lean 6 sigma metrology - productivity from enhanced metrology

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Lean 6-Sigma Metrology for Aerospace


Aspirations for change

•  Improving quality processes to drive profitability

–  Reduce non-value added activity – reduce costs

–  Utilise data for value-added activity rather than just verification

•  Moving beyond a ‘gatekeeper’ approach to quality

–  Understand and control the process itself

–  Capture and correct non-conformance prior to adding further value

–  Utilise in-process data to correct and enhance the manufacturing process

•  Adopting data driven manufacturing as part of a right first time philosophy


An integrated Approach

•  Metrology needs to be considered and implemented as a holistic system.

•  Addressing individual elements in isolation will not yield significant business impact.

•  However improvements need to be incremental focusing on discrete areas.

•  As such an overall strategy is required to ensure all elements of the improvement programme are aligned.


Supply Chain Companies

An integrated Approach

In-House Manufacturing


Lean 6-Sigma Metrology

- The INSPHERE framework for metrology improvement

Effective Data

Efficient Data

Robust Data

Utilise data for process improvement and right first time manufacturing processes

Optimise metrology processes to maximise efficiency, miniming non-value added activity

Ensure data generated is reliable and follows best practice processes and standards


Why? –  De-risk current operations

•  Limit risk of escapes

–  Ensure compliance with standards •  Quality (ISO9100 etc) + Customer specific (Rolls-Royce SABRe etc)

What? –  Calibration processes –  Application of MSA to understand and monitor

measurement capability –  Equipment selection and alignment with specification –  Operator training –  Standardisation via SOPs, WIs for consistent operations –  Application of metrology best practice principles


Robust Data – Generating data you can trust



Why? –  Reduce operational costs, increased profitability

–  Reduce TAKT times - Increase operational capacity –  Future proof operations for growth

What? –  Metrology Process Analysis

•  Value stream maps, time value maps, value add charts

•  Five Laws of Lean, Seven Wastes

–  Design for manufacture analysis •  Specification analysis - Tolerance, Datum structures

–  Measurement planning •  What to measure, when to measure

Efficient Data – Optimising the process to minimise non-value added activity



Why? –  Enhancement of manufacturing processes through use of data

•  Increased accuracy and precision

•  Time, cost, quality improvements.

–  Known and controlled manufacturing capability •  Design rules updated, less material use, more cost effective

–  Right first time manufacturing What? –  Application of 6-Sigma methodology

•  Define, Measure, Analyse, Improve, Control

•  Monitoring and feedback, SPC, CPk

–  Data driven manufacturing solutions •  Metrology guided automation, live feedback, adaptive assembly

Effective Data – Manufacturing process improvement through value added metrology


Quality Cascade

The principles of lean 6-sigma metrology can also be applied to supply chain companies.

•  This will help ensure products supplied are right first time, to the product specification.

•  Ultimately increasing efficiencies in the supply chain will lower bought-in product costs.

Some considerations..

•  Internal processes need to be in order first to provide suppliers with the correct specification for verification.

•  Carrot or Stick approach to adoption by suppliers

•  Supplier investment implications

Supply Chain Management


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