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Aft Body Rate Readiness Swoop Chart Doors (252/257)

Aft Body Rate Readiness Swoop Chart Doors (252/257). Aft Body Rate Readiness Swoop Chart Doors. Aft Body Rate Readiness CS 260. Jamie Bigley Tim Bittner Ben Kearns. Team Focal/Leader: Manager Focal/Leader: Sponsor: Resources:. BCD Drill Plates Failed PTI. G.

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Aft Body Rate Readiness Swoop Chart Doors (252/257)

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  1. Aft Body Rate ReadinessSwoop Chart Doors (252/257)

  2. Aft Body Rate ReadinessSwoop Chart Doors

  3. Aft Body Rate ReadinessCS 260

  4. Jamie Bigley Tim Bittner Ben Kearns Team Focal/Leader: Manager Focal/Leader: Sponsor: Resources: BCD Drill Plates Failed PTI G Status Date: 6/14/2012 Actions/Tasks/Next Steps: TE to revise drawing DL478Z5000-1 Sent Request for Quotes (RFQ) Fabrication of new Drill Jigs Complete Tool Try out Release in ENOVIA Problem Statement: BCD DJ478Z5000-1 was sent out for PTI and failed curvature. This could be the cause for the repeated breaking of drill bits and brake out created during the drilling of the BCD edge frames. Target: Order new drill plates that meet drawing requirements. Will also incorporate new manufacturing build requirement for Brotje as a result from NCPSR P6050 Closure Criteria: Obtain new DJs that meet drawing requirements. 5 10 9 8 1,2,3 6 4 7 Accomplishments: Initiate EE EPD for DJ478Z5000-1 failing curvature requirements. TE disposition EE EPD ME create SRR to incorporate planning of TE disposition. ME to create SOW for new BCD Drill Jigs ME create ENOVIA action to modify DL478Z5000-1 Risks/Issues: Requesting duplicate tool in SOW, this may add to the fabrication time. • Help Needed: • None at this time

  5. Team Focal/Leader: Jamie Bigley Manager Focal/Leader: Tim Bittner Sponsor: Resources: Brotje Drilling PAX Door Surround G Status Date: 6/14/2012 Actions/Tasks/Next Steps: Submit ARF and NCPSR to update SMIRMs based off of NC Programming‘s re-examination. Create SRR to redline planning until ARFs can be incorporated. Submit ARF to update Planning to meet new SMIRM requirements Problem Statement: Currently CS 260 has to drill approx. 40+ fasteners in the DS eggcrate assembly before the 47 section barrel moves to Brotje. To support rate, the quantity of the fasteners drill CS 260 must be reduced. Target: Maximize the number of holes drilled by Brotje on the DS eggcrate assembly . Closure Criteria: Determine locations accessibly by Brotje and reduce fastener installation my CS 260 MTs to support rate increase. 2 1 8 5 6 3 & 4 7 • Accomplishments: • Brotje Access review complete LH/RH Door surrounds • 16 Locations must still be drilled in CS 260 (LUT’s req) • NCPSR P6050 Submitted for BCD. • One LUT was received to test MT access under Sill to back drill undersize holes in edge frame. (success) • Submitted EE EPD for LUT remaining locations on LH/RH door surrounds. • Create EE EPD to have LUT’s made for the holes that cannot be drilled by Brotje for the BCD Risks/Issues: Limited access behind Sill Clips (Determined that not all locations can be drilled by Brotje) Limited access to Sill behind Adj Frames (Determined that not all locations can be drilled by Brotje) Help Needed: None at this time

  6. Jamie Bigley Tim Bittner Ben Kearns MMO Heather Baird Team Focal/Leader: Manager Focal/Leader: Sponsor: Resources: Door Surround Shim Installation G Status Date: 5/24/2012 Actions/Tasks/Next Steps: Develop plan and process flow for shim kits, (MMO) Identify first AP with shim kits, (MMO/ME) Order shims for AP 82 and on, (MMO) Problem Statement: Manufacturing LH/RH BCD door surround shims on an AP by AP basis causes production delays. Need a rate capable solution. Target: Shim kits. MMO orders and provides required shims before production need date. Closure Criteria: Process established to kit the shims and first airplane complete. Flow save is realized. Complete 6 5 7 1 2 3&4 • Accomplishments: • ME has identified required shims for installation of Door Surrounds. • ME has redlined an operation for machine shop to manufacture required shims for 5 LN to provide time for MMO to order required shims. • Verify engineering shim defs, ECD 4/23 • Provide shim information to MMO, ECD 4/24 Risks/Issues: • Help Needed: • None at this time

  7. ACCOMPLISHMENTS STA 1719 BCD Edge Frame Previous build plan 478Z1242-3 was located, drilled, and installed in CS 260. Primary indexing was on the LH lower sill. This required the shear-tie to be removed for deburring. CS 257 Located and drilled the shear-tie and floor fitting and temp installed all components. New build plan EE EPD was created for tooling to provide an LUT to locate the Sill Clip. Now, CS257 can Locate, Drill, and Install all components except the sill clip is temp installed. Savings CS260 not longer needs to remove temp fastener and permanentlyinstall (44) fasteners in the edge frame. 471Z3205-3 Shear-Tie 478Z1242-3 EGGCRT Sill Clip

  8. Aft Body Rate ReadinessCS 260

  9. Aft Body Rate ReadinessSwoop Chart - Floors

  10. Aft Body Rate Readiness275 SWOOP Chart

  11. Title: Floor Grid Assembly Aft Galley Drill Jigs Team Focal/Leader: M. Hudson Manager Focal/Leader: T. Bittner Sponsor: B. Kearns G Status Date: 6/14/2012 Priority: 1 ,1 • Actions/Tasks/Next Steps: • TE to provide tool order to Mesa • Fabricate Tools to Build Plan • Tool Try Out • Project ME integrate tool into baseline planning • Problem Statement: Floor AssyAft Galley Drill Jigs required to meet rate increases. • Target: Develop a 6 month Build Plan to provide a set of tools. • Closure Criteria: • Tools have completed tool try out and integrated into baseline planning. • Risks/Issues: • None at this time • Help Needed: • None at this time Accomplishments: Initiate ENOVIA M-Action M.E and Production Approved tool for Design 2 1 3 4 5 6

  12. Title: Floor Grid Assembly Aft Galley Drill Jigs Team Focal/Leader: M. Hudson Manager Focal/Leader: T. Bittner Sponsor: B. Kearns G Status Date: 6/14/2012 Priority: 1 ,1 • Actions/Tasks/Next Steps: • TE to provide tool order to Mesa • Fabricate Tools to Build Plan • Tool Try Out • Project ME integrate tool into baseline planning • Problem Statement: Floor AssyAft Galley Drill Jigs required to meet rate increases. • Target: Develop a 6 month Build Plan to provide a set of tools. • Closure Criteria: • Tools have completed tool try out and integrated into baseline planning. • Risks/Issues: • None at this time • Help Needed: • None at this time Accomplishments: Initiate ENOVIA M-Action M.E and Production Approved tool for Design 2 1 3 4 5 6

  13. Title: Beam Rotation Tool Team Focal/Leader: Y. Ahmed Manager Focal/Leader: T. Bittner Sponsor: B. Kearns G Status Date: 6/14/2012 Priority: 1 ,1 Problem Statement: In order to increase the rate readiness of CS 274 a tooling solution is required that will allow the rotation of the Beam by the MT’s Target: Design and Fabricate a Beam Rotation Tool Closure Criteria: A Designed Tool that will allow the MT’s the ability to rotate the Floor Beam Actions/Tasks/Next Steps: RFQ to suppliers Design/Fabricate tool. Tool tryout Implementation into Baseline Plans • Risks/Issues: • None • Help Needed: • None at this time Accomplishments: Initiate M Action M.E and Production Approved tool for Design on 04/16/2012 3 2 1 4 5 6

  14. Title: PNCA’s Team Focal/Leader: M. Hudson Manager Focal/Leader: T. Bittner Sponsor: B. Kearns Status Date: 4/27/12 G Priority: 1 ,1 • Actions/Tasks/Next Steps: • Insert Text • Problem Statement: Insert Text • Target: Insert Text • Closure Criteria: • Insert Text Complete • Risks/Issues: • Insert Text • Help Needed: • Insert Text • Accomplishments: • Insert Text

  15. Title: Angularity Tool Team Focal/Leader: W. Conner Manager Focal/Leader: T. Bittner Sponsor: B. Kearns R Status Date: 6/14/2012 Priority: 1 ,1 • Actions/Tasks/Next Steps: • Engineering must have requirements for beam angularity. • Tools are in the process of being released for CMA. • Project ME to update baseline planning to incorporate new requirements and tool usage. • Problem Statement: Floor Beams are being installed at an angle that has the potential to be outside of engineering requirements. • Target: Ensure Angularity requirements of floor beams are met to provide a stable build for the Floor Grid Assembly • Closure Criteria: • Tool Tryout completed • Risks/Issues: • None at this time • Help Needed: • Waiting for Engineering requirements to define tolerance for each beam to seat track angle. • Held for Leadership Approval to Proceed • Accomplishments: • Tools have been manufactured • FAJ rework complete • Initiate ELR to drive engineering for new angularity requirement. (475Z0002-31) (ELR # 073916) 2 1 3 4 5 6

  16. Title: Angularity Tool – Backup Data BSC DE: Kyle Starck Status Date: 04/25/12 Approved by: H. Harr LCPT POC: L. Curtright Engineering Rate Enablers – Aft Body15) Section 47 PAX Floor Grid Build-Up and Installation Project Lead: Kyle Starck Customer: Mark Wigant / CS280 DE Status: • 1) 100% (ACD 3/1/12) • 2) 0% (ECD 5/19/12) • 3) 0% (ECD 5/24/12) • 4) 0% (ECD 5/31/2012) • 5) 0% (ECD 5/31/2012) • 6) 0% (ECD 6/4/2012) • 7) 0% (ECD 6/8/2012) Description / Problem Statement: • FA&D is spending 3.25 days to rework floor during Section 46-47 join • Locating floor grid properly per requirements to facilitate successful FA&D join results in excessive gaps between floor beam and frame fittings. • Current Floor Grid Assy tolerances fail to produce a product that will comply with end item installation requirements. Target: • Provide FA&D with Aft Sect 47 that meets end item requirements and requires no seat track rework Proposal / Closure Criteria: • Incorporate improved datum and tolerance structure for floor grid assy • Increase MBD shim allowance between floor beam and frame fittings at STA 1618, 1644, 1670 and 1695 • Incorporation point: A/C 100 Process Info: • ELR 072169 – Floor Grid Instl • ELR 072438 – Floor Grid Assy • ELR 073916 – Floor Grid Assy Last Now DE Project R R R R Risk: Issues: • LCPT has indicated that they will not support change Help Needed: • Held for leadership approval to proceed (rec. Friday 4/27) DE Plan: • 1) Floor grid installation dimensional analysis (ACD 3/1/12) • ELR 072169 and 072438 initiated by ME (ACD 3/15/12) • 2) Evaluate increased shim allowance for 8 locations (ECD 5/19/12) • 3) Preliminary Stress Assessment (10 locations) (ECD 5/24/12) • 4) Create Change Package / DE DWS (ECD 5/31/12) • 5) Baseline DE plan (ECD 5/31/12) • 6) Receive ERB Approval (ECD 6/4/12) • 7) Receive CCB3 Approval (ECD 6/8/12) Recovery Plans: LN127 DE Release 3 1 7 2 6 4 5

  17. Title: Option to use Lockboltsvs Existing NX Fasteners Team Focal/Leader: C. Godin Manager Focal/Leader: T. Bittner Sponsor: B. Kearns Y Status Date: 6/14/2012 Priority: 1 ,1 • Actions/Tasks/Next Steps: • MT’s to provide all IRM’s associated with each SOI (ECD 5/15) • ME to create spreadsheet for SOI to IRM (ECD 5/23) • DE evaluates and incorporates changes into baseline engineering as alternate (ECD 7/27) • Project ME incorporates changes into baseline planning (ECD 8/30) • Problem Statement: Lockbolts will help Production meet rate increase due to faster installation time. • Target: Locate all locations where Lockbolts can be used instead of existing NX Fasteners • Closure Criteria: • DE has incorporated changes into baseline engineering, Project ME has incorporated changes into baseline planning. • Risks/Issues: • None at this time • Help Needed: • MT’s need to provide IRM’s for potential lockboltuse • Accomplishments: • IE to provide full size bar chart 3 1 2 4 5

  18. Aft Body Rate Readiness280_SWOOP Chart

  19. Aft Body Rate Readiness280_SWOOP Chart

  20. Floor Grid Installation G Helms / Johnson Team Focal: Status Date: 6/14/2012 • Actions/Tasks/Next Steps: • Review Build plan and create standard work packages for MTs • Complete 2/2012 • Assign Project Manager to Implementation. • Complete 2/2012 • Correct manipulator inconsistency • Complete 5/2012 • Dimen Mgmt to track and status TAA • ECD 8/15/2012 • DE/LE team to Open Shim Tolerances for Selected STA • ELR 072169 ECD 6/19/2012 • Implement Digital Gage for gap check • Gage R&R 8/15/2012 • Procur CAMS laser Equip for use at LU110 • ECD for Cap Purch approval 6/1/2012 • Problem Statement: • Current engineering tolerances are not being always met. • Floor Grid Assembly has no datum scheme and poor tolerance definition. • CN 30538 and -9 introduce new requirements for the Seat tracks in relation to the barrel datum scheme to allow for improved join to Sec 46 in FAD. • Current Best Fit still gives excessive Gaps • Target:Agreed upon tolerances for each cell involved with the floor grid, verification steps to ensure tolerances are met, and build plan can support tolerances are met. • Closure Criteria: • Planning, Design and Tooling updated to reduce NCs in floor grid 50% and Improve average labor time flow into 1 shift • Agreement between all share holders on tolerances. • Individual Project 4 Square Break Out: • DM 47 Floor Grid Variability • Floor Grid Shim Tolerance • Floor End Fitting –M fitting Pre-made • Manipulator Adjustments • BR&T Gage Progress • CAMS Laser EQ Progress • Risks/Issues: • Side frames splice fittings twist FWD as much as .150 when it Sec 47 arrives in CS280. CS260 to install more tacks, this will help or create a pre-load ..https://vtr3a.web.boeing.com/sites/Spec_Prog/515 Reports/Project 4 Square/Aft 4 Square/FS4_S47 Frame Install_ Current.ppt • Help Needed: • CAMS team to finish quotes from Vendors 6. BR&T Gage Team Review Build and Create Std Work 2. Assign Proj Mgr 4. Dimen Mgmt TAA 7. Review and Purch Common Met Equip from Cn 4. 5. 6. 7 Lu110 Completion 5. DE ELR Submitted 5. ELR Answer expected 2012 2012

  21. Manufacturing EngineeringTitle: Section 47 Floor Grid Assembly InstallationCharge Number: Boeing Proprietary Y • Problem Statement: • Variability of floor grid build package causes 2+ days for install and does not meet FAD join requirements. Additionally, no repeatable process exists to locate the floor. Target: • Identify and Reduce floor grid variation, no tags related to floor grid build Fit, and meeting FAD join (IARM) requirements. Closure Criteria: • Floor grid deliverable meets IARM seat track requirements. • Actions/Tasks/Next Steps: • Update ERMs: 8/18/12 ELR Submitted 3/12/12 Kyle Starck (DE) • Fix FAJ Fwd bushing locations: 7/31/12 Rob Radar (TE) • Develop improved floor insertion process 7/31/12 Complete • Reduce Variation of 1836 C-Channel 7/31/12 (SM) • Update Planning for insertion method: LN110 P. Johnson • Process verification Study 12/16/13 Risks/Issues: • Need significant changes in engineering and/or installation process to reduce variation of Side Frame Assembly Splice Fittings. Help Needed: • Tooling – Fix FAJ non-conformances ASAP • CAMs Quality – 16hrs/wk Shoot Floor Grid FAJ before and after fix and process improvement verifications. ASAP. • Barry Cooke- Develop CAMs routine for floor installation. ASAP • Al Upham SM - Get CD Zodiak to fix 1836 C-Channel. ASAP • Kris Helms ME- update planning to include new insertion method. Accomplishments: TAA buy-in by ME, DE and TE: 1/17/12 Presentation of TAA to PST: 1/25/12 Metrology insertion method in use. Cell 280. Discovered variation issue in driven by FAJ. Working CA. 3/1 9 (12/16/13) 8 (10/31/12) 1/2 (1/03 3 (1/11) 4 6/7/9 5

  22. BSC DE: Kyle Starck Status Date: 06/01/12 Approved by: H. Harr LCPT POC: L. Curtright Engineering Rate Enablers – Aft Body15) Section 47 PAX Floor Grid Build-Up and Installation Project Lead: Kyle Starck Customer: Mark Wigant / CS280 DE Status: • 1) 100% (ACD 3/1/12) • 2) 0% (ECD 5/19/12) • 3) 0% (ECD 5/24/12) • 4) 0% (ECD 5/31/2012) • 5) 0% (ECD 5/31/2012) • 6) 0% (ECD 6/4/2012) • 7) 0% (ECD 6/8/2012) Description / Problem Statement: • FA&D is spending 3.25 days to rework floor during Section 46-47 join • Locating floor grid properly per requirements to facilitate successful FA&D join results in excessive gaps between floor beam and frame fittings. • Current Floor Grid Assy tolerances fail to produce a product that will comply with end item installation requirements. Target: • Provide FA&D with Aft Sect 47 that meets end item requirements and requires no seat track rework Proposal / Closure Criteria: • Incorporate improved datum and tolerance structure for floor grid assy • Increase MBD shim allowance between floor beam and frame fittings at STA 1618, 1644, 1670 and 1695 • Incorporation point: A/C 100 Process Info: • ELR 072169 – Floor Grid Instl • ELR 072438 – Floor Grid Assy • ELR 073916 – Floor Grid Assy Last Now DE Project R R R R Risk: Issues: • LCPT has indicated that they will not support change Help Needed: • Held for leadership approval to proceed DE Plan: • 1) Floor grid installation dimensional analysis (ACD 3/1/12) • ELR 072169 and 072438 initiated by ME (ACD 3/15/12) • 2) Evaluate increased shim allowance for 8 locations (ECD 5/19/12) • 3) Preliminary Stress Assessment (10 locations) (ECD 5/24/12) • 4) Create Change Package / DE DWS (ECD 5/31/12) • 5) Baseline DE plan (ECD 5/31/12) • 6) Receive ERB Approval (ECD 6/4/12) • 7) Receive CCB3 Approval (ECD 6/8/12) Recovery Plans: LN127 DE Release 3 1 7 2 6 4 5

  23. Floor Grid Pre-fabricate –M fittings Y Helms / Johnson Team Focal: Status Date: 6/14/2012 • Problem Statement: • Floor Grid has a gap issue that is causing –M parts to be order every AP • Ordering 3-4 –M parts per AP and AP 60 saw 10 –M parts • Ordering Special Ti Fitting and Special Bushes, as the dimension is different each AP and each part is link to a EPD that calls out the unique dimensions • Actions/Tasks/Next Steps: • ME to define new -9000 numbers for the fittings with added material. • Due 3/9/2012 Actual 3/26 • ME to redo Models (Complete 4-10) • MMO to order PNCA parts to keep in inventory as needed to support rate. • MMO to order parts 3/14/2012. (Complete 5/11) • Parts on Dock (471Z3410-9001 / 9002 and 403Z1501-9004) • ECD 9/10/2012 • Target: Define Part and Part Number that has larger enough dimensions that allows Boeing to mill down to the size needed for MMO to order a safety stock. • Closure Criteria: • Part(s) defined (Complete 3/26) • Parts on dock • Accomplishments: • Identified fitting locations for pre-fabricating floor fittings and thicknesses • PNCAs created by planning and reviewed by DE • Demand created and Parts on order.16 Week Lead time (9/10) • MMO coord. with Auburn to use as Emerg. Ops if needed before 9/10 • Number of –M fittings reduced by over 75% • Risks/Issues: • Cost issues, move Dock date to end of AUG • Will use Auburn Emergent Ops (10 day turn) if –M fitting is needed • between now and SEP • Lu110 Tolerance requirements ,may increase need for fittings • Help Needed: • MMO Lead time is 16 weeks order 2 ea STA1836 fittings (1 LH, 1 RH) and Bushings • LE needs to ensure Anti-rotation rings go into NCs as needed Team met to discuss potential solutions Team met to discuss potential solutions Order 1836 PNCA parts Define and Rel. PNCAs Parts Available Solution identified 2011 2012

  24. Thru-Hole Gap Gage (Digital) – 47/48 Join Gap Check & Floor Grid Responsible: Dzoan Tran (BR&T)_ Status Date: 6/11/2012___ Approved by: _____________ G G GTG: ______ Is / Was Current Situation Target Insert Photo • 90-Degree Filler Gage: • Trial and error approach to assess and assign the appropriate gap values. • High measurement variation • Thru-Hole Gap Gage: • Target to gain improved measurement precision. • Eliminate trial-and error approach. X X X X • Status: • Completed Gage R&R study of Mitutoyo. Results showed good repeatability, but poor reproducibility. BR&T working on modifying the tool setup to address reproducibility problem. This is needed for Join cell. • BR&T evaluated Floor Grid gap measurement. Process and determined GapMan could be used. Will train QTs to measure gaps and modify the wand if required for Floor Grid application. Schedule 1 2 3 4 5

  25. CS280 Manipulator Movements G Johnson Team Focal: Status Date: 6/14/2012 • Problem Statement: • CS manipulator does not move consistently during floor install • Actions/Tasks/Next Steps: • Review Manipulator actions with PST Team (Complete) • Meet with AIT team to discuss Issues (Complete) • AIT on site checked mechanical system • AIT programmer go over code • Make adjustments (Complete) • Bring AIT team back with PST review (Complete) • Coordinate fix and implement tests show correct for 3 LUs • Target: Improve System (Equip and/or Software) to ensure consistent manipulator movement to improve floor grid install cycle time • Closure Criteria: • 3 consecutive Ship sets with manipulator and laser system giving consistent readings Closure Criteria met and closed thru PST • Accomplishments: • Reviewed inconsistency of Manip movements through Lus 67-71 • Met with AIT mechanical expert and programming expert, made an adjustment • LU72 still shows inconsistent results • LU74 install w / AIT today, programming change on Lu74 improved movement • 1 more Lu’s to test before the PST says the manipulator is “Fixed” • YAW worked well for LU75, LU76 • Maximo requests input at Lu75 for tablet • COMPLETE • Risks/Issues: • AIT correction doesn’t stay, Mt have to go back to manual moves correctly. Help Needed: Closed Per PST 5 4 3 1 2 2011 2012

  26. LU110 Seat Track Requirements Y Sinkevitch / Johnson Team Focal: Status Date: 06/01/2012 • Actions/Tasks/Next Steps: • Obtain and Begin Capital Expenditure packet from Finance • Complete 4/16 • Create and submit Business Case • Complete 5/21 • Review/Update Purch Requirements (CAMS, -9, Tooling) • Complete 5-29 • Submit Capital packet for review • ECD 6/18 • Receive, Train and Test EQ at Lu90 for Lu110 Execution ECD 9/1 • Problem Statement: • CN 30348 at Lu110 Tightens Floor Grid install Requirements to call out Tight tolerances at the seat track locations • Target:Use CAMS equipment to meet specification requirements starting at LU90. Closure Criteria: Successful completion of floor grid installation by using CAMS Laser shoot equipment to align seat track locations • Accomplishments: • Risks/Issues: • Tighter tolerance of STA lines may result in increased –M fitting needs • Future Factory criteria (Qty of jigs) hasn’t flowed down yet (Mitigating to make this adaptable into any tooling concepts) • API Tracker laser needs to be cert’d through BR&T • Capital Expenditure packet started • Equip selection out for Confirmation quotes • Business case presented and passed • Met with Tooling, CAMs and -9 to review • requests, update status • Help Needed: • CAMS and -9 team help to finish Capital Expenditure packet 5 2 3 1 4 2012

  27. CS280 Side Guide Rails hole and gap mismatch Y Davis / Johnson Team Focal: Status Date: 06/12/2012 • Problem Statement: • CS has issues with hole mis-alignment between Side Guide Fittings installed in CS260 and Side Guide rails installed in Cs280 • CS 280 has exaggerated shim gaps getting side guide rails to line up with Side guide fittings • Actions/Tasks/Next Steps: • CS280 and CS260 meet for brainstorming • Due 3/22/2012 (Complete) • ME to review Side Guide seq and review program • Due 3/30/2012 Actual 4/9 • Hold Web-ex to determine full impacts with Customer and -9 • Complete 5/2 • Conduct Problem analysis using DM team for Tolerance • Witness/document installation process LN 78 Thursday, 5/31/2012 • Review/baseline 41/43 study (6/1/2012)  • Identify requirements for FAD (6/4/2012) • Analyze requirements-RSS variation analysis for STA,  BL and WL (6/6/2012) • Review DM plan and execute solution based on Data (in #4 above) • Target: Create System to ensure holes in fittings align and gaps give proper fit for part stack up • Closure Criteria: • 3 consecutive Ship sets with no hole or gap issues in CS280 • Proposal re-evaluated / readjusted for 4 day flow rate • Accomplishments: • Met with Project MEs and reviewed Job Sequencing • Met with -9 ME team to review their CNs and build plan • Held Web Ex with FAD, -9, Project Pln and SST ME • Currently Conducting Problem analysis with Dim. Mgmnt Team • Charter completed and approved with Full up team consisting of ME, Project, MFG, SM, DM, QE. Notified IE, DE and TE for reoccurring mtg series to review progress • DM Team RSS analysis complete for “As Designed”, results report this week • CAMS team scheduled for Lu81 (Thurs) and NEW Door FAJ location Inspection • Risks/Issues: • Current SG Rail Supplier (Goodrich) is not healthy enough to bring in parts ahead of build plan to use as a gage in CS260 for fit up tests • Sequential build plan (6 associated SOI’s) • Pull-up project (increased tack fasten) project in CS260 could potentially help, but may in-fact increase pre-load condition on frames and Side guide fittings. • DA analysis could turn this into a large scale re-design Help Needed:Dim. Mgmnt: Research and review current Build data Tolerances and Specifications for “As Built” 1 2 3 4 5 2011 2012

  28. CS280 OPB Movement (NFL) Y Smeltzer/Johnson Team Focal: Status Date: 06/01/2012 • Problem Statement: • Moving the OPB with beat up scooters and pushing by forklift or by hand presents high risk to personal injury or property damages • Actions/Tasks/Next Steps: • CS280 ME create SOW for tooling team • Due 4/27/2012 Actual 5/16 • PST tooling members review SOW and advise • Cell leadership provide CN for procuring items as needed • ME create Tooling actions from CN • Tooling models solutions • Tooling Try out • Tooling support implement • Target: Improve current scooters and reduce OPB manual movement to promote a safe environment • Closure Criteria: • New tools on site for OPB scooters and provide an on site alternative to manual OPB moving • Accomplishments: • ME SOW Completed and to Tooling • Risks/Issues: • Tooling resource tied into CS257 and 275 move Help Needed: Tooling: Ready for prelim design MGMt: Need CN for Tool action 2 5 1 3 and 4 6 7 2012

  29. CS280 PST Value Stream Map Y Summers / Johnson Team Focal: Status Date: 06/11/2012 • Actions/Tasks/Next Steps: • Notify team and review Workshop criteria • ECD 6/15/2012 • Perform and execute Pre-workshop checklist. • ECD 6/29/2012 • Execute 3 Day workshop with PST • ECD 7/13/2012 • Hold post workshop After Action Review • ECD 7/18/2012 • Present VSMs to Cell • ECD 7/25/2012 • Re-set Continuous Improvement Cycle • NLT 8/1/2012 • Problem Statement: • Current PST Value Stream Map (VSM) is out of date • Target:Use Lean+ tools to have a Current and Future Value Stream maps to provide direction and vision to PST. Closure Criteria: Successful completion of VSM Workshop including deliverables of Current and Future Tier 2 (Cell, Process) level VSM, and a Kaizen Newspaper outlining Steps and Projects • Accomplishments: • PST met with Lean Coordinator and used Lean guide books to create and approve plan, working to meet LMA requirements • Have Project workbook started and now assigning planning tasks • Risks/Issues: • Future Factory Workshop results still pending • Help Needed: • LEAN+ Team and resources 3. 3 Day VSM Workshop 1. Notify Team and review Criteria 4. AAR 2. Execute Pre-workshop checklist 5. Present to Cell 6. Start again 2012 2012

  30. ACCOMPLISHMENTS • Gapman scheduled for Thursday night • Laser shoot for Lu81 Side guide rail Sched Thursday night

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