Single ThemeDTA-172STD-161clinicclinicRefine ThemeRefine ThemeSTD-Single Theme Direction DSO Design Sign Offf STD-MD Single Theme Direction Math Data SF Styling FreezeDTA Design Theme Alternatives VPI Vehicle Program initiation PSD Preliminary Styling Data IDR Initial Data ReleaseAD Alternatives Development ESO Engineering Sign Off CSO Contact Sign off VDR Verified Data ReleaseDSI-181TA-115TA-115AD-155clinicclinicSTD MD-140STD MD-15523GVDP v5_Upd_trg.ppt/Don Smith/5/22/2006/version 6.0INDEXStyling&Surfacing Process ChangeWhat has changed?Theme development has been reduced by 16 weeks(STD to SF)Single theme math is now 15 weeks closer to the marketIDR/VDR activities consolidated(6 to 3)and moved to single IDRTime between DSO and SF reduced by 8 weeksPreliminary Styling Data(PSD)&Theme Approval(TA)have been removed Why has it changed?Enabled by higher fidelity theme at STD due to added time between DSI&VPI IDR/VDR work stream consolidation now aligns more closely with interdependent surface development Single IDR and proximity of DSO and SF eliminates need for PSDTheme approval not a separate milestone and essentially occurs at DSO.Final design reflected in SF 4 weeks laterWhat does this mean to Program Teams?Earlier decisions required(relative to VPI)to support earlier styling critical sourcing Less time between STD and SF reduces the opportunity for iterations,reducing the program teams ability to make changes post DSOLess potential change after IDR since panels are developed simultaneously before IDR releaseEasier tracking of surface releases Requires rigorous adherence to R/B Process for IDR/VDR surface change management(formerly R/B/G Process)Critical for inner metal release integrity,IV fidelity,and overlap with ME workstreamIDRVDR Single ThemeVDRsm-96ESO-127SF-116100%VDR-90GVDP 5.0IDR-106-116-106-90Interior-116-106-96Metal-116-106-94VPI-144DSO-120CSO-108Fascias/Lamps/Grilles/MoldingsDSI-172AD-155Theme AlternativesDevelop Single Theme AlternativesDTA-163clinicSTD-148clinicRefine ThemeDSI Document of Strategic Intent STD-Single Theme Direction DSO Design Sign Offf SF Styling FreezeDTA Design Theme Alternatives VPI Vehicle Program initiation PSD Preliminary Styling Data IDR Initial Data ReleaseAD Alternatives Development ESO Engineering Sign Off CSO Contact Sign off VDR Verified Data ReleaseVDRsm VDR Sheet Metal STD MD Single Theme Direction Math DataSTD MD-140clinic24GVDP v5_Upd_trg.ppt/Don Smith/5/22/2006/version 6.0INDEXSourcing of Styling Critical ComponentsESO-127SF-116GVDP 5.0VPI-144DSO-120CSO-108DSI-172clinic-133Fascias/GrillesDCSSOR(6)Supplier Selection(14)-153LampsDCSSOR(5)Supplier Selection(12)-144-161MirrorsDCSSOR(6)Supplier Selection(14)-134-154DCSSupplier Selection(14)-133-153Luggage RackSOR(6)SeatsDCSSOR(6)Supplier Selection(14)-144-164IPs,Consoles,DoorsDCSSOR(6)Supplier Selection(14)-140-160DCSSupplier Selection(14)-136-156Wheels,HVAC OutletsSOR(7)DCSSupplier Selection(14)-127-147ClusterSOR(6)Design Center has eliminated 16 weeks(STD-SF)to enable 5.0.This is a 40%reduction in the amount of styling time Design Timing Reductions based on Key Suppliers Selected at designated timesSourcing timing is driven by need for styling to work with suppliers to develop criteria before ESO25GVDP v5_Upd_trg.ppt/Don Smith/5/22/2006/version 6.0INDEXSORVDRsm-96-104Final Soln Design-140BCTProcure Parts-113CVER-109FinalSoln-124-105-137-165GVDP 5.0SVER/IVBR-98ARC-151NEXT Sourcing-172DSI-172DSI Document of Strategic IntentCVER Concept Vehicle Engineering ReleaseVPI Vehicle Program InitiationSVER Structure Vehicle Engineering ReleaseARC Architecture Refinement CompleteVDR Verified Data Release19 Weeks37 WeeksMRD GAMRD GADev Structure Veh Design SolnDev Concept Veh Design SolnVPI-144SVER/IVBR-100-104-121CVER-117FinalSoln FinalSoln Design ARMBSourcingSORSORSourcingDesign NRM-150-149Procure PartsBCTProcure Parts-173-170-149-121-104-134-131-121-163-95VDRsmGVDP 4.1DSI-181Dev Concept Veh Design SolnDev Structure Veh Design SolnCT-159VPIMule Stream Pull-ahead Relative to VPIFMC-12126GVDP v5_Upd_trg.ppt/Don Smith/5/22/2006/version 6.0INDEXSORWhat has changed?Mule process consolidated to common BIW,non-running and running workstreamFirst Mule Complete(FMC)wk-121,First Running Mule available 2 weeks later at wk-119BIW,Non-running&Running Mules moved earlier relative to VPINew Milestone(ARC Architecture Refinement Complete)Why has it changed?Mules are not driving timing post VPI(Design Center and Powertrain Calibration are)Pulling Mules ahead re
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