ALENIA EXPERIENCE ABOUT VARIATION MANAGEMENT OF KEY CHARACTERISTICS
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1 ALENIA EXPERIENCE ABOUT VARIATION MANAGEMENT OF KEY CHARACTERISTICS R. del Pezzo Alenia Aeronautica S.p.A. April 11th, 2003 Edinburgh General Assembly 1
2 Alenia starting with Boeing programs has gained significant experience about variation management of Key Characteristics The following major steps have been carried out to achieve the objective:! Working Group Appointment! Key Characteristics Identification! Data Collection to measure Key Characteristics Variation! Cpk Calculation Process Capability Assessment! Results Evaluation in terms of Quality & Costs April 11th, 2003 Edinburgh General Assembly 2
3 BOEING Vertical Fin Case Objectives Team Appointment K.C. identification Customer Satisfaction Non Conformities Reduction Assembly Cost Reduction Gage R&R Statistical Process Control (S.P.C.) April 11th, 2003 Edinburgh General Assembly 3
4 Risk Analysis - Results A B C A B C Critical Zones Mismatch Tip Assy Int Gap Tip Assy Int Gap L.E. Assy Int The K.C. have been identified in Critical Zones April 11th, 2003 Edinburgh General Assembly 4
5 K.C. Example A B C A = Trim Critical Zones K. C. Mismatch Tip Assy Int a, a1 Gap Tip Assy Int. b, b1, b2, b3, b4, b5, b6, b7, b8 Gap L.E. Assy Int c, c1, c2, c3, c4, c5 B = Fin Tip / Panels gap C = Leading Edge / Panels gap April 11th, 2003 Edinburgh General Assembly 5
6 Cpk - Example of achieved results 4,00 3, ,00 1,00 0,00 a a1 c c1 c2 c3 c4 c5 b b1 b2 b3 b4 b b5 b6 b7 K.C. April 11th, 2003 Edinburgh General Assembly 6
7 Vertical Fin Non Conformity Trend N/C Vertical Fin Rejection Trend R/S April 11th, 2003 Edinburgh General Assembly 7
8 Vertical fin - Non Quality Cost M/H April 11th, 2003 Edinburgh General Assembly 8
9 Further Cases B 767 B 777 Flap Radome Slat Flap Radome April 11th, 2003 Edinburgh General Assembly 9
10 Boeing Programs Non Quality Cost Unit Trend M/H April 11th, 2003 Edinburgh General Assembly 10
11 Based on positive results obtained by K.C. Variation Management application, ALENIA has extended this approach to: A 380 Program According to pren 9103 Alenia is responsible for definition and development of design and production of significant part of A380 central fuselage (sect - 15) April 11th, 2003 Edinburgh General Assembly 11
12 THAT MEANS Full compliance to pren 9103 Standard is a Company goal for the present and the future Programs April 11th, 2003 Edinburgh General Assembly 12
13 A 380 PROGRAM Determination of Key Characteristics has been performed in Concurrent Engineering using Risk Analysis method in order to identify the risks connected to Candidate Key Characteristics variation Extensive training on statistical techniques has been carried out for middle management and operation personnel involved in the Program April 11th, 2003 Edinburgh General Assembly 13
14 ACTIVITIES BLOCK DIAGRAM Team Appointment Team Training Process Flow Diagram Key Characteristics identification by Risk Analysis Gage R&R Process Continuous Improvement Data Collection S.P.C. Cpk Assessment April 11th, 2003 Edinburgh General Assembly 14
15 TEAM COMPOSITION Manufacturing Logistics Quality Statistical Techniques Specialist 35% Staff Design Manufacturing Engineering Purchasing 65% Technicians April 11th, 2003 Edinburgh General Assembly 15
16 A 380 TEAM TRAINING Syllabus preparation 65% Personnel trained 35% Personnel to be trained April 11th, 2003 Edinburgh General Assembly 16
17 UPPER REAR UNIT A380 BRACKETRY BRACKETRY CROWN PANEL ASSY CROWN SKIN ASSY FRAME SEGMENTS 6/6 UPR FRAME WORK ASSY BEAMS UPR FRAMEWORK FLR BEAM DETAIL INSTL ASSY C72-C73 LINKS TUBES TUBES END LAP JOINT SIDE SUPER PNL STRG S ASSY RH&LH SEAL DEPRESSO R TOBOGGAN SCUFF PLATE LAP JOINT SHEAR CLIPS PARALLEL FTG S ZEE SEAL INTERNAL DEPRESSOR DOOR ASSY ITEMS FRAME SPLICES STRUT PAX FLOOR ASSY WATER DETAIL DEFLECT: S FALSE DOOR RAIL SURROUND PNL ASSY RH&LH CRASH LINKS FLR BEAM SEAT ASSY TRACK STRG S SHEA R CLIPS BUTT STRA P CROWN SKIN UPR SIDE PNL ASSY RH&LH FRAME STRG S LAP JOINT LAP JOINT SPLICESCLEAT STRG SHEAR CLIPS LWR SIDE PNL ASSY RH&LH DOORBACKUPS & SILLS HINGE FTG DOOR FRAMES BRACKETRY UPR SIDE SKIN ASSY RH&LH FRAMES 6/17 BUTT STRAP LWR DOUBLERS WINDOW FRAMES STRG S LWR SIDE SKIN RH & LH FRAME SEGMENTS 17/39 UPR DOUBLERS STRG S SHEAR CLIPS BUTT STRAP UPR SIDE SKIN RH&LH WINDOW FRAMES April 11th, 2003 Edinburgh General Assembly 17
18 Shear Clip Assembly issues Process issues Raw Material Mat. Alum 2024-T0. Routing and Drilling Pilot Holes N/C Machine N/C Tape Tooling Holes Checking TW Bending Hydro Form Bending Machine Bending Tool Aging to 42 Drilling N/C Machine N/C Tape Surface Treatment Surface Treatment Facilities Painting Painting Facilities Final Inspection April 11th, 2003 Edinburgh General Assembly 18
19 Risk Analysis Example Shear Clips K. C. Code A B C D E F G P S D Potential variation Variation Effect r e e cause o v t b e e a r c b i t i t a l y b i i t l y i t Candidate Key Characteristics Risk Number SCC1 Coordinate drilling position - Part Program Error - N/C Machine axis -Wrong part positioning Cannot be mounted SCC2 Coordinate holes dimension -Wrong tool - Worn tool Assembly difficulty SCC3 Bending angle - Process time Station displacement April 11th, 2003 Edinburgh General Assembly 19 SCC4 Profile - Process time Assembly difficulty
20 K.C. List - By Typology Total K.C. s = 30 "Part "K.C. Code "Risk "Number "Part "K.C. "Code "Risk Number "Part "K.C. "Code "Risk "Number "Part "K.C. "Code "Risk "Number "Machined "Stringer "Shear Clip "(Casoria Plant) "SMN 1 "126 "SCC 1 "72 "IC1 "72 "DC1 "96 "SMN 2 "12 "SCC 2 "12 "IC2 "12 "DC2 "12 "SMN 3 "24 "SCC 3 "320 "IC3 "320 "DC3 "60 "SMN 4 "70 "SCC 4 "112 "IC4 "280 "Intercostal "Doublers "(Casoria "Plant) "Estrused Stringer "STRN 1 "126 "SMN 1 "126 "DN 1 "126 "Machined Sills "Doublers "(Nola Plant) "STRN 2 "12 "SMN 2 "12 "DN 2 "30 "STRN 3 "24 "SMN 3 "24 "DN 3 "72 "STRN 4 "70 "SMN 4 "70 "DN 4 "280 "STRN 5 "72 "SMN 5 "20 "DN 5 "32 "SMN 6 "72 "Machined Frames "(Skin interface) "FMN 1 "126 "SN 1 "126 "FEC 1 "72 "FMN 2 "12 "SN 2 "30 "FEC 2 "12 "Skins "(Nola Plant) "FMN 3 "72 "SN 3 "72 "FEC 3 "64 "FMN 4 "70 "SN 4 "168 "FEC 4 "96 "FMN 5 "72 "SN 5 "32 "FEC 5 "18 "Estrused Frames "FMN 6 "126 "SN 6 "20 April 11th, 2003 Edinburgh General Assembly 20
21 Difficulties in implementing the model! Change! Personnel Obtaining Model Preparation, cultural principles training management approval approach flow-down and towards commitment deployment suppliers Defect Prevention of and to dedicated relevant devote by resources management procedure K.C. variation to effectively management implement model LSL USL No Good Equally Good No Good LSL T USL LSL T USL LSL T USL Supplier 1 Supplier 3 Supplier 2 Good Hardly Acceptable No Good April 11th, 2003 Edinburgh General Assembly 21
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