Adam Opel AG

Manufacturing Engineering Body

RFQ - Attachment J – 45XX

Digital Documentation of the Manufacturing Process with Process

Designer

1 Overview ................................................................................................................ 2
1.1 Software Requirements 2
1.2 Sources provided by Opel 2
1.3 Deliverables 3
1.4 Variant Sets and Filters 3
1.5 High level Workflow overview to create/ update deliverables 4
1.6 Documents with detailed process description + procedure standards 4
2 GME specifics ........................................................................................................ 5
2.1 Legacy Area Naming and Numbering 5
2.1.1 Base Rule 5
2.1.2 Legacy Station Name 5
2.1.3 Legacy Station Tool Number 5
2.1.4 Legacy Welding Gun Design 6
2.1.5 Legacy BOP-Manager Report 6
2.2 Attach Queries as Excel file 7
2.3 Weld Buy Off Documents 7
2.4 Sealer and Adhesive documentation 11
2.4.1 How to implement Sealer and Adhesive Images from other Systems 11
3 Timing .................................................................................................................. 12
3.1 Timing for data delivery/ Number of update loops 12
4 Contact Persons .................................................................................................. 12

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Manufacturing Engineering Body

1 Overview

Tecnomatix Process Designer is used to plan and document the manufacturing process.

1.1 Software Requirements

Teamcenter, NX, Tecnomatix (Process Designer + GM Customization + GM BIW Tools
+ GM Reports + Bop-Manager + jt-Data-Acquisition Tool (JDA)), ODETTE SFTP (DXM).
Please contact Gisela Herzing-Degen (ME IT) for details on the Tecnomatix software.

1.2 Sources provided by Opel

Project Template.
Robot Resource Objects (without 3D rep).
MDM as UG NX and jt data set at TcAE.

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1.3 Deliverables
Operation- and synchronized Resource-Tree.
Product, Datums, Welds, Weld Gun Resource Objects and Robot Resource
Objects assigned to Stations and Operations.
Process Flow shown by PERT-View.
Dynamic In Process Assembly (IPA)
Reports according to Global GM standards: Weld Data Sheets, Datum Sheets,
Process Flow Sheets, Hemmer Sheets, Sealer Sheets, Fastener Sheets, Induction
Cure Sheets, Metal Removal Sheets, GM BIW Reports (.xls: QAP & QCD &
QWD), Process Change Summary (.xls: QCS).
Weld Buy Off documents (WBOD).
All Robcad Studies from the Deliverables folder where the Snapshots were
saved. Only at SORP.

1.4 Variant Sets and Filters

Variant Sets and Filters are not used anymore. Create model option specific Sub-
Zones, Stations and Operations within the Operation Tree to handle the different
model options (e. g. “AA Zone_B01_LHD” with “AA050_B01_LHD” with “OP70_LHD”)
See example screenshot below for Motor Compartment Main Line with Right Hand
Drive (RHD) and Left Hand Drive (LHD) model options.

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1.5 High level Workflow overview to create/ update deliverables

1. 2. 3.
Export MDM from Import MDM into Create/update
TcAE with JDA-Tool PD Operation Tree +
Resource Tree

4. Create/update 5. 6. Create/update
Parts Create/Update Dynamic In
assignment to Pert View Process
Stations Assembly (IPA)

7. Create/update 8. 9. Create/update
Datums Create/update weldgun + robot
assignment to Welds assignment resource objects
Operations to Operations assignment

10. 11. Type in/ 12. 13. 14.

Create/ update Create/ Create/ Export
update attributes to update update PD data
images for complete BIW WBOD and
BOP- Reports (e. g. Reports forward
Reports Tool Number) to Opel

1.6 Documents with detailed process description + procedure standards

GEP1 (in particular Section 3.3. Process Designer System)
GEP1 (in particular Section 5 - Naming and Numbering)
GCE1
All mentioned above Global Specifications are online available at GM Supply
Power within the Global Standards Library:
https://www.gmsupplypower.com/apps/bodyext/

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2 GME specifics

2.1 Legacy Area Naming and Numbering

2.1.1 Base Rule

Follow GEP1 Section 5 for naming and numbering.

2.1.2 Legacy Station Name

2.1.3 Legacy Station Tool Number

Legacy Tool Number (TcAE Item ID) also allowed for Production ToolNum at Station
Attribute Tab if Tool design is reused.

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2.1.4 Legacy Welding Gun Design
Check Weld Gun Resource Library provided by Opel for availability of Legacy Welding
Gun Prototype first. If Welding Gun Prototype is not available create a new one and
type in the TcAE item id of the reuse welding gun at the Catalog Number field. See
SKM Revision 09.2 Section 11 for more details about reuse welding guns.

2.1.5 Legacy BOP-Manager Report

e. g. Weld Data Sheet

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2.2 Attach Queries as Excel file
Due to the different separators Excel uses at the different regions it is required to
attach Queries (e. g. QAP & QCD & QWD) as Excel file to make them readable for the
plant folks. The Excel files have to show the data in a correct spreadsheet format
(more than one column with content, correct values for X, Y, Z) after opening. To
make this possible it could be required to rearrange the spreadsheet after opening
the .csv-file that was created by the Process Designer Query Tool. If all text is shown
within one column the Excel functionality [DATA – TEXT INTO COLUMN] has to be
used to bring the spreadsheet into a proper format before safe.

2.3 Weld Buy Off Documents

The weld buy of documents are required to review the welded assemblies and to
validate that all welds spots, welding seams and Clinch spots provided by Product
Engineering (PE) are executed and available in a proper quality.

Weld Buy Off Documents (WBOD) are created within Process Designer based on the
product assemblies and weld files provided through the MDMs. The major difference
to the Weld Data Sheet is that all weld spots (welded by different welding guns + POA
welds) along a weld flange are shown. Only the numbers for the weld spots to be
checked at the specific Sub-Zone are shown.

The following workflow steps are required to provide the Weld Buy Off documents for
a specific Sub-Zone (e. g. AA Zone_B01_LHD - Motor Compartments Mainline LHD):
1. Load the Operation Tree Sub-Zone (e. g. AA Zone_B01_LHD) from the Navigation
Tree (PRD Assembly=Last IPA of the Sub-Zone).
2. Select and display all Weld spots from the MfG Tree Viewer.
3. Create Objects Notes for all weld spots displayed.
4. Display the product parts.

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5. Search all weld spots that are connected to the loaded product parts by using the
Power Bar – Search Tool to show the POA welds also (Search Scope: The MDM
related WLD Library from the Manufacturing Features Libraries folder; Assigned
to Parts; Use IPA Parts; Operation: Select the Sub-Zone top knot in the Operation
Tree Viewer; Exact Match). See example below.

6. Load all welds from the Power Bar Search Result window. (Hint: Use the Relation
Tree Viewer with “Show Sub-tree Relations” to remember the welds that are
assigned to the Operation Tree Sub-Zone you initially loaded.)
7. Arrange the note flags for the first image.
8. Each image has to show one dimension as a reference. The dimension should be
between two weld spots that are in a plane which is parallel to the screen (e. g. X-
Y plane).
9. Each image has to show two note flags with X, Y, Z coordinates for orientation.
One near to the upper left corner and one near to the lower right corner of the
image. Use shown below Note Settings (Use Customize… to get the Note Settings
button) for this Note Flags.

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10. Create a snapshot. Snapshot Naming Convention: WBOD_[Sub-Zone
designator]_[Project #]_[Image Number]_[Version] (e. g.
WBOD_AA_B01_LHD_3400_01_01).
11. Use Add Markup to add the snapshot name to the image and to save the snapshot
as jpg-file to a temporary folder (e. g. C:\temp). File Naming Convention:
WBOD_[Sub-Zone designator]_[Project #]_[Image Number]_[Version].jpg (e. g.
WBOD_AA_B01_LHD_3400_01_01.jpg)
12. Create as much snapshots and images as required to document all welds that
have a Note Flag. See example image below. Remember that the images have to
be printed out in full scale later (Paper Width is the driver for the image Size; e. g.
paper coil width=900 mm allows to show a maximum of 900 mm real product
view on the image height and a resulting larger value (e. g. 1150 mm) on the
image width.

AA_B01_LHD_3400_01_01

13. Select File, Save As. Select the according Zone Study Folder. Study file naming
convention: WBOD_[Sub-Zone designator]_[Project #] (e. g.
WBOD_AA_B01_LHD_3400).

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14. Run the predefined GM-BIW Report QWD-MFGTab-AssignedWelds.rpt from the
Operation Tree Sub-Zone. Delete all columns except: Number, SPOT #, X_POS,
Y_POS, Z_POS, Part Number, Material, WELD CLASS, ROB #, Gauge. Save the
selected columns Local for further use. Run the report. Sort spreadsheet by Name
(Spot Number) descending.

15. Save the spreadsheet as Excel file. File Naming Convention: QWBO_[Sub-Zone
designator]_[Project #]_[Version].xls (e. g. QWBO_ AA_B01_LHD_3400_001.xls) to
#\sysroot\LibraryRoot\[Lead Program#]\BIW\Docs\ Queries\[Plant]\QWBO (e. g.
#\sysroot\LibraryRoot\3400\BIW\Docs\Queries\Bochum\QWBO)
16. Print out Excel spreadsheet (DIN A4).
17. Insert all images created for the Sub-Zone into one PowerPoint file. File
Naming Convention: WBOD_[Sub-Zone designator]_[Project
#]_[Version].ppt (e. g. WBOD_AA_B01_LHD_3400_001.ppt). File Location:
#\sysroot\LibraryRoot\[Lead Program#]\BIW\Docs\Reports\[Plant]\WBOD
(e. g. #\sysroot\LibraryRoot\3400\BIW\Docs\Reports\Bochum\WBOD).
18. Add footer with Name of Creator, Date of Creation, Page Number/Total pages to
the PowerPoint file.

19. Print out each PowerPoint slide in full vehicle scale (1:1) two times (one plot for
archival storage at the plant and one plot for WBOD Execution).
20. Create a Drawing list in Excel for each Sub-Zone with all Drawing Sheet Numbers,
Name of Creator, Date of Creation, and Change Description. Insert a change
description at column “D” starting with the second Revision of a drawing sheet.
File Naming Convention: WBODO_[Sub-Zone designator]_[Project
#]_[Version].xlsx (e. g. WBODO_AA_B01_LHD_3400_001.xlsx).

21. Print out the WBODO Excel Spread Sheet to paper sheet size DIN A4 (or Letter).
22. Attach the PowerPoint and Excel files to the corresponding top knot of the Sub-
Zone within the Operation Tree to archive these documents.

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2.4 Sealer and Adhesive documentation
BOP-Manager is used as the official source for providing Sealer and Adhesive
documentation for the body shop. The documents provided are used to check the
correct application of Sealer and Adhesive at the plants.

In general the BOP-Manager standard report called Sealer Application Sheet should be
used for all types of Antiflutter, Crash toughened adhesive, Structural hem flange
adhesive and sealing seams. The Sealer Application Sheet is available on station level.

BOP-Manager Sealer Application Sheets have to provide the following information on

Sealer and Adhesive:
1. Sealer/Adhesive Type
2. Diameter of each sealer/adhesive bead
3. Length of each sealer/adhesive bead
4. Clear bead position which was determined during the launch phase at the
plant.

2.4.1 How to implement Sealer and Adhesive Images from other Systems
1. If an image created with Process Designer (PD) does not fulfill the
requirements especially if a lot of dimensions are required it could be replaced
by an image out of other Systems (e. g. UG NX, PowerPoint).
2. To display the image within the Sealer Application Report the following
requirements have to be fulfilled:
a. The image was saved as jpg-file.
b. The image size was set to 600x400 pixel.
c. The Image file was saved at the correct Sysroot path.
d. File name must be compliant to GMEMS naming convention
(SA_staxxx_##.jpg).

The easiest way to find the correct image path is to look at the properties of an
already attached Process Flow image. The image path is including the External
ID of the station created by the system (e. g.
…\sysroot\images\Gliwice_3400\PP-GM-6-7-2009-13-20-13-312195-
943069\version_1305\).

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3 Timing
3.1 Timing for data delivery/ Number of update loops
Update Process Designer project within the supplier environment. Follow the
complete workflow shown at Section 1.5 to create all deliverables mentioned at
Section 1.3. Send updated Process Designer data to Opel for the listed below Master
Timing milestones. The exact delivery date will be announced by Opel minimum four
weeks prior to the supplier delivery is required.

1. CVER M1, SVER M1, IVER P2

2. PPV (Start of PPV build phase, WBOD initial creation inclusively)
3. SMVBns (WBOD update inclusively)
4. SORP (WBOD update inclusively)

4 Contact Persons
For further information please contact:

Regarding Processing Workflow: ME Body, Frank Kiefer

Phone: +49-6142-7-61776
Email: frank.kiefer@de.opel.com

Regarding Process Content: Responsible MEB Planning Engineer

Regarding MDM: ME Body, Thomas Kinzel

Phone: +49-6142-7-61281
Email: thomas.kinzel@de.opel.com

Regarding IT: IS&S, Gisela Herzing-Degen

Phone: +49-6142-7-76372
Email: gisela.herzing-degen@de.opel.com

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