Development of a Generic Measurement Point System to Improve the Dimensional Control Processes in Automotive Body-In-White Manufacturing

During a vehicle launch period, a critical dimensional management step is the Body-In-White (BIW) measurement point selection process, vital to ensure the dimensional quality control elements in the BIW production. This process is repeated for every new vehicle launch with a dedicated cross-functional team. Although it uses many precious resources during the vehicle launch, it cannot guarantee the success of the selection result as it may lead to too many points or disregard of some key process control points. The effect can vary from model to model according to the composition of the selection team. However, the vehicle design and manufacturing processes do not change dramatically from model to model. Hence the dimensional control requirements should remain similar.

A research project has been developed to apply a lean strategy to, and eliminate waste from, the measurement point selection process and has resulted in the Generic Measurement Point System (GMPS). The GMPS project applies lean principles to identify waste in the selection process, and applies knowledge management methods to select generic measurement points at each stage of process control. It has been applied during a recent product launch at a car manufacturer. This paper will introduce aspects of the newly developed system, which involves objectives, methodologies, development approaches, justifications and recommendations for the future development.