ALENIA EXPERIENCE ABOUT VARIATION MANAGEMENT OF KEY ... · management of Key Characteristics The...

April 11th, 2003 Edinburgh General Assembly 1

ALENIA EXPERIENCE ABOUT

VARIATION MANAGEMENT OF KEY CHARACTERISTICS

R. del PezzoAlenia Aeronautica S.p.A.


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:

! Results Evaluation in terms of Quality & Costs! Cpk Calculation ⇒ Process Capability Assessment

! Data Collection to measure Key Characteristics Variation

! Key Characteristics Identification

! Working Group Appointment


prEN 9103 Variation Management of Key Characteristics

Team Appointment

BOEING 767 - Vertical Fin Case

Objectives

CustomerSatisfaction

Gage R&R

Assembly CostReduction

Statistical Process Control (S.P.C.)

K.C. identification

Non ConformitiesReduction



A

B

C

Risk Analysis - Results

The K.C. have been identified in Critical Zones

A Mismatch Tip Assy Int. 72-73

B Gap Tip Assy Int.72-73

CGap L.E. Assy Int. 72-75

Critical Zones



K.C. Example

A = Trim

B = Fin Tip / Panels gap

C = Leading Edge / Panels gap

K. C.

AMismatch Tip Assy Int. 72-73 a, a1

BGap Tip Assy Int. 72-73

b, b1, b2, b3, b4, b5, b6, b7, b8

CGap L.E. Assy Int. 72-75 c, c1, c2, c3, c4, c5

Critical Zones



Cpk - Example of achieved results

0,00

1,00

2,00

3,00

4,00

a a1 c c1 c2 c3 c4 c5 b b1 b2 b3 b4 b b5 b6 b7

K.C.

1995

2001



02468

101214

1995 1996 1997 1998 1999 2000 2001

N/C

0

5

10

15

1995 1996 1997 1998 1999 2000 2001

R/S

Vertical FinNon Conformity

Trend

Vertical FinRejection Trend



Vertical fin - Non Quality Cost M/H

1995 1996 1997 1998 1999 2000 2001



Further Cases

B 767 B 777

Flap

Slat

Radome

Flap

Radome



Boeing ProgramsNon Quality Cost Unit Trend

M/H19

95

1996

1997

1998

1999

2000

2001



Based on positive results obtained by K.C. Variation Management application, ALENIA has extended this approach to:

A 380 ProgramAccording to prEN 9103

Alenia is responsible for definition and development of design and production of significant part of A380

central fuselage (sect - 15)



THAT MEANS

Full compliance to prEN 9103 Standard is a Company goal for the present and the future Programs



A 380 PROGRAMDetermination of Key Characteristics has been performed in “Concurrent Engineering” using Risk Analysis method in order to identify the risks connected to “Candidate” Key Characteristics variationExtensive training on “statistical techniques” has been carried out for middle management and operation personnel involved in the Program


ACTIVITIES BLOCK DIAGRAM

Team Appointment Team Training

Process Flow Diagram

Key Characteristics identificationby Risk Analysis

Gage R&R Data Collection

S.P.C.

Cpk Assessment Process Continuous

Improvement



TEAM COMPOSITION

•Manufacturing•Logistics •Quality •Statistical Techniques Specialist

•Design

•Manufacturing Engineering•Purchasing

35% Staff

65% Technicians



A 380 TEAM TRAINING

Syllabus preparation

65% Personnel trained

35% Personnel to be trained



UPPER REAR UNIT

A380

SIDE SUPER PNL ASSY RH&LH

LAP JOINT STRG’S

FRAME SPLICES PAX FLOOR

ASSY

SEAT TRACK

FLR BEAM ASSY

FALSE RAIL

LAP JOINT SHEAR CLIPS

LWR SIDE PNL ASSY

RH&LH

UPR SIDE PNL ASSY

RH&LH

FRAMES 6/17UPR SIDE SKIN ASSY

RH&LH

WINDOW FRAMESUPR SIDE

SKIN RH&LH

BUTTSTRAP

SHEAR CLIPSSTRG’S

CRASHLINKS

CROWN SKIN ASSY

FRAME SEGMENTS

6/6’

CROWN SKIN

STRUT

DETAILS

SILLSDOOR

FRAMES

FRAME SPLICES

UPR DOUBLERS

BUTTSTRAP LWR

DOUBLERS

WINDOW FRAMES LWR SIDE

SKIN RH & LHFRAME

SEGMENTS 17/39

STRG’S

STRG’S BUTT STRA

P

SHEAR

CLIPS

LAP JOINT SHEAR CLIPSCROWN

PANEL ASSY

LAP JOINT STRG

STRG’S CLEAT

SEAL DEPRESSO

RINTERNAL

DOOR ITEMS

TOBOGGANSCUFF PLATE

DOOR SURROUND PNL

ASSY RH&LH

WATER DEFLECT:

BRACKETRY

BRACKETRY

TUBESEND

UPR FRAMEWORK DETAIL INSTL

TUBESBEAMSLINKS

UPR FRAME WORK ASSY

BRACKETRY

FLR BEAM ASSY

C72-C73

ZEE SEAL DEPRESSOR

ASSY

PARALLEL FTG’S

DOORBACKUPS & HINGE FTG



Assembly issues

Process issuesRouting

andDrilling

• N/C Machine

• N/C Tape

Raw Material

• N/C Machine

• N/C Tape

Surface Treatment

• Surface Treatment Facilities

Painting

• Painting Facilities

Bending

• Hydro Form Bending Machine

• Bending Tool

Drilling

Checking

Tooling Holes

Pilot Holes

Final Inspection

Aging to 42

TW

Shear Clip

• Mat. Alum 2024-T0.



Risk Analysis ExampleShear Clips

A B C D E F G

K. C. Code

Candidate

Key Characteristics

Potential variation

cause

Variation Effect

Probability

Severity

Detectabilit

Risk

Number

SCC1 Coordinate drilling position

- Part Program Error - N/C Machine axis -Wrong part positioning

Cannot be mounted 4 6 3 72

SCC2 Coordinate holes dimension

-Wrong tool - Worn tool Assembly difficulty 2 3 2 12

SCC3 Bending angle - Process time Station displacement 8 8 5 320

SCC4 Profile - Process time Assembly difficulty 8 7 2 112



K.C. List - By TypologyTotal 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

"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

"STRN 1 "126 "SMN 1 "126 "DN 1 "126

"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

"FMN 1 "126 "SN 1 "126 "FEC 1 "72

"FMN 2 "12 "SN 2 "30 "FEC 2 "12

"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

"FMN 6 "126 "SN 6 "20

"Es

trus

edFr

ames

"Es

trus

edSt

ringe

r"

Mac

hine

d Fr

ames

"

(Ski

n in

terfa

ce)

"Sk

ins

"(N

ola

Plan

t)

"D

oubl

ers

"

(Cas

oria

"Pl

ant)

"Sh

ear C

lip

"(C

asor

iaPl

ant)

"M

achi

ned

Sills

"M

achi

ned

"St

ringe

r

"In

terc

osta

l"

Dou

bler

s

"

(Nol

a Pl

ant)



Difficulties in implementing the model

! Personnel training! Preparation, approval and deployment of dedicated procedure

! Obtaining management commitment to devote resources to effectively implement model

! Model principles flow-down to suppliers and relevant management

Supplier 1

Supplier 2

Supplier 3

! Change cultural approach towards “Defect Prevention” by K.C. variation management

LSL USL

LSL T USL LSL T USL LSL T USL

Good Hardly Acceptable No Good

EquallyGood

NoGood

NoGood

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