Risk Management Application to Production and Products: From a pilot project to an well-established established application

Transcription

1 International Aerospace Quality Group GENERAL ASSEMBLY Risk Management Application to Production and Products: From a pilot project to an well-established established application Naples - 11 April 2008

2 AleniaAermacchi: A Deep Experience in Military Aviation Nieuport Macchi Macchi Castoldi Macchi Castoldi MB MB SF-260 and S M-346 First Flight :15 th July 2004 M-311 First Flight :1 st June = 2006

3 AeniaAermacchi joins the Finmeccanica Group AERONAUTICS ENERGY TRANSP. SPACE DEFENCE ELECTRONICS Alenia Aeronautica Ansaldo Breda Thales Alenia Space SELEX Sensor and Airborne Systems AleniaAeronavali Ansaldo Energia Telespazio Galileo Avionica AleniaAermacchi Ansaldo STS SELEX Sensor and Airborne Systems U.K. ATR Fata SELEX Communications DEFENCE SYSTEMS Oto Melara MBDA WASS HELICOPTERS AgustaWestland Joint Venture Owned Company SELEX Sistemi Integrati SELEX Service Mangement DATAMAT Elsag Orizzonte Elettronica

4 Risk Management application: History : CUSTOMER REQUIREMENTS A Critical Item Review applied to a production process Processes requiring inquiry identified. Risk associated to process identified. Identified risks evaluated. Corrective Actions established : 2003: THESES POLITECNICO/AEM academic - Tutor Eng. C.NOE : R.M application for the production process of the acoustic panel for an Airbus A330 nacelle. LIUC/AEM academic - Tutor Eng. A.BRUN: R.M application for the production process of a Falcon 900 nacelle panel : 2004: PILOT PROJECT Definition of a methodical approach to R.M. in Aermacchi. Validation of defined method. Method applied to a PRODUCTION PROCESS.

5 Pilot Project: Stub Pylon EF2000 WHY THE STUB PYLON? Rail Slot: out of tolerance per dwg Boss: thickness oversize WHAT S THE SUBJECT? EFA 2000: Integrated Tip Stub Pylon Launcher

6 Pilot Project: Stub Pylon EF2000 MACHINES MATERIALS STAFF Ishikawa SUPPORT TOOLS METHOD TOOLS PHASE Brainstorming Risk Identification Probability Residual Risks List of Risks Impact Risk Closure Risk Reporting & Monitoring Risk Register Risk Assessment IPR=PxI Action Plan Risks Assessed Risk Treatment Top-Down Method Validation Bottom-Up

7 Stub Pylon EF2000: Obtained Results BEFORE STUB Year Year NC Management Rework N 3 Scraps N 2 Scraps RH N 5 Scraps - LH +24% TWINMISSILE Transversal Risks? OUTBOARD Year N 8 Scraps Rework N 3 Scraps

8 Stub Pylon EF2000: Obtained Results BEFORE STUB Year Year NC Management Rework N 3 Scraps N 2Scraps RH N 5Scraps-LH +24% AFTER From September 2004 NC Management Rework +5% STUB +5%

9 NADCAP Certification NADCAP National Aerospace and Defence Contractors Accreditation Program What is it? International Program for the Certification which the Leading Aerospace Industries and Governments of the Western Countries have adhered to. What is it for? The verification that Special Processes and Non Destructive Tests carried out by Aerospace Manufactures are comply with Customer Requirements and International Standards ( AMS-MIL-FED. STANDARD- SAE ect.). Standardize the performance and quality requirements of Special Processes and Non Destructive Examinations. Why Qualify? As of Today, our customers (es. Airbus, Boeing ) have a mandatory requirement for NADCAP Certification for Special Processes and Non Destructive Examinations of their suppliers.

10 NADCAP Certification AC 7118 Composites Audit Para Controlled Contamination Area: Are Temperature and Humidity continuosly recorded? BEFORE AFTER Analogic System Recording Weekly endurance Record analysis and filing data manual Digital System Recording Unlimited endurance Automatic Record analysis and filing data Greater Reliability and Accuracy

11 Risk Management Application: A Guarantee for NADCAP Certification Steps required for NADCAP Certification: Audit Planning Establishment of a dedicated Workgroup Analysis of Reference Documents (Check List) NADCAP Audit NC Management Risk Management Planning of Corrective Actions Predict Investments Obtainment of NADCAP Certification

12 Risk Management Application: A Guarantee for NADCAP Certification Steps required for NADCAP Certification: Audit Planning Establishment of a dedicated Workgroup Freeze, Share and Spread approach method 4 active work groups on 4 technologies Create a Risk Database Manage transversal risks Analysis of Reference Documents (Check List) NADCAP Audit NC Management Risk Management Planning of Corrective Actions Predict Investments Obtainment of NADCAP Certification

13 Risk Management Application: A Guarantee for NADCAP Certification Steps required for NADCAP Certification: Audit Planning Establishment of a dedicated Workgroup Freeze, Share and Spread approach method 4 active work groups on 4 technologies Create a Risk Database Manage transversal risks Analysis of Reference Documents (Check List) NADCAP Audit NC Management Obtainment of NADCAP Certification Risk Management Planning of Corrective Actions Predict Investments 44 Nadcap Certifications

14 Conclusion Risk Management is a low cost application. It doesn t need COMPLEX software or expensive INVESTMENT. Risk Management is an intuitive application. It doesn t need complex TRAINING. Risk Management is a matrix application: EVERYONE can use it. Risk Management is able to change the COMPANY and PEOPLE.

15 Conclusion. Because the light at the end of the tunnel, could be a train!!