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T7 to T9 by Mind Map: T7 to T9

1. Main goals

1.1. On time delivery

1.1.1. check the rate of parts delivered

1.1.2. Supply chain management

1.2. Recurrent costs

1.2.1. Check production costs

1.3. First time yield

1.3.1. No discrepancies on delivered parts (no concession, no scrapping parts..)

1.4. Function control

1.4.1. Check that the process is capable and robust on characteristics

2. Milestones

2.1. T7-1

2.1.1. deliverable of current state

2.1.2. T9 target definition

2.1.3. Milestone planning

2.2. T7-3

2.2.1. Capability of target measurement

2.2.2. Detailed objectives and road map definition

2.2.3. Compliance with road map

2.3. T7-5 and T7-8

2.3.1. Objectives under control

2.4. T9

2.4.1. Objectives achieved

2.4.2. Long term objectives durability

2.5. validated/milestone review

3. KC at the centre of industrialization

3.1. Measurable KC

3.1.1. Dimensional

3.1.2. Inspectable

3.2. KC by NDT

3.3. KC in DMF

3.4. KC process parameter

3.4.1. For control of special process

4. Standards and codes

4.1. EN9102 FAI

4.2. EN9103 KC

4.3. AS 13002

4.3.1. Sampling and reducing inspection/inspectable items

4.4. AS 13003/Safran INS

4.4.1. Measurement system analysis

4.5. AS 13004

4.5.1. FMEA process

4.5.2. Process flow diagram

4.6. INS-1239

4.6.1. implementing inspection optimisation/reduction

4.7. INS-0707/Appendix 2

4.7.1. Measurement system analysis for classified characterristics

5. Requirements (industrialisation risks)

5.1. comply with GRP-0087/PPAP

5.1.1. Standard de pilotage des industrialisations

5.1.2. Risk analysis

5.1.2.1. SAFARI

5.1.2.2. New GRF-0160

6. Forms

6.1. FAI form

6.1.1. Standard EN9102

6.2. MSA form

6.2.1. Standard AS13003

6.3. Control plan

6.3.1. Standard AS13004

6.4. Key process characteristics

6.5. PPAP approval form

6.5.1. Standard EN9145

6.6. Process capability study

6.6.1. Standard EN9103

7. SPOC Methodology

7.1. Includes

7.1.1. Standard process with specific deliverables at each milestone

7.1.2. Set of rules and tools to optimize inspections in a structured and controlled way

7.2. SPOC objectives

7.2.1. Cost reduction

7.2.2. Lower leap production costs

7.2.3. Reduction of cycles and inspection times

7.3. Controls and inspections

7.3.1. Dimensional

7.3.1.1. CMM, Standard tools, Multi-gauges

7.3.2. NDT

7.3.2.1. FPI, US, X-RAY, Tomographic, Macroprahic

7.3.3. control and inspection optimization need to be

7.3.3.1. Validated

7.3.3.1.1. ensure that required conditions are in place

7.3.3.1.2. No optimzations without traceability file

7.3.3.2. Monitored

7.3.3.2.1. ensure that correct conditions are in place

7.3.3.3. Audited

7.3.3.3.1. Guarantee quality

8. DVI Industrial substantiation form

8.1. goals

8.1.1. demonstration of manufacturing process for a part produced in compliance with certified model

8.1.2. Demonstration of key characteristics that comply with the air safety regulations

8.1.3. control any changes in the manufacturing process and their impact on the quality of the parts

8.1.3.1. perform also risk analysis

8.1.4. keep it as a proof in case of investigations or projects that involve improvement of manufacturing processes

8.2. DVI PPAP (production part approval process) deployment

8.2.1. GRF-0041 and GRF-0160: operational tools

8.2.2. E-learning "industrialise process"

8.2.3. Other tools (check presentation slides 215-216)

9. Special processes

9.1. SAFRAN requirements

9.1.1. FRP-0087

9.1.1.1. Qualification of special processes is mandatory before implementing on SAFRAN products or parts

9.1.2. GRM-0123

9.1.2.1. Supplier guide for monitoring and qualification of special processes

9.1.3. PRO-0822

9.1.3.1. Procedures for SAE requirements applicable to suppliers

9.2. SP qualification process

9.2.1. Identified qualification needs

9.2.1.1. Reception and analysis of DQ (qualification file)

9.2.1.1.1. discrepancies are highlighted in DQ

9.2.1.2. Processing of discrepancies

9.2.1.2.1. Discrepancies should be corrected/or accepted by SAFRAN

9.2.2. Provisional qualification

9.2.2.1. on-site audit

9.2.2.2. open discrepancies corrected

9.2.3. Final qualification

9.3. SP qualification process update

9.3.1. review of DQ

9.3.2. Traceability of revisons

9.4. SP qualification renewal

9.4.1. Supplier's evaluation of special processes

9.4.2. Qualification with no time limit (updated on a monthly basis)

9.5. Special process qualification certificate

9.5.1. contents

9.5.1.1. supplier's name

9.5.1.2. Address

9.5.1.3. Special process covered with references to SAFRAN specifications

9.5.1.4. Qualified facilities and scope approved by SAFRAN

9.5.1.5. any change/addition to the facility

9.5.1.5.1. submit to SAFRAN for approval

9.5.1.5.2. update of DQ and DVI

10. Logistic performance and supplier quality (2018)

10.1. Objectives

10.1.1. Excellent operational performance level

10.1.2. Concession eradication plan (with respect to LEAP)

10.1.3. Industrialisation

10.1.3.1. controlled under SPI

10.1.3.1.1. T9 achievement plan

10.1.3.2. not controlled under SPI

10.1.3.2.1. Control plan for key characteristics

10.1.4. monitoring

10.1.4.1. Baseline

10.1.4.1.1. risk analysis

10.1.4.1.2. Workload/capacity analysis

10.1.4.1.3. Action plan

10.1.4.1.4. Additional analysis

11. Non-conformity and markings

11.1. concession

11.1.1. concession request through e-quality portal

11.1.2. Quality concession tab to determine state of each part

11.1.2.1. parts that can be used without any change

11.1.2.2. parts with restriction (specific marking)

11.1.2.3. Parts to be scrapped

11.2. Production permit

11.2.1. Request is sent to SAFRAN through e-quality portal/ or through FOR-0184 form)

11.2.2. Validity period is determined by SAFRAN

11.3. Quality escape

11.3.1. requirements

11.3.1.1. inform SAFRAN within 48 hours

11.3.1.2. request a concession for the parts that are not yet delivered

11.3.1.3. Implementing the 8D problem solving (root causes analysis, corrective actions)

11.4. Pre-release (INS-1157)

11.4.1. requirements

11.4.1.1. pre-release is issued by SAE

11.4.1.2. pre-release reference should be mentioned by the supplier on "nonconformity certificate'

11.4.1.3. Label should be added on the shipping documents

11.4.1.4. separate items delivered under pre-release from the items that are not subject to a non-quality event

11.5. Process pending validation (Form 5 of DVI)

11.5.1. DVI file is pending approval

11.5.1.1. parts cannot be delivered to SAE

11.5.2. submit PECV

11.5.2.1. At request of SAE

11.5.2.2. supplier specify missing items

11.5.2.3. SAE approve the PECV

11.6. Procurement non-quality event (ENQA)

11.6.1. requirements

11.6.1.1. implement 8D methodology (according to AS13000)

11.6.1.2. protect customer

11.6.1.3. Respond within allotted time

11.6.1.4. Guarantee conformance of other parts

11.6.1.5. Instruction INS-1166 for SAE

11.7. Deviation of process or system

11.7.1. SAE issues corrective actions requests

11.7.2. 8D methodology (according to AS13000)

11.8. Nonconformance on a product before delivery

11.8.1. submit to SAE through a concession request

11.8.2. Identify root causes and corrective actions

11.8.3. SAE decision is mandatory before shiping

11.8.4. quality escape have to be declared within 24 hours

11.9. non quality events

11.9.1. main root causes of quality escape

11.9.1.1. DVI

11.9.1.1.1. insufficient capability/ variability of means

11.9.1.1.2. Test plans/ insufficient controls

11.9.1.1.3. incomplete/ inappropriate job instruction sheets

11.9.1.1.4. Change of mean/ process specifications are not respected

11.9.1.1.5. incomplete/ inappropriate job instruction sheets

11.9.1.1.6. incomplete/ inappropriate job instruction sheets

11.9.1.2. Human factor HF

11.9.1.2.1. Instructions not respected

11.9.1.2.2. Documentation not respected

11.9.1.3. Monitoring

11.9.1.3.1. Insufficient sampling rate

11.9.1.3.2. Insufficient monitoring of mean or process

11.9.1.4. Lessons learned

11.9.1.4.1. No lessons learned made with similar products

11.9.2. Recurring non quality events: marking

11.9.2.1. issues with traceability or packaging

11.10. concessions reduction SPRED (standard process for reducing concessions)

11.10.1. Objectives

11.10.1.1. reduction in number of concession lines on development program parts (LEAP 1A- 1B)

11.10.1.2. Reduce concession processing time ( automation of concession processing-TAC tool)

11.10.2. SPRED milestones (for the supplier)

11.10.2.1. D4

11.10.2.1.1. Definition changes effective at manufacture's

11.10.2.2. D4-D5

11.10.2.2.1. nonconformity analysis (Pareto charts)

11.10.2.3. D5-D6

11.10.2.3.1. Sheet action approved, identified and substantiated

11.10.2.4. D6

11.10.2.4.1. Approved sheets implemented

12. Pre-shipment product inspection (DPRV)

12.1. intercept all anomalies

12.1.1. Production documentation

12.1.2. Marking

12.1.3. Visual appearance

12.1.4. Packaging, labeling, packing

12.2. in process inspection

12.2.1. manufacturing processes should be checked

12.2.2. Final inspection

12.2.2.1. inspection of the final product

12.2.3. Pre-shipment product inspection