Introduction
General Motors Company (GM) designs, builds, and sells cars, trucks and automobile parts globally (SEC, 2011). It also provides automotive financing services through GM Financial. The vehicle development activities are integrated into a single global organization to consolidate and standardize the approach to vehicle development (SEC, 2011). The company purchases wide varieties of raw materials, supplies, parts, freight, energy, and other services from various suppliers, for the manufacture of its products. The raw materials are generally made up of steel, aluminum, copper, lead, resins and platinum group metals. This paper analyses the process of manufacturing automobile parts. In particular, it discusses the general process of manufacturing the mechanical parts; provides the process map for the manufacturing process; and identifies the areas that the company needs to improve.
GM manufactures automobile parts under the GM Global Manufacturing System which is an entirely unique process (AutoPartsWAY, 2012). The system is an important building block of integrated strategies that develop the parts and products to satisfy the needs of the global customers. The manufacturing plants and processes are designed such that efficiency is enhanced so that great vehicles can be built; vehicles that provide customers with quality, value, and responsiveness (AutoPartsWAY, 2012). The parts are factory-developed, engineered, and tested, based on strict standards.
Manufacturing process begins with the raw materials. For mechanical parts, the raw materials include iron steel, copper, aluminum, carbon steel, solder alloys, bronze, or other materials, depending on the type of the automobile. The materials are then mixed in the required proportions and compound inspection done. If the mixture is not satisfactory (not according to the required proportions) then, it is re-mixed until the required proportion is reached. The mixture is then shaped and surface treatment conducted (Yamada, 2010). The treatments include preheating, UHF curing, hot air curing, and coating. An online check is done for the parts that require it before hot air cutting. If the materials pass the online check, then, hot air cutting is done. If they fail the test, then they are recoated and offline check conducted. Once the offline check is satisfactory, the parts are taken for cross section check. If the parts do not satisfy the offline check, then they are recoated until the check is satisfactory, and then taken for cross section check. Meanwhile, the parts that went through hot air cutting, are further drilled, cooled, bended, and cut depending on the materials. Inspection is then carried out. If not satisfactory, the parts are reworked and inspected again until satisfactory results are realized. The inspected materials are taken for cross section check. If the cross section check fails, then the materials are rendered scrap. Function check is carried out for the parts that have passed the cross section check. If they fail the function check, then they are considered scrap. After the function check, the following processes include aging, final cut, point mark, end joint, and adhesive application, depending on the parts. Final inspection is then carried out and the parts parked, ready for shipping. If the parts fail in the final inspection, then they can be reworked and further inspected until they meet the requirements, or rendered as waste, depending on the parts and the materials.
Process Map
A revised process map showing areas that could be improved
Considering the process map above, it’s evident that the process encourages waste of materials. There is no provision for re-use of the scraps. There are three stages where scraps are collected, but no stage where they are fed back into the system. While some scraps cannot be reused, it’s illogical to believe that all the scraps are waste, as highlighted in the process map. The revised process map injects the scraps back into the system to improve the efficiency and reduce the wastes.
When observed keenly, it’s realized that the given process map has no provision for storage. Storage is necessary, especially after receiving the raw materials and before mixing. Storage is also necessary after compound inspection, immediately before shaping and pretreatment. In other words, not all the raw materials received are fed into the system; some are stored temporarily before mixing and after compound check. Storage is also necessary after packaging, just before shipping. All these recommendations are included in the revised process map below
Revised process map
GM is a make-to-stock company. The production is matched with the customer demand forecasts. Demand forecasts help in determining the quantity produced. The company doesn’t outsource its manufacturing. There is a central organization mainly concerned with the development of non-visible parts such as the heating system, brake system, ventilation; and the global architecture development teams concerned with the development of unique components of each brand such as the interior and exterior design, brand character requirements, and government requirements (SEC, 2011). According to the first process map, GM appears as if it is a make-to-order company since there is no provision for the storage of the final products. However, this is corrected in the second process map to reflect the company’s actual situation.
References
AutoPartsWAY (2012). GMC Parts. Retrieved November 28, 2012 from
GM (2000). GM Global APQP (Advanced Product Quality Planning). Retrieved November 28, 2012 from
GM (2008). Global Supplier Quality Manual. Retrieved November 28, 2012 from
U.S. SEC. (2011). General Motors Company, Form 10-K. Retrieved November 28, 2012 from
Yamada, M. (2010). GM Global APQP for Suppliers. Retrieved November 28, 2012 from
