April 11th, 2003 Edinburgh General Assembly 1
ALENIA EXPERIENCE ABOUT
VARIATION MANAGEMENT OF KEY CHARACTERISTICS
R. del PezzoAlenia Aeronautica S.p.A.
April 11th, 2003 Edinburgh General Assembly 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:
! 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
April 11th, 2003 Edinburgh General Assembly 3
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
April 11th, 2003 Edinburgh General Assembly 4
prEN 9103 Variation Management of Key Characteristics
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
April 11th, 2003 Edinburgh General Assembly 5
prEN 9103 Variation Management of Key Characteristics
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
April 11th, 2003 Edinburgh General Assembly 6
prEN 9103 Variation Management of Key Characteristics
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
April 11th, 2003 Edinburgh General Assembly 7
prEN 9103 Variation Management of Key Characteristics
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
April 11th, 2003 Edinburgh General Assembly 8
prEN 9103 Variation Management of Key Characteristics
Vertical fin - Non Quality Cost M/H
1995 1996 1997 1998 1999 2000 2001
April 11th, 2003 Edinburgh General Assembly 9
prEN 9103 Variation Management of Key Characteristics
Further Cases
B 767 B 777
Flap
Slat
Radome
Flap
Radome
April 11th, 2003 Edinburgh General Assembly 10
prEN 9103 Variation Management of Key Characteristics
Boeing ProgramsNon Quality Cost Unit Trend
M/H19
95
1996
1997
1998
1999
2000
2001
April 11th, 2003 Edinburgh General Assembly 11
prEN 9103 Variation Management of Key Characteristics
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)
April 11th, 2003 Edinburgh General Assembly 12
prEN 9103 Variation Management of Key Characteristics
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 13
prEN 9103 Variation Management of Key Characteristics
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
April 11th, 2003 Edinburgh General Assembly 14
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
April 11th, 2003 Edinburgh General Assembly 15
prEN 9103 Variation Management of Key Characteristics
TEAM COMPOSITION
•Manufacturing•Logistics •Quality •Statistical Techniques Specialist
•Design
•Manufacturing Engineering•Purchasing
35% Staff
65% Technicians
April 11th, 2003 Edinburgh General Assembly 16
prEN 9103 Variation Management of Key Characteristics
A 380 TEAM TRAINING
Syllabus preparation
65% Personnel trained
35% Personnel to be trained
April 11th, 2003 Edinburgh General Assembly 17
prEN 9103 Variation Management of Key Characteristics
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
April 11th, 2003 Edinburgh General Assembly 18
prEN 9103 Variation Management of Key Characteristics
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.
April 11th, 2003 Edinburgh General Assembly 19
prEN 9103 Variation Management of Key Characteristics
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
April 11th, 2003 Edinburgh General Assembly 20
prEN 9103 Variation Management of Key Characteristics
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)
April 11th, 2003 Edinburgh General Assembly 21
prEN 9103 Variation Management of Key Characteristics
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