Aircraft NPI Case Study Lean Enterprise Approach Lean Development FAR – Type Certificate (Part 21) FAR – Prod Cert AS9100 – Quality Management System Supplier Quality Process and Org Advanced Product Quality Planning Manufacturing Execution Systems Quality Control and Plan for variation Type Certificate – Goal 2024 Lean Development FAR – Type Certificate (Part 21.21) Conceptual Design Phase Req Definition Process Orientation Preliminary TCBM Pre-Project Guidance Form TC team Familiarization Briefing TC Project Plan TCBM for Certif Basis Certification Basis FAR – Prod Cert Compliance Planning TCBM for Cert Plan Implementation Test Plan and FAA approval Experimental AW Cert Engineering Conformity Plan Flight Test preparation Applicant Flight Test Certification Flight Test Issuance of TC and Data sheet Quality Management System Lean Development FAR – Type Certificate (Part 21) FAR – Prod Cert AS9100 – Quality Management System Supplier Quality Process and Org Advanced Product Quality Planning Manufacturing Execution Systems Quality Control and Plan for variation Quality Management System Lean Development AS9100 – Quality Management System External Issues Internal Issues Dependency on Suppliers Early-stage nature Relatively new market Ability to manufacture aircraft at comercial-scale Regulatory requirements Workforce retention Quality Management System Lean Development AS9100 – Quality Management System Quality Manual Company’s Priorities Safety Quality On-time deliveries Efficiency Roles and Responsablities Design Quality Assurance Manufacturing Materials Purchasing Production Control Operations Quality Control Costs • SIPOC for each process Risk and Oportunities Identify CTQ processes Establish control checkpoints Quality assesment after every process Define Quality objectives for every process Quality Management System Lean Development AS9100 – Quality Management System Quality Manual Operation Performance Evaluation Improvement APQP – Both Internal and External Define KPI In-service non conformances First Article Inspections Internal Audit Program – Periodically performed Expedite Corrective actions Data-driven Continuous Improvement Non-conformances On-target preventive and systematic actions Supplier Quality Process and Org Lean Development FAR – Type Certificate (Part 21) FAR – Prod Cert AS9100 – Quality Management System Supplier Quality Process and Org Advanced Product Quality Planning Manufacturing Execution Systems Quality Control and Plan for variation Supplier Quality Process and Org Lean Development Supplier Quality Process and Org Supplier capabilities RFI RFQ Supplier selection Initial screening Supplier shortlist Manufacturing MFG capabilities Draft / restricted drawings shared Quality Multiple potential suppliers Compliance Based on costs advantage Product / Process Complexity Supplier Scorecard Quality Supplier Corrective actions Deliveries Supplier Preventive action Cost 8D Inspection Plan based on AQL Airframe/CF Avionics Aircraft Integration In-House Outsourced In-House Supplier QA Advanced Product Quality Planning Lean Development FAR – Type Certificate (Part 21) FAR – Prod Cert AS9100 – Quality Management System Supplier Quality Process and Org Advanced Product Quality Planning Manufacturing Execution Systems Quality Control and Plan for variation Advanced Product Quality Planning Lean Development Supplier select Advanced Product Quality Planning Planning In-House Outsourced In-House Product Design and Development Process Design and Development Product and Process Validation On-Going Prod and Post-Delivery Serv Design Scope DFMEA Top RPN PFMEA Top RPN Outputs Outputs Airframe/CF ! Material strength ! Resin-Hardener ratio Production Run Reduced variation Avionics ! Short Length ! Misrouting Process Capability Customer satisfaction Aircraft Integration ! Tolerances (GD&T) ! Incorrect Parts installed SPC Manufacturing Execution Systems Lean Development FAR – Type Certificate (Part 21) FAR – Prod Cert AS9100 – Quality Management System Supplier Quality Process and Org Advanced Product Quality Planning Manufacturing Execution Systems Quality Control and Plan for variation Manufacturing Execution Systems Lean Development Supplier select Process Validation Work Preparation Airframe / CF Manufacturing Execution Systems Quality Control Inspection Plan Item List records Level of acceptance (Dwg, Specs) MBOM creation Work Order execution Non-conformances Process sign-off Discrepancy Report CTQ data collection Defect Codes Tool data collection Material disposition Quality sign-off Corrective and Preventive actions Inspection Check Points Avionics Work Plan creation Inspection documents (IPC) Cut-in Effectivities QC Inspectors skills Aircraft Integration IoT – Industry 4.0 Work Centers Inspection equipment Quality Control Plan and variation management Lean Development FAR – Type Certificate (Part 21) FAR – Prod Cert AS9100 – Quality Management System Supplier Quality Process and Org Advanced Product Quality Planning Manufacturing Execution Systems Quality Control Plan and variation management Root Cause Analysis and Corrective Actions Discrepancy Report Internal Quality External Quality Gemba RPS Andon Base team: Ops, QC, Mfg, QA Go & See 8D Problem Solving Structure Root Cause Analysis and Corrective Actions Base Team – Decision Makers 8D Problem Solving 1. Create a team 2. Define and describe the problem 3. Containment actions 4. Root Cause analysis 5. Corrective Actions 6. Implement and validate CA 7. Preventive Actions 8. Celebrate with your team Problem Definition through 5W + 1H Reinforce checkpoints for containment 5 Why’s / Ishikawa / Pareto Charts for Analysis QMS approach for preventive actions Lean Enterprise Approach Lean Development FAR – Type Certificate (Part 21) FAR – Prod Cert AS9100 – Quality Management System Supplier Quality Process and Org Advanced Product Quality Planning Manufacturing Execution Systems Quality Control and Plan for variation Thank you!
