1. KC at the centre of industrialization
1.1. Measurable KC
1.1.1. Dimensional
1.1.2. Inspectable
1.2. KC by NDT
1.3. KC in DMF
1.4. KC process parameter
1.4.1. For control of special process
2. Standards and codes
2.1. EN9102 FAI
2.2. EN9103 KC
2.3. AS 13002
2.3.1. Sampling and reducing inspection/inspectable items
2.4. AS 13003/Safran INS
2.4.1. Measurement system analysis
2.5. AS 13004
2.5.1. FMEA process
2.5.2. Process flow diagram
2.6. INS-1239
2.6.1. implementing inspection optimisation/reduction
2.7. INS-0707/Appendix 2
2.7.1. Measurement system analysis for classified characterristics
3. Requirements (industrialisation risks)
3.1. comply with GRP-0087/PPAP
3.1.1. Standard de pilotage des industrialisations
3.1.2. Risk analysis
3.1.2.1. SAFARI
3.1.2.2. New GRF-0160
4. DVI Industrial substantiation form
4.1. goals
4.1.1. demonstration of manufacturing process for a part produced in compliance with certified model
4.1.2. Demonstration of key characteristics that comply with the air safety regulations
4.1.3. control any changes in the manufacturing process and their impact on the quality of the parts
4.1.3.1. perform also risk analysis
4.1.4. keep it as a proof in case of investigations or projects that involve improvement of manufacturing processes
4.2. DVI PPAP (production part approval process) deployment
4.2.1. GRF-0041 and GRF-0160: operational tools
4.2.2. E-learning "industrialise process"
4.2.3. Other tools (check presentation slides 215-216)
5. Special processes
5.1. SAFRAN requirements
5.1.1. FRP-0087
5.1.1.1. Qualification of special processes is mandatory before implementing on SAFRAN products or parts
5.1.2. GRM-0123
5.1.2.1. Supplier guide for monitoring and qualification of special processes
5.1.3. PRO-0822
5.1.3.1. Procedures for SAE requirements applicable to suppliers
5.2. SP qualification process
5.2.1. Identified qualification needs
5.2.1.1. Reception and analysis of DQ (qualification file)
5.2.1.1.1. discrepancies are highlighted in DQ
5.2.1.2. Processing of discrepancies
5.2.1.2.1. Discrepancies should be corrected/or accepted by SAFRAN
5.2.2. Provisional qualification
5.2.2.1. on-site audit
5.2.2.2. open discrepancies corrected
5.2.3. Final qualification
5.3. SP qualification process update
5.3.1. review of DQ
5.3.2. Traceability of revisons
5.4. SP qualification renewal
5.4.1. Supplier's evaluation of special processes
5.4.2. Qualification with no time limit (updated on a monthly basis)
5.5. Special process qualification certificate
5.5.1. contents
5.5.1.1. supplier's name
5.5.1.2. Address
5.5.1.3. Special process covered with references to SAFRAN specifications
5.5.1.4. Qualified facilities and scope approved by SAFRAN
5.5.1.5. any change/addition to the facility
5.5.1.5.1. submit to SAFRAN for approval
5.5.1.5.2. update of DQ and DVI
6. Non-conformity and markings
6.1. concession
6.1.1. concession request through e-quality portal
6.1.2. Quality concession tab to determine state of each part
6.1.2.1. parts that can be used without any change
6.1.2.2. parts with restriction (specific marking)
6.1.2.3. Parts to be scrapped
6.2. Production permit
6.2.1. Request is sent to SAFRAN through e-quality portal/ or through FOR-0184 form)
6.2.2. Validity period is determined by SAFRAN
6.3. Quality escape
6.3.1. requirements
6.3.1.1. inform SAFRAN within 48 hours
6.3.1.2. request a concession for the parts that are not yet delivered
6.3.1.3. Implementing the 8D problem solving (root causes analysis, corrective actions)
6.4. Pre-release (INS-1157)
6.4.1. requirements
6.4.1.1. pre-release is issued by SAE
6.4.1.2. pre-release reference should be mentioned by the supplier on "nonconformity certificate'
6.4.1.3. Label should be added on the shipping documents
6.4.1.4. separate items delivered under pre-release from the items that are not subject to a non-quality event
6.5. Process pending validation (Form 5 of DVI)
6.5.1. DVI file is pending approval
6.5.1.1. parts cannot be delivered to SAE
6.5.2. submit PECV
6.5.2.1. At request of SAE
6.5.2.2. supplier specify missing items
6.5.2.3. SAE approve the PECV
6.6. Procurement non-quality event (ENQA)
6.6.1. requirements
6.6.1.1. implement 8D methodology (according to AS13000)
6.6.1.2. protect customer
6.6.1.3. Respond within allotted time
6.6.1.4. Guarantee conformance of other parts
6.6.1.5. Instruction INS-1166 for SAE
6.7. Deviation of process or system
6.7.1. SAE issues corrective actions requests
6.7.2. 8D methodology (according to AS13000)
6.8. Nonconformance on a product before delivery
6.8.1. submit to SAE through a concession request
6.8.2. Identify root causes and corrective actions
6.8.3. SAE decision is mandatory before shiping
6.8.4. quality escape have to be declared within 24 hours
6.9. non quality events
6.9.1. main root causes of quality escape
6.9.1.1. DVI
6.9.1.1.1. insufficient capability/ variability of means
6.9.1.1.2. Test plans/ insufficient controls
6.9.1.1.3. incomplete/ inappropriate job instruction sheets
6.9.1.1.4. Change of mean/ process specifications are not respected
6.9.1.1.5. incomplete/ inappropriate job instruction sheets
6.9.1.1.6. incomplete/ inappropriate job instruction sheets
6.9.1.2. Human factor HF
6.9.1.2.1. Instructions not respected
6.9.1.2.2. Documentation not respected
6.9.1.3. Monitoring
6.9.1.3.1. Insufficient sampling rate
6.9.1.3.2. Insufficient monitoring of mean or process
6.9.1.4. Lessons learned
6.9.1.4.1. No lessons learned made with similar products
6.9.2. Recurring non quality events: marking
6.9.2.1. issues with traceability or packaging
6.10. concessions reduction SPRED (standard process for reducing concessions)
6.10.1. Objectives
6.10.1.1. reduction in number of concession lines on development program parts (LEAP 1A- 1B)
6.10.1.2. Reduce concession processing time ( automation of concession processing-TAC tool)
6.10.2. SPRED milestones (for the supplier)
6.10.2.1. D4
6.10.2.1.1. Definition changes effective at manufacture's
6.10.2.2. D4-D5
6.10.2.2.1. nonconformity analysis (Pareto charts)
6.10.2.3. D5-D6
6.10.2.3.1. Sheet action approved, identified and substantiated
6.10.2.4. D6
6.10.2.4.1. Approved sheets implemented
7. Main goals
7.1. On time delivery
7.1.1. check the rate of parts delivered
7.1.2. Supply chain management
7.2. Recurrent costs
7.2.1. Check production costs
7.3. First time yield
7.3.1. No discrepancies on delivered parts (no concession, no scrapping parts..)
7.4. Function control
7.4.1. Check that the process is capable and robust on characteristics
8. Milestones
8.1. T7-1
8.1.1. deliverable of current state
8.1.2. T9 target definition
8.1.3. Milestone planning
8.2. T7-3
8.2.1. Capability of target measurement
8.2.2. Detailed objectives and road map definition
8.2.3. Compliance with road map
8.3. T7-5 and T7-8
8.3.1. Objectives under control
8.4. T9
8.4.1. Objectives achieved
8.4.2. Long term objectives durability
8.5. validated/milestone review
9. Forms
9.1. FAI form
9.1.1. Standard EN9102
9.2. MSA form
9.2.1. Standard AS13003
9.3. Control plan
9.3.1. Standard AS13004
9.4. Key process characteristics
9.5. PPAP approval form
9.5.1. Standard EN9145
9.6. Process capability study
9.6.1. Standard EN9103
10. SPOC Methodology
10.1. Includes
10.1.1. Standard process with specific deliverables at each milestone
10.1.2. Set of rules and tools to optimize inspections in a structured and controlled way
10.2. SPOC objectives
10.2.1. Cost reduction
10.2.2. Lower leap production costs
10.2.3. Reduction of cycles and inspection times
10.3. Controls and inspections
10.3.1. Dimensional
10.3.1.1. CMM, Standard tools, Multi-gauges
10.3.2. NDT
10.3.2.1. FPI, US, X-RAY, Tomographic, Macroprahic
10.3.3. control and inspection optimization need to be
10.3.3.1. Validated
10.3.3.1.1. ensure that required conditions are in place
10.3.3.1.2. No optimzations without traceability file
10.3.3.2. Monitored
10.3.3.2.1. ensure that correct conditions are in place
10.3.3.3. Audited
10.3.3.3.1. Guarantee quality
11. Logistic performance and supplier quality (2018)
11.1. Objectives
11.1.1. Excellent operational performance level
11.1.2. Concession eradication plan (with respect to LEAP)
11.1.3. Industrialisation
11.1.3.1. controlled under SPI
11.1.3.1.1. T9 achievement plan
11.1.3.2. not controlled under SPI
11.1.3.2.1. Control plan for key characteristics
11.1.4. monitoring
11.1.4.1. Baseline
11.1.4.1.1. risk analysis
11.1.4.1.2. Workload/capacity analysis
11.1.4.1.3. Action plan
11.1.4.1.4. Additional analysis
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