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ProCert Support

Project at XXXX

August, 20th 2004

Presented par:

Jean Denis,

Ninon L.,

Nathalie G.


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Assembly & Test


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Renaiscience :JL Denis 2004 slide 3

ObjectivesObjectives

Increase practical and applied knowledge for Problemesolution in !e" personnel

Organi#e $ Prioritise engine assembl" $ test issues

using the Pro%ert approach


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&ummar" of 'ork Accomplished&ummar" of 'ork Accomplished

Pro%ert (eplo"ment

(etermined road blocks to (eplo"ment (eveloped means to improve $ accelerate deplo"ment

)entored Pro%ert leaders to understand and appl"

concepts Projects

Provided guidance and engineering support during projecte*ecution


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Plant XX Assembly

& TestProCert Deployment


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IssueIssueProCert IntegrationProCert Integration

Pro%ert not considered in e*isting or planned

%ontinuous Improvement program: +ack of visibilit" of owner, strateg" $ deplo"ment plan for Procert

ualit" %linic and A%- teams not full" functional. missing part of infrastructure for Pro%ert deplo"ment

-ngine development occurring in production,overloaded P%- group identified to deplo" Pro%ert

Intense pressure to /uickl" solve major issues

Pro%ert ke" resources not "et identified or funded

)echanism lacking for topdown Project Identification $ &election A%- teams work from bottom-up, Pro%ert works mostl" top-down

)easurement $ &P% not routine practice within assembl" $ test,. therefore lacking reliable data, rigor $ e*perience


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esolution1ecommendationProCert Integration

Implement bottomup means of integrating Pro%ert into

planned3 %ontinuous Improvement Program

Quality Clinic

Process

collects $ transforms info

into actions, priorities for

resolution and commits

resources to supportproblem resolution

Stakeholders:

Plant mgr

Quality mgrs

Program mgrs

ProCert leaders & teams

ACE pilots & cells

Procurement

Producers

etc.

stakeholder needs:

0 info to base decisions $ actions

0 status of issues0 clinic performance metrics

0 etc4

2define whether a stakeholder is

accountable for results, responsible for

action, should be consulted or simpl"

needs to be informed 53

Clinic Inputs:

ACE cell out-of-scope issues

QNs

QCPCs

MFA misses

quality escapes

Measurable Outputs:

clinic effectiveness

issues raised vs

closed

time to resolve escapes

! completion status

issues per part or

program

etc.

Deliverable Outputs:

Issue priorit" list

Identification of s"stemic and

common root causes

6%OP7

ProCert Project selections

etc4

Notes:

- ProCert elements in italics

- "o #e furt$er developed are: list of %tae$olders & t$eir needs'

QC process metrics' clinic delivera#les.- Criticism of e(isting Clinic design proposal is t$at $ig$ level

mgrs )ould #e at t$e mtg and t$at t$e mtg often deals )it$ lo)

level issues. "$erefore' it is useful to *st e(amine )$o t$e

stae$olders are and )$at t$eir real needs are' t$en tailor t$e

process and outputs to suit. ProCert is a NE+ stae$older,


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esolutionesolution11ecommendationecommendationProCert IntegrationProCert Integration

8ormalise Top-downproject identification process

8ormalise Bottom-upproject identification process (efine $ 8ormalise deplo"ment process

use inputprocessoutputmetricsstakeholder anal"sis3

Identif" deplo"ment risk and acceleration factors


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IIssuessueProblem-Solving StrategyProblem-Solving Strategy

Pro%ert not recognised as a problemsolving strateg"

for major %9 9op(own3 problems %omple*it" of appl"ing Pro%ert in Assembl" and 9est

for problemsolving

+owvolume, highl" comple* product lack of good, plentiful data from consistent e*amples

:igh unit costs difficult and costl" to e*periment for causes $ solutions


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esolutionesolution11ecommendationecommendationProblem-Solving StrategyProblem-Solving Strategy

-stablished $ walked management through a 9op

down problem solving strateg" for major %9problems;


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IssueIssueVibe Measurement UncertaintyVibe Measurement Uncertainty

=ibe measurement uncertaint" unknown %auses multiple vibe surve"s to be done Passes engines that should be failed %auses rebuild $ retest of engines that should be passed

%onfuses and masks causes of e*cess vibration Incurs tremendous costs and multiplication of production dela"s

-*tremel" costl" to assess uncertaint" b"

conventional Pro%ert methodolog" gage $3 >eed to develop practical and effective alternative 5


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Renaiscience :JL Denis 2004 slide 1$

Adapted and transferred means of assessing vibrationmeasurement uncertaint" Approach and methodolog" to perform assessment

in most economical fashion Identification $ grouping of influential variables 9est Procedures (ata anal"sis of transducer variation

>e*t &teps; Identif" greatest contributors to uncertaint" and improve where

possible Implement &P% in 9est %ells

esolution1ecommendationVibe Measurement Uncertainty


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Plant Assembly &

TestPro%ets


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8acilitated improvement of Pro%ert )andate form

Identified, got consensus on :igh+evel %ustomerissues and priorities: :igh rotor $ +ow rotor =ibration?

&pecific 8uel %onsumption? Inter9urbine 9emperature?

Operabilit"

'ork Accomplished


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Renaiscience :JL Denis 2004 slide 1&

8acilitated identification and prioritisation of

contributor" elements midlevel projects3:@3 :P9 Ass" $ Install process

23 :P9 alancing processes

B3 :P9@ =ane $ +P9B =ane ring Ass" $ flow measurement43 +P9 Ass" balancing process

C3 +P9 install process

D3 :P9 tip clearance 9urbine3

E3 :P9 tip clearance shroud3

'ork Accomplished


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)apped !e" Process at midlevel

:P 9urbine assembl" $ install, including tieshaft r1o aseline Anal"sis of )ap using e*isting data Assessed statistical control, identified suspects;

9urbine assembl" $ install using proprietar" algorithm;random outcome, not a capable process for P' B0F :P9 or :P%,could be either:assembl" process or AGIA) process

:P% $ :P9 component initial outofbalanceselect alternate datum points and revise mfg process

AGIA) dimensioning and stacking processinvestigate, compare with earlier model engine data $ e*perience 9est %ell =ibration )easurement

initial anal"sis of transducers suggests large contributor to variation

'ork Accomplished


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'ork Accomplished'ork Accomplished

Identified lowerlevel projects;

:P9 assembl" :P% assembl" Assessment of =ibration )easurement Hncertaint" (imensioning $ stacking process 9ieshaft stretching :P% $ :P9 component initialoutofbalance

&upplied concepts not considered within Pro%ert training:

(ata collection strateg" and toolsevolves to control planJ later3

Project planning structure to establish time and resourcere/uirements and commitments


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>e*t &teps>e*t &teps

(efine $ write project mandates

Prepare draft Project Plans Identif" project team members and launch projects;

Implement structured data collection plan in specific areas of

assembl" and test Identif" practical, costeffective means for developing

needed but missing information through(esigned -*periments )an" designed e*periments to be conducted

-*ecute projects +arge /uantit" of processes to certif"


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To Reach Us

'e(n Denis

e-m(il : %ld*+(lues,"m(il*om

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