risk management application to production and … project: stub pylon ef2000 stub year 2003-2004 nc...

Risk Management Application Risk Management Application to Production and Products: to Production and Products:

From a pilot project to an From a pilot project to an wellwell--established applicationestablished application

NaplesNaples -- 11 11 AprilApril 20082008

International Aerospace Quality GroupGENERAL ASSEMBLY

Nieuport Macchi 10.0001913

Macchi Castoldi 72 1934

Macchi Castoldi 205 1942

MB-326 1960

SF-260 and S-2111997

M-346First Flight :15th July 2004

M-311First Flight :1st June 2005

AleniaAermacchi:A Deep Experience in Military Aviation

20062006+ =20032003

MB3391976

AeniaAermacchi joins the Finmeccanica Group

AERONAUTICSAERONAUTICSAlenia Aeronautica

AleniaAeronavali

AleniaAermacchi

ATR

DEFENCE SYSTEMSDEFENCE SYSTEMSOto Melara

MBDA

WASS

ENERGY TRANSP.ENERGY TRANSP.Ansaldo Breda

Ansaldo Energia

Fata

Ansaldo STS

SPACESPACEThales Alenia Space

Telespazio

HELICOPTERSHELICOPTERSAgustaWestland

DEFENCE ELECTRONICSDEFENCE ELECTRONICSSELEX Sensor and Airborne Systems

Galileo Avionica

SELEX Communications

SELEX Sensor and Airborne Systems U.K.

SELEX Sistemi Integrati

SELEX Service Mangement

DATAMAT

Elsag

Orizzonte

Elettronica

Owned Company

Joint Venture

ATR

SELEX Sensor and Airborne Systems

Orizzonte

Elettronica

MBDA

1.1. 2001: CUSTOMER REQUIREMENTS2001: CUSTOMER REQUIREMENTSA Critical Item Review applied to a production process

• Processes requiring inquiry identified. • Risk associated to process identified.• Identified risks evaluated.• Corrective Actions established.

2.2. 20012001--2003: THESES 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.

3.3. 20032003--2004: PILOT PROJECT 2004: PILOT PROJECT • Definition of a methodical approach to R.M. in Aermacchi.• Validation of defined method.• Method applied to a PRODUCTION PROCESS.

Risk Management application: History

Pilot Project: Stub Pylon EF2000

WHATWHAT’’SS THE SUBJECT?THE SUBJECT?

EFA 2000: Integrated Tip

Stub Pylon Launcher

WHY THE STUB PYLON?WHY THE STUB PYLON?• Rail Slot:

out of tolerance per dwg

• Boss: thickness oversize

PHASEPHASE

MACHINESMACHINES MATERIALSMATERIALS STAFFSTAFF

SUPPORT TOOLSSUPPORT TOOLS METHODMETHOD TOOLSTOOLS

IshikawaBrainstorming

5 55 1010 1515

4 44 88 1212

3 33 66 99

2 22 44 66

1 11 22 33

1 2 3

Impact

IPR=PxI

Pro

babi

l ity

Risk Assessment

Risk Treatment

Risk Reporting & Monitoring

List of Risks

Risks AssessedAction Plan

Residual Risks

Risk Register

Risk Identification

Risk Closure

Method Validation

TopTop--DownDown

BottomBottom--UpUp

Pilot Project: Stub Pylon EF2000

STUB Year

2003

-200

4 NC ManagementReworkN°3 ScrapsN°2 Scraps – RHN°5 Scraps - LH

Year

2001

-200

3

€ 33.000

TWINMISSILE

OUTBOARDOUTBOARD

ReworkN°3 Scraps

N°8 Scraps

Year

2003

-200

4

€ 59.000

+24%+24%+24%

Transversal Risks ?

Stub Pylon EF2000: Obtained Results

BEFOREBEFORE

STUBN°2 Scraps – RHN°5 Scraps - LH

Year

2001

-200

3

€ 33.000

+24%+24%+24%

BEFOREBEFOREFr

om S

epte

mbe

rFr

om S

epte

mbe

r 200

420

04

NC ManagementNC ManagementReworkRework

AFTERAFTER

STUB +5%+5%+5%

Year

2003

-200

4 NC ManagementReworkN°3 Scraps

Stub Pylon EF2000: Obtained Results

NNational ational AAerospaceerospace andand DDefenceefence CContractorsontractors AAccreditationccreditation PProgramrogram

NADCAPNADCAP

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.

NADCAP Certification

AC 7118 Composites Audit

Para 6.2.7 - Controlled Contamination Area: “Are Temperature and Humidity continuosly recorded…?”

•Analogic System Recording

•Weekly endurance

•Record analysis and filing data manual

BEFORE AFTER

•Digital System Recording

•Unlimited endurance

•Automatic Record analysis and filing data

•Greater Reliability and Accuracy

NADCAP Certification

Audit Planning

Analysis of Reference Documents (Check List)

NADCAP Audit

Obtainment of NADCAP Certification

NC Management

Establishment of a dedicated Workgroup

Risk ManagementRisk Management

Risk Management Application: A Guarantee for NADCAP Certification

Steps required for NADCAP Certification:

•Planning of Corrective Actions•Predict Investments


• “Freeze”, Share and Spread approach method

4 active work groups on 4 4 active work groups on 4 technologiestechnologies

•• Create a Risk Database•Manage transversal risks



Audit Planning


NADCAP Audit


NC Management



••4 Nadcap 4 Nadcap CertificationsCertifications


• “Freeze”, Share and Spread approach method

4 active work groups on 4 4 active work groups on 4 technologiestechnologies

•• Create a Risk Database•Manage transversal risks



Audit Planning


NADCAP Audit


NC Management



Risk Management is an intuitive application.

It doesn’t need complex TRAINING.

Risk Management is a low cost application.

It doesn’t need COMPLEX software or expensive

INVESTMENT.

Risk Management is a matrix application: EVERYONE can use it.

Risk Management is able to change the COMPANY and PEOPLE.

Conclusion

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

Conclusion