project final 11 26

7/25/2019 Project Final 11 26

1/15


2/15

NO SINIFICANT RE!ATIONSHIP WASNOTED FROM THE PARETO ANA!YSIS.

THE REJECTIONS SEEMS TO E FAIR!Y

CONSTANT IRRESPECTIVE OF THE DAYOF THE WEE.

TOM JIM JOHN ED0

5

10

15

20

25

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

22 20 19 16

29%

55%

79%

100%REJECTIONS Y O!ERATOR

DEFECTS

QUANTITY CUMM%

FRI MON TH WED TE

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

17 16 16 15 13

22%

43%

64%

83%

100%REJECTIONS Y DAY OF T"E #EE$

ASSEMLY SECTION

QUANTITY

C&&%

REASON FORIMPROVEMENT

THE TEAM THEN REVIEWED THEREJECTION DATA Y THE OPERATORMANFACTRIN THE ASSEM!Y TO

NDERSTAND IF THE REJECTIONS ARECASED Y ANY PARTIC!AROPERATOR.

THE TEAM NARROWED ITS FINDINSFROM THE PARETO ANA!YSIS TODEVE!OP THE THEME FORIMRPOVEMENT.

WE A!SO DECIDED TO !OO IF THEREWAS ANY RE!ATION ETWEEN THEREJECTIONS AND THE DAY OF THE

WEE IT WAS CASED.

THE NMER OF REJECTION IS FAIR!YCONSTANT REARD!ESS OF THE

OPERATORHENCE THE TEAM CO!D NOTATTRITE THE NMER OFREJECTIONS TO ANY PARTIC!AROPERATOR.


3/15

THEME AND INDICATOR

OVER !AST ONE YEAR 83% OF THERI AP ISSES WERE FOND IN THE!E02 SECTION

FINDINGS

REDCE THE RI AP ISSE IN !E02SECTION

T"EME


4/15

THE TEAM REVIEWED THE REJECTIONDATA OF 64 !E02 ASSEM!IES

CRRENT SITATION

RI 1 RI 6 RI 2 RI 5 RI 4 RI 30

10

20

30

40

5060

70

0%

20%

40%

60%

80%

100%

64 57

6 4

2 2

47%

90% 94% 97%

99% 100%

NUMER OF REJECTIONS Y RI'

RIS

Q()*+*, C&&%

90% OF THE REJECTIONS IN !E02 ARECASED DE TO RI HEIHT ISSES INRI;1 AND RI;6

THE RI HEIHT DATA OF RI;1 AND RI;6FROM REJECTED NIT ED

RI'

1

RI'

S? 16.240@0?.005

MA" 16.240MIN 16.210

RANE OF OOT .0030

S? 10.082@0?.005

MA" 10.090MIN 10.060

RANE OF OOT .0030

THE RI HEIHT DATA OF DETAI!ED RI;1 ANDRI;6 WAS A!SO ANA!Y>ED AND FOND TO EIN TO!ERANCE

THIS ANA!YSIS SHOWED THAT RIS AREFO!!OWIN OOT AFTER ASSEM!Y PROCESS

R#$;6

R#$;5

R#$;4

R#$;3

R#$;2

R#$;1

S#*

P,-*B

R#$

0-#%0+


5/15

CRRENT SITATION

TO ETTER NDERSTAND THE REASONS FOR REJECTION THE TEAM REVIEWED THE ASSEM!YPROCESS OF !E02 SECTION.

1/!OAD SINAND RIS ON

TO AF

2/DRI!!

HO!ES C?TMONTIN

STRAPSAND RISSIN DJ

/DERRCS AND

ATTACH THERIS TO THESIN SIN

HI!OS

4/!OCATEP!ENMS

ANDTRANSFERDRI!! HO!ES

TO THE SIN

5/DERRCS AND

ATTACH THEP!ENMS TOSIN SIN

RIVETS

/FINA! FINISH

ANDINSPECTION

RI HIEHT MEASREMENTS ON RI ;1 AND RI; 6 WERE TAEN AT EACH STEP OF THE I!DPROCESS FOR TWO CONSECTIVE NITS

LE02S.NO 227

NOMINAL0-.005

D3*(+(6*

D3*(6o&

)o&+)(

1/Co)8*6(+)* +) AF

D3*(6o&

)o&+)(

/I)8*((*+o) o "+o98

D3*(6o&

)o&+)(

5/I)8*((*+o

) o!3)&

D3*(F6o&

No&+)(RI ; 1 !E02 IND 16.24 16.236 0.004 16.24 0 16.226 0.014 16.226 0.014RI; 6 !E02 OTD 10.082 10.080 0.002 10.088 0.006 10.067 0.015 10.069 0.013

LE02S.NO 22:

NOMINAL0-.005

D3*(+(6*

D3*(

6o&)o&+)(

1/

Co)8*6(+)* +) AF

D3*(6o&

)o&+)(

/

I)8*((*+o) o "+o98

D3*(

6o&)o&+)(

5/I)8*((*+o

) o!3)&

D3*(

F6o&No&+)(

RI; 1 !E02 IND 16.24 16.239 0.001 16.237 0.003 16.216 0.024 16.217 0.023RI; 6 !E02 OTD 10.082 10.081 0.001 10.081 0.001 10.067 0.015 10.068 0.014MAJOR DEVIATION IN THE RI HEIHT IS OSERVED AFTER THE INSTA!!ATION OF HI!OS WHICH

ARE SED TO SECRE THE RI TO THE SIN.


6/15

ANA!YSIS

R+;

C


7/15

ANA!YSIS..CONTD

THE TEAM PROPOSED AND CONDCTED TESTS TO VERIFY PROA!E ROOT CASES.

SUMMARY OF TERMINOLOGY AND MEASUREMENTS>IN THE FO!!OWIN TESTS CRITERIA WERE ESTA!ISHED FOR RI TERMINO!OY AND STANDARD POINTS OF MEASRE

A STANDARD CHEC SHEET WAS DEVE!OPED TO RECORD THE DATA AS SHOWN E!OW.RI; 1 WAS SE!ECTED FOR THESE TESTS.

MEASREMENTS WERE TAEN AT OTH INOARD AND OTOARD !OCATION OF THE RI ASSHOWN FOR A!! THE TESTS

WE ENSRED THAT A!! THE TESTS WERE CONDCTED Y THE SAME OPERATOR AND THAT A!!THE MEASREMENTS WERE TAEN Y THE SAME INSPECTOR

PPER

!OWER


8/15

ANA!YSIS..CONTD

TEST 1

TEST WAS CONDCTED TO MEASRE THE DEFE!ECTION DRIN THE DRI!!IN AND FASTENER

INSTA!!ATION PROCESS FOR TWO DIFFERENT ASSEM!IES. THE MEASREMENTS WERE TAEN ATEACH PROCESS STEP OF DRI!!IN AND INSTA!!IN TWO FASTENERS. THE MEASREMENTS WERERECORDED AT EACH STEP.

SIGNIFICANT RESULTS NOTED1 THE RI EIN TO DEF!ECT AS FASTENERS IN THE CROWN AREA WERE INSTA!!ED AND

TOR:ED TO FINA! CO!!AR REAOFF.2 MEASREMENTS ETWEEN INOARD AND OTOARD POINTS OF MEASRE ON THE INTERFACE

PADS INDICATED THAT THE RI !ES TWISTED FROM THEIR FREE STATE CONDITION.3 DEF!ECTION OF .015 OTOARD AND .020 INOARD WAS NOTED.

1 2 3 4 5 6 7 8 9

16.220

16.225

16.230

16.235

16.240

16.245

TEST 1> UNIT 2

DRILLING AND INSTALLATION OF FASTENER

OB+$)&(I*$)&(STE!

MEASUREMENT

C()* Beyond Crown

1 2 3 4 5 6 7 8 9

16.220

16.225

16.230

16.235

16.240

16.245

TEST1 > UNIT 1

DRILLING AND INSTALLATION OF FASTENER

OB+$)&(

STE!

MEASUREMENT

Beyond Crown

C()*


9/15

ANA!YSIS..CONTD

TEST 2

TEST 2 WAS CONDCTED ON AN ASSEM!Y TO INSTA!! C!EARANCE FIT FASTENERS AT THE CROWN

AREA TO VA!IDATE THE EFFECT OF FASTENER FIT IN THE HO!ES.

SIGNIFICANT RESULTS NOTED1 THE RI DIMENSIONS REMAINED STA!E AS FASTENERS OVER THE ENTIRE RI WERE DRI!!ED

INSTA!!ED AND TOR:ED TO FINA! CO!!AR REAOFF.2 MEASREMENTS ETWEEN INOARD AND OTOARD POINTS OF MEASRE ON THE RI

INTERFACE PADS INDICATED THAT THE RI !ES DID NOT TWIST FROM THEIR FREE STATECONDITION.

1 2 3 4 5 6 7 8 9

16.230

16.235

16.240

16.245

TEST 2INSTALLATION OF CLEARANCE FASTENERS

OB+$)&

(

STE!

MEASUREMENT

T),-(&*/- >)*-

C()* Beyond Crown


10/15

ANA!YSIS..CONTD

TEST

TEST 3 WAS CONDCTED ON AN ASSEM!Y TO RESE:ENCE THE DRI!!IN AND INSTA!!ATION OF

FASTENERS TO START FROM CROWN AND MOVE TOWARDS THE !E AND A!TERNATIN FROM PPERTO !OWER !ES

SIGNIFICANT RESULTS NOTED1 THE RI DIMENSIONS SHOWED DEF!ECTION T WERE ON!Y .003 EYOND !OW !IMIT.2 MEASREMENTS ETWEEN INOARD AND OTOARD POINTS OF MEASRE ON THE RI

INTERFACE PADS INDICATED THAT THE RI !ES SHOWED TWISTIN FROM THEIR FREE STATECONDITION.

1 2 3 4 5 6 7 8 9

16.230

16.235

16.240

16.245

TEST RESEQUENCED INSTALLTION OF FASTENER

OB+$)&

(

STE!

MEASUREMENTS

Beyond Crown

C()*


11/15

ANA!YSIS..CONTD

TEST 4

IN TEST 4 FINITE E!EMENT ANA!YSIS WAS CONDCTED TO DEMONSTRATE !OCATION OF STRESS

CONCENTRATIONS IN THE PRESENT RI DESIN SIN A SIMP!E !OADIN CONDITION. THE TEST WASCONDSCTED TO VA!IDATE THE !IHT WEIHT DESIN OF THE RI

SIGNIFICANT RESULTS NOTEDLESS THAN 30 LB. IS REQUIRED TO CLOSE THE RIB 0.030 IN.

D 0.030D

Max Principa

S!r"## $ %&'0 p#i

Min PrincipaS!r"## 3()0 p#i

THE TEAM WAS NOW READY TO DEVE!OP THE CORRECTIVE ACTIONS FOR THE ROOT CASES WHICHWERE ESTA!ISHED Y TEST 1 2 3 AND 4


12/15

CONTERMEASRES

FOUR 4/ !RACTICAL MET"ODS #ERE SELECTED FORIM!LEMENTATION

RI4

HEI5HT

O

TOF

TO!ERANC

E

DRI!!IN SE:ENCE

RESE:ENCE THEDRI!!IN AND

INSTA!!ATION OFFASTENERS

REVISE THE OPERATIONWOR SHEET

TRAIN THE OPERATORSWITH NEW SE:ENCE

DESINED TRANSITIONFIT OF FASTENERS

REDESIN FORC!EARANCE FIT OF

FASTENERS

DRI!! THE HO!ES TOHIH END OFTO!ERANCE

RE:EST CSTOMERTO PDATE THE HO!E

TO!ERANCE

!IHT WEIHT RIDESIN

REDESIN THE RISFOR !ESS DEF!ECTION

RE:EST CSTOMERFOR STRENTHENIN

THE RI !ES

EFF.

FEAS.

YN?

3 5 15

4 5 20

2 3 6

4 5 20

5 4 25

COUNTERMEASUREMATRI@

!ROLEM

ROOTCAUSES

COUNTERMEAUSRE

!RACTICALMET"ODS

A

D

E

C

A E PRACTICA!METHODS

!OW HIH

1 5

!EENDS

CONTERMEASRES


13/15

CONTERMEASRESCONTD

ARRIERS AIDS

CSTOMERS WI!!INNESS REDCED REJECTION

COSTINCREASED CSTOMER

SATISFACTION

TIME REDCED !EAD TIME

ENINEERIN MANPOWER REDCED REWOR

IMPROVED F!OW

MEET SCHED!E

ARRIERS ANDAIDS


14/15

RES!TS

THE CONTERMEASRES WERE PROPOSED AND HAVE NOT EENIMP!EMENTED YET..

TO E

DETERMINED


15/15

STANDARDI>ATION

TO EDETERMINED

project final 11 26

Documents