Sequencing Center for OEM
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The document outlines plans for managing off-site warehousing and sequencing assemblies for GM assembly plants. It describes setting up linear kitting lines to sequence parts and subassemblies for delivery to plants just-in-time based on their broadcasts. It aims to enable plants to operate with lower inventories and higher turns by controlling quality issues and rapid responses from the off-site location.
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![[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],TPS – GM Sequencing Project](https://image.slidesharecdn.com/sequencingcenter915082-12556910511088-phpapp01/85/Sequencing-Center-for-OEM-1-320.jpg)
![TPS - GM Sequencing Project TPS Off Site Central Warehouse GM Receiving and Assembly Line Distribution ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Rack 1 Rack 2 Rack 3 C B A C B A C B A JIT ATV Kits Station 1 Kits Station 2 Kits Station 3 Receiving Door Delivery Schedule](data:image/gif;base64,R0lGODlhAQABAIAAAAAAAP///yH5BAEAAAAALAAAAAABAAEAAAIBRAA7)
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- 3. Manage Off Site Central Warehousing (w/ Multiple Linear Kitting Lines) Linear Kitting Line #1 Linear Kitting Line #2 Linear Kitting Line #3 Warehouse Tugger Service Trucking Service GM Suppliers Broadcast 1 Line 1 Kit Station 1 C1 B1 A1 C2 B2 A3 A2 Line 1 Kit Station 2 F1 E1 D1 F2 E2 D3 D2 Line 2 Kit Station 1 C1 B1 A1 C2 B2 A3 A2 Line 2 Kit Station 2 F1 E1 D1 F2 E2 D3 D2 Line 3 Kit Station 1 C1 B1 A1 C2 B2 A3 A2 Line 3 Kit Station 2 F1 E1 D F2 E2 D3 D2 X GM Broadcast Signal Kanban Fork Lift Service
- 4. Integrated Kitting and Sub assembly Line (Linear Kitting Line) w/ (U-shape flexible cell) LOAD ENTRY to Sub assembly Line Linear Kitting Line 1 4 2 3 5 6 7 Typical ‘U-shaped’ sub-assembly Cell 2 Kit Station 1 C1 B1 A1 C2 B2 A3 A2 Kit Station 2 F1 E1 D1 F2 E2 D3 D2
- 6. Control Non-conforming material Off Site @ TPS Warehousing 4 Linear Kitting Line #3 Warehouse Trucking Service GM PR&R’d Supplier PR&R Certified Stock Recurrent Non conformances Rapid Break Point TPS Control Line 3 Kit Station 1 C1 B1 A1 C2 B2 A3 A2 Line 3 Kit Station 2 F1 E1 D F2 E2 D3 D2 Fork Lift Service Quarantine Inventory & WIP @ TPS facility Manage 3 rd party containment if required 100% Certify
- 7. Manage Containers and Dunnage Disposable and Returnable 5 Disposable &/or Scrap Inspect & Clean Wash Finished Goods Container Management Process TPS Warehouse Suppliers GM Assembly Plants Kitting & Sequencing Containers Bulk Containers Tracking System 1 2 3 5 5 Re-order 6 No Yes Repair
- 8. Off site Plant Layout 6 Supermarket Shipping Fork Lift Service Fork Lift Service X Tugger Service Linear Kitting Line #1 Linear Kitting Line #1 Linear Kitting Line #1 Quarantine And Certification Packaging and Dunnage Control Sequencing Tugger Service Area TPS Office Supplier Receiving Doors GM Shipping Doors
- 9. Off site Plant Supermarket Layout 7 Racking Layout Bulk Material Storrage
- 10. Off site Plant - Tugger System 8 Dolly Exchange Tugger Vehicle Sequencing Line Racking 180’ turn inside 10 Feet !
- 11. Off site Plant – Kanban Delivery System 9 Kitting Line Rack 1 Rack 2 Rack 3 C B A C B A C B A C B A Central Supermarket Storage X X Kanban Card Delivery Route X Empty Containers X Standardized routes delivering small containers on a frequent schedule (once per hour or less). More frequent deliveries lower material inventory at operations. 12 1 2 3 Signal alerts time for Kanban cards to be collected from posts. A-107 A-108
- 12. Off site Plant – Dolly Delivery System 10 Dolly Exchange Empty Full Full Full Full Full Full Part: Adjuster Part No: 9981427 Std. Pack: 90 Min: 1 Max: 3 Stack: 3 High Part: Pan Part No: 4563273 Std. Pack: 75 Min: 1 Max: 3 Stack: 3 High Full Full Route driver delivers dolly & full container based on signal. Full Empty Empty dolly signals replenishment. Operator pushes out empty dolly & container then pulls next dolly into position. A-108