solumina mro: maintenance execution - nsrp€¦ · 3 solumina mro overview & demo •...
TRANSCRIPT
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June 21, 2017
Solumina MRO:Maintenance Execution
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Agenda
1 What is the problem we Solve?• Typical Maintenance Landscape
2 What is Solumina MRO?
3 Solumina MRO Overview & Demo• Maintenance Process
Planning and Execution• Quality Management
4 Real-time Reports
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Typical Aircraft Maintenance Landscape
Maintenance Technicians receive maintenance instructions on a spreadsheet (or via paper workbook) and must access separate systems for drawings, tool information and recording data collections.
Can you quickly report where assemblies are in the maintenance process? Are you able to demonstrate full part/assembly traceability (as-maintained) in one system?
Is quality data (i.e. squawks, fault logs, discrepancies) collected in disparate silos? How do you know all fault logs have been cleared and aircraft can be delivered?
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What is the Problem We Solve? Typical MRO Landscape
Quality Data& SPC
Shop Floor Control
WorkInstructions
ToolManagement
Buy Offs
Product History
CorrectiveAction
ProductNon Conformance
PersonnelCertification
AvailableWork Job Start/
Completion
LaborReporting
Material Logistics
Tool Usage
ToolAvailability
ProductDrawings/models
OperationalStandards
Supplier Quality
AuthoredText
RequirementsDocuments
Work OrderChanges
PaperTravelers
Many Applications
Loosely Coupled
GovernmentCompliance
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About iBASEt and Solumina
iBASEt is the creator and distributor of Solumina’s Suite of Products.Headquartered in Foothill Ranch, CAwww.solumina.com
Solumina is a Paperless Product Lifecycle Execution SolutionSpecialized in Complex Discrete Industries:
• Aerospace Manufacturing (Fab and Assembly)• Aerospace Maintenance, Repair, Overhaul and Modifications• Defense Electronics Manufacturing• Defense Electronics Repair & Overhaul• DOE Contracted Mfg + MRO (Weapons & Reactor Cores)• Satellite Manufacturing• Jet Engine Overhaul• Engine Component Manufacturing & Repair• Medical Devices• Launch Vehicles & Launch Operations• Complex Industrial Equipment
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iBASEt is a Recognized Leader in Complex Discrete
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Agenda
1 What is the problem we Solve?• Typical Maintenance Landscape
2 What is Solumina MRO?
3 Solumina MRO Overview & Demo• Maintenance Process
Planning and Execution• Quality Management
4 Real-time Reports
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Solumina MRO is an eMaintenance System
that allows for the creation, management,
and control of products needing diagnoses,
repair, or routine maintenance.
End-to-end integrated functionality tracks the
product to the serial level to ensure quality of
work.
Features include:
✓ Easy to use Graphical Interface
for Standard Templates and
Repair Instructions
✓ Embedded workflow approval
cycles
✓ Hyperlinks to Manuals
✓ Discrepancy/squawk
documentation and disposition
✓ Over and Above work management
✓ Change Incorporation (Engineering,
Material, Process)
✓ Product Traceability (As- Maintained
BOM)
✓ Real-time information for supervisor/
executive dashboards
✓ OOB Integration to ERP and PLM
systems
Solumina MRO for Maintenance Execution
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Solumina Functions
Audits and Reporting
Quality Requirements Planning
• Product Characteristics and Requirements
Supplier Quantity Planning
• Product Inspection Definition
Supplier Quality Execution
• Source and Receiving Inspection
Manufacturing Req’ts Planning
• Product Characteristics and Requirements
Process Planning
• Manufacturing Process Definition
Process Execution
• Manufacturing Work Order Execution
MRO Requirements Planning
• MRO Requirements Definition
Process Planning
• MRO Routine Work and Process Planning
Process Execution
• MRO Planned Work Order Execution
Supplier Quality Correction
• Supplier Discrepancies and Corrective Action
Process Quality
• Discrepancy and Corrective Action
Non-routine Execution
• Over and Above, Inspection Findings and Sub-work Approvals
SQA MES MRO
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Agenda
1 What is the problem we Solve?• Typical Maintenance Landscape
2 What is Solumina MRO?
3 Solumina MRO Overview & Demo• Maintenance Process
Planning and Execution• Quality Management
4 Real-time Reports
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Solumina MRO : Maintenance Requirements Definition
Library of:
Data Collections/PMI
Bills of Material
Files – models/specs
Tools
Inspections
Skills and Certifications
Customer signatures
Material Master
MRO Requirements Planning
• MRO Requirements Definition
Process Planning
• MRO Routine Work and Process Planning
Process Execution
• MRO Planned Work Order Execution
Non-routine Execution
• Over and Above, Inspection Findings and Sub-work Approvals
MRO
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Solumina MRO: Maintenance Planning
MRO Requirements Planning
• MRO Requirements Definition
Process Planning
• MRO Routine Work and Process Planning
Process Execution
• MRO Planned Work Order Execution
Non-routine Execution
• Over and Above, Inspection Findings and Sub-work Approvals
MRO
Process Planning
• MRO Routine Work and Process Planning
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Solumina MRO: Maintenance Process Planning
Operation Detail
Operation Groupings
Tools required
Data to be collected
Visual aids
Materials required
Certifications necessary
Detailed instruction
Operation sequence
Signatures required
Inspection requirements
• Operation number• Operation title• Department and workcenter• Batch options• Outside process allocation• Time and labor standards• Machine type assignment
• Tool type• Tool quantity• Calibration tracking
requirements
• Upper and lower limits• Selectable• Shelf life/expirations• Calculations• SPC• File upload• File template
• Revision specific or latest• Illustrations• Specifications• Videos• Models• Drawings
• BOM parts• Ad-hoc material• Issued material• Quantities required• Over/under allocation• Backflushed material• Floor stock/General store
items
• Hard stops• Self inspection qualification• Data collection• Signature• Standard text• PPE information• Ad hoc text• Multi-language• Manufacturing/technician• Inspection/quality• Customer• Combinations
• Machine data• NC Programs• Sampling• PPV/FAI
Pro
cess
Pla
nn
ing
•M
RO
Ro
uti
ne
Wo
rk a
nd
Pla
nn
ing
• Module/product assignment• Work scope assignment• Conditional assignment
• Operation grouping• Interoperation sequence• Inter-order sequence
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Solumina Maintenance Execution
Process Execution
• MRO Planned Work Order Execution
MRO Requirements Planning
• MRO Requirements Definition
Process Planning
• MRO Routine Work and Process Planning
Process Execution
• MRO Planned Work Order Execution
Non-routine Execution
• Over and Above, Inspection Findings and Sub-work Approvals
MRO
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WYSIWYG: What You See Is What You Get
Manufacturing Engineer View
Technician View
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One Stop Shop Execution
Operators Will:Report Progress
Capture Serial NumbersCapture Variable data
(optional)Request Parts
Record FindingsSign-Off Work completions
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Solumina for Over and Above
Non-routine Execution
• Over and Above, Induction Findings, non-conformance management
MRO Requirements Planning
• MRO Requirements Definition
Process Planning
• MRO Routine Work and Process Planning
Process Execution
• MRO Planned Work Order Execution
Non-routine Execution
• Over and Above, Inspection Findings and Sub-work Approvals
MRO
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Execution
•Inspection Orders
•Sampling Orders
•Rework orders
Quality
•First Article Inspection
•Defect and disposition
management
•Supplier Inspection
Process Improvement
•Corrective Actions
•Simple & Detail (8D)
•Metrics
Audits
Continuous Manufacturing improvement through• Closed loop quality and non-conformance tracking• Periodic audit planning and execution• Direct incorporation of process improvements• Integrated quality
Standalone quality solutions can count,
document, and provide metrics but
cannot enforce process control.
Managing Quality
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Day in the Life of a Maintenance Technician
• Execution of a Maintenance Order
• Squawks/ Non-Conformance
Solumina Demonstration
2020
• Product Control• Data and Documentation tied to each unit by
serial or lot number
• Process Control• Operator skills and Certs
• Tools with Calibration dates
• Current process documentation
• Controlled change procedures for process instructions
• SPC
• Disposition Instructions• Authoring
• Execution
• Discrepancy (Non- Conformance) management• Full Integration with Process Execution
• Configurable Workflow
• Dispositioning
Integrated Quality Management
• Inspection and Test Plans
– FAI and PPV
• Quality Metrics
– Six Sigma and Defect Normalization
• Corrective and Preventive Action
– Requests
– Investigation and Action Items
– Verifications
• Audits
Plan… Detect… Resolve
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Embedded CAPA = Consistent Problem Resolution
Add templates to streamline processing and automatically attach to each CA 8D
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Digital Thread
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WIP Tracking
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Track Product Lifecycle
Unit (serial or lot) and
operation detail tracking.
Assembly level project or
shipment tracking.
Supplier or Receiving
shipment tracking
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As Maintained Log
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BACK UP SLIDES
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Typical Data Flow
ERP
Pro
cess
P
lan
nin
gEx
ecu
tio
n &
Q
ual
ity
PD
MTi
me
&
Att
end
ance
Product Definition &
BOMs
Engineering Change
Drawings, specifications,
3D models
Work order execution &
data validation
Quality management,
nonconformance & CA
Product genealogy
As built record
Engineering change
incorporation
Detailed process plan & operation
sequence
Inventory master &
manufacturing Bill of Material
Operations schedule
Work OrderFinished goods inventory and
shipment
Labor time tracking
Data Use Case
Solu
min
a
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SOLUMINA
Data Flow Between Solumina and SAP
Procurementand Inventory Management
(MM)
Item Disposition
SAP
Production Planning and Controlling
(PP)
Process Planning
Process Execution &
Quality
Equipment (QM)
Tool MastermBOMs
Part MasterProcess Routing
WO Request
WO Schedule
Material Issue
Supplier Quality
Purchase Orders
Operation Status
WO Revision
WO Status
WO Issue
WO Split
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Solumina MRO - Breakdown
Change Management
MRO Requirements Planning
• MRO Requirements Definition
Process Planning
• MRO Routine Work and Process Planning
Process Execution
• MRO Planned Work Order Execution
Non-routine Execution
• Over and Above, Inspection Findings and Sub-work Approvals
MRO
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Close the loop on change management
Change Incorporation
Enter Change Information
Enter Affected and Resulting
Objects
Determine Impact
Analysis
Create an Action Plan
Incorporate the Changes
New Revision of Definition ECO
(PDM)
Determine effectivity
Incorporate Timing (ERP)
Understand Impact to Shop Floor (Solumina)
Close Change Request
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Real time information:• WIP/order status, job assignment, help calls and order
notes provide quick access to information with work flow
Trending reports:• Cycle time, backlog, on time completion, cost of non-
conformance, yield, SPC, and efficiency help spot trends and opportunities for improvement
Product reports:• As-maintained BOM, unit production status, device
history record keep the information flow consistent
Reports