ProCert Support

Project at XXXX
August, 20th 2004
Presented par:

Jean Denis,
Ninon L.,
Nathalie G.

Assembly & Test
Renaiscience : JL Denis 2004 slide 3
Objectives
Objectives

Increase practical and applied knowledge for Problem

esolution in !e" personnel

Organi#e $ Prioritise engine assembl" $ test issues

using the Pro%ert approach
Renaiscience : JL Denis 2004 slide 4
&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 project

e*ecution

Plant XX Assembly
& Test
ProCert Deployment
Renaiscience : JL Denis 2004 slide 6
Issue
Issue
ProCert Integration ProCert 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 top0down 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
Renaiscience : JL Denis 2004 slide 7
esolution1ecommendation
ProCert Integration

Implement bottom0up means of integrating Pro%ert into

2planned3 %ontinuous Improvement Program
Quality Clinic
Process
collects $ transforms info
into actions, priorities for
resolution and commits
resources to support
problem 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 issues
0 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%OP,7
ProCert Project selections
etc4
Notes:
- ProCert elements in italics
- "o #e furt$er developed are: list of %ta&e$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$e
sta&e$olders are and )$at t$eir real needs are' t$en tailor t$e
process and outputs to suit. ProCert is a NE+ sta&e$older,
Renaiscience : JL Denis 2004 slide 8
esolution
esolution
1
1
ecommendation
ecommendation
ProCert Integration ProCert Integration

8ormalise Top-down project identification process

8ormalise Bottom-up project identification process

(efine $ 8ormalise deplo"ment process

2use input0process0output0metrics0stakeholder anal"sis3

Identif" deplo"ment risk and acceleration factors

Renaiscience : JL Denis 2004 slide 9
I
I
ssue
ssue
Problem-Solving Strategy Problem-Solving Strategy

Pro%ert not recognised as a problem0solving strateg"

for major %9, 29op0(own3 problems

%omple*it" of appl"ing Pro%ert in Assembl" and 9est

for problem0solving

+ow0volume, highl" comple* product

0 lack of good, plentiful data from consistent e*amples

:igh unit costs

0 difficult and costl" to e*periment for causes $ solutions
Renaiscience : JL Denis 2004 slide 10
esolution
esolution
1
1
ecommendation
ecommendation
Problem-Solving Strategy Problem-Solving Strategy

-stablished $ walked management through a 9op

down problem solving strateg" for major %9,
problems;

<ained consensus on major customer issues

+acking data, used consensus of e*pertise to identif"

processes and elements as likel" contributors to problems

aised awareness of need for reliable data

-vidence of process control used to identif" solution paths

Premise; 9hose influential proesses s!owin" out-o#-ontrol are
Key to spread in vibration 2or other3 performance
Renaiscience : JL Denis 2004 slide 11
Issue
Issue
Vibe Measurement Uncertainty Vibe 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" 2gage $3

>eed to develop practical and effective alternative 5

Renaiscience : JL Denis 2004 slide 1$

Adapted and transferred means of assessing vibration

measurement 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

esolution1ecommendation
Vibe Measurement Uncertainty

Plant Assembly &
Test
Pro%ets
Renaiscience : JL Denis 2004 slide 14

8acilitated improvement of Pro%ert )andate form

Identified, got consensus on :igh0+evel %ustomer

issues and priorities:

:igh rotor $ +ow rotor =ibration?

&pecific 8uel %onsumption?

Inter09urbine 9emperature?

Operabilit"
'ork Accomplished
Renaiscience : JL Denis 2004 slide 1&

8acilitated identification and prioritisation of

contributor" elements 2mid0level projects3:
@3 :P9 Ass" $ Install process
23 :P9 Aalancing processes
B3 :P9@ =ane $ +P9B =ane ring Ass" $ flow measurement
43 +P9 Ass" balancing process
C3 +P9 install process
D3 :P9 tip clearance 29urbine3
E3 :P9 tip clearance 2shroud3
'ork Accomplished
Renaiscience : JL Denis 2004 slide 16

)apped !e" Process at mid0level

:P 9urbine assembl" $ install, including tie0shaft r1o

Aaseline 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 out0of0balance

select alternate datum points and revise mfg process

AGIA) dimensioning and stacking process

investigate, compare with earlier model engine data $ e*perience

9est %ell =ibration )easurement

initial anal"sis of transducers suggests large contributor to variation
'ork Accomplished
Renaiscience : JL Denis 2004 slide 17
'ork Accomplished
'ork Accomplished
Identified lower0level projects;

:P9 assembl"

:P% assembl"

Assessment of =ibration )easurement Hncertaint"

(imensioning $ stacking process

9ie0shaft stretching

:P% $ :P9 component initial0out0of0balance

&upplied concepts not considered within Pro%ert training:

(ata collection strateg" and tools

2evolves to Icontrol planJ later3

Project planning structure to establish time and resource

re/uirements and commitments
Renaiscience : JL Denis 2004 slide 18
>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, cost0effective 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"

To Reach Us
'e(n Denis
e-m(il: %ld*+(lues,"m(il*om