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Drive for Zero Defects Dr Ian Riggs Quality Executive, Civil Aerospace

Drive for Zero Defects

Dr Ian Riggs

Quality Executive,

Civil Aerospace

Drive for Zero Defects Dr Ian Riggs Quality Executive, Civil Aerospace

What would your normal working day be like if there were

2

What would your normal working day be like if there were 2 Zero Defects? © Smallpeice

Zero Defects?

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What would your normal working day be like if there were 2 Zero Defects? © Smallpeice

We do amazing things…. but

We do amazing things…. but Are our Customers satisfied with our Quality & Reliability? Are we
We do amazing things…. but Are our Customers satisfied with our Quality & Reliability? Are we
We do amazing things…. but Are our Customers satisfied with our Quality & Reliability? Are we

Are our Customers satisfied with our Quality & Reliability?

Are we Efficient?

40 – 60% of people’s time spend ‘putting things right’

Rework & Remaking uses up capacity

things right’ Rework & Remaking uses up capacity What is it Costing us? Benchmarking studies estimate

What is it Costing us?

Benchmarking studies estimate true Cost of Quality at 20%25% of

sales. It is always cheaper to do it ‘right first time’

sales. It is always cheaper to do it ‘right first time’ Can we Deliver? 60% of

Can we Deliver?

60% of our delivery issues result from Quality issues somewhere in

the supply chain. Significant ramp up in volume ahead Opportunity or Risk?

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© Smallpeice Enterprises
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Zero Defects Context

Zero Defects Context Metrics continuing to improve, but… Customers’ quality expectations are increasing Customer
Zero Defects Context Metrics continuing to improve, but… Customers’ quality expectations are increasing Customer

Metrics continuing to

improve, but…

Zero Defects Context Metrics continuing to improve, but… Customers’ quality expectations are increasing Customer

Customers’ quality expectations are increasing

but… Customers’ quality expectations are increasing Customer disruption is always unacceptable What are we doing

Customer disruption is always unacceptable

What are we doing to prevent the next big Quality Disruption?

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© Smallpeice Enterprises
www.smallpeice.com

Zero Defect Principles : The Four Absolutes of Quality

Zero Defect Principles : The Four Absolutes of Quality Quality has to be defined as conformance
Zero Defect Principles : The Four Absolutes of Quality Quality has to be defined as conformance
Zero Defect Principles : The Four Absolutes of Quality Quality has to be defined as conformance
Zero Defect Principles : The Four Absolutes of Quality Quality has to be defined as conformance
Zero Defect Principles : The Four Absolutes of Quality Quality has to be defined as conformance

Quality has to be defined as conformance to requirements, not as goodness or elegance.

The System for assuring quality is Prevention, not Appraisal.

The performance standard must be Zero Defects, not ‘that’s good enough’.

The measurement of quality is the price of non- conformance, not indices.

Philip B. Crosby

Quality is Free

1979

Defect Prevention Approach
Defect Prevention Approach
Leadership & Culture ZD Technical Organisational Capability Capability
Leadership &
Culture
ZD
Technical
Organisational
Capability
Capability

Do we create the right environment to support our Zero Defect Goal and engage everyone?

MINDSET

Do we have

the right tools to prevent the creation of

defects?

Do we know

how to use these tools effectively?

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© Smallpeice Enterprises
www.smallpeice.com

Core Product Defect Prevention Tools

Core Product Defect Prevention Tools Product Life Cycle Product Design Process Design Production & Service Advanced

Product Life Cycle

Product Design

Process Design Production & Service
Process Design
Production & Service

Advanced Product Quality Planning (APQP) &

Production Part Approval Process (PPAP)

Process Control Error Process Control MSA Capability FMEA Plan Proofing (SPC)
Process
Control
Error
Process Control
MSA
Capability
FMEA
Plan
Proofing
(SPC)
8D Problem Solving
8D Problem Solving

Design FMEA

FMEA Plan Proofing (SPC) 8D Problem Solving Design FMEA Must be applied as a ‘system’ of

Must be applied as a ‘system’ of tools Must be applied at part number level Effectiveness relies on Cross Functional working

© Smallpeice Enterprises www.smallpeice.com
© Smallpeice Enterprises
www.smallpeice.com
© Smallpeice Enterprises www.smallpeice.com
© Smallpeice Enterprises www.smallpeice.com
© Smallpeice Enterprises www.smallpeice.com
© Smallpeice Enterprises
www.smallpeice.com

Aerospace Defect Prevention Maturity Baseline

Aerospace Defect Prevention Maturity Baseline 100% 75% 50% 25% 10% DFMEA PFMEA Control Plan Gauge R&R

100%

75%

50%

25%

10%

Defect Prevention Maturity Baseline 100% 75% 50% 25% 10% DFMEA PFMEA Control Plan Gauge R&R Attribute

DFMEA

PFMEA

Control

Plan

Gauge

R&R

Attribute

Agreement

Analysis

Capability

SPC

Variables

Attribute

SPC

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© Smallpeice Enterprises
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Zero Defects Leadership Program in Rolls-Royce

10

Zero Defects Leadership Program in Rolls-Royce 1 0 Overview: • Aimed at the top 1000 leaders
Zero Defects Leadership Program in Rolls-Royce 1 0 Overview: • Aimed at the top 1000 leaders

Overview:

Aimed at the top 1000 leaders in Civil Aerospace Operations

3-Day Program covers;

Training in the Defect Prevention Tools

Review of real examples of current practice

Reflections on how we can improve the current situation

Creation of prioritised action plans

Leaders capable of having coaching conversations with their teams and suppliers

Success factors :

Teams from same business

Cross functional

Focus on ‘what we can do’ not on ‘what

others need to do’

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© Smallpeice Enterprises
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Leadership Program Supplier Forum

Leadership Program – Supplier Forum Indianapolis Derby Shanghai © Smallpeice Enterprises www.smallpeice.com

Indianapolis

Derby
Derby
Shanghai
Shanghai
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© Smallpeice Enterprises
www.smallpeice.com

LEAN Leadership Behaviours for ZD Maturity

LEAN Leadership Behaviours for ZD Maturity 5. Business Improvement Plan created / updated 4. Assess Defect
LEAN Leadership Behaviours for ZD Maturity 5. Business Improvement Plan created / updated 4. Assess Defect

5. Business Improvement

Plan created / updated

ZD Maturity 5. Business Improvement Plan created / updated 4. Assess Defect Prevention Maturity Baseline /

4. Assess Defect Prevention Maturity Baseline / Status

1.

4. Assess Defect Prevention Maturity Baseline / Status 1. C ross- f unc ti ona l

Cross-functional leadership Team

REPEAT
REPEAT
Status 1. C ross- f unc ti ona l leadership Team REPEAT 3. Agree Go-Look-See Schedule

3. Agree Go-Look-See Schedule

ona l leadership Team REPEAT 3. Agree Go-Look-See Schedule 2. Focus on Key Part Numbers ©

2. Focus on Key

Part Numbers

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© Smallpeice Enterprises
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Success Stories

Success Stories 16 Part Specific FMEAs in 3 months Introduction of error proofing and prevention controls.
Success Stories 16 Part Specific FMEAs in 3 months Introduction of error proofing and prevention controls.

16 Part Specific FMEAs in 3 months

Introduction of error proofing and prevention controls.

Defect Free since

September 2017

and prevention controls. Defect Free since September 2017 30 of 35 DARs requests cancelled after process

30 of 35 DARs requests cancelled after process centering was introduced

Also improvement in

RFT seen as a result of

removing concession

process. (Operators took more time to set up process to avoid scrap). Zero Defects

Mindset.

to set up process to avoid scrap). Zero Defects Mindset. Trent 700 in-load to Indianapolis using

Trent 700 in-load to Indianapolis using Real Time SPC.

98% of features Cpk >2, the other 2% Cpk

>1.67

© Smallpeice Enterprises www.smallpeice.com
© Smallpeice Enterprises
www.smallpeice.com

AESQ Objectives

AESQ Objectives http://aesq.saeitc.org/ • Simplify & Standardize supplier requirements • Build on existing
AESQ Objectives http://aesq.saeitc.org/ • Simplify & Standardize supplier requirements • Build on existing

http://aesq.saeitc.org/

Simplify & Standardize supplier

requirements

Build on existing industry standards

Common language for Quality

Standards are simple, prescriptive & auditable

Promote standardized 3rd party training

Easy to adopt within existing process/systems

Deliver results rapidly, through focused activities

© Smallpeice Enterprises

www.smallpeice.com

process/systems • Deliver results rapidly, through focused activities © Smallpeice Enterprises www.smallpeice.com

AS9145 (APQP/PPAP) & AESQ Standards

AS9145 (APQP/PPAP) & AESQ Standards 5. Ongoing Production, use and Post Delivery Service AS9145 (PDP) Kick
AS9145 (APQP/PPAP) & AESQ Standards 5. Ongoing Production, use and Post Delivery Service AS9145 (PDP) Kick
AS9145 (APQP/PPAP) & AESQ Standards 5. Ongoing Production, use and Post Delivery Service AS9145 (PDP) Kick

5. Ongoing Production, use and Post Delivery Service

AS9145

(PDP)

Kick Off

AS9145

APQP Phases

AS9145 Key

PPAP Events

AS9145 PPAP

Element Timing

AESQ

Process

Documents

AESQ

Systems

Documents

Design Release

Initial Prod.

(CDR)

Approval

End of Concept

Production

(PDR)

Launch

4. Product & Process Validation AS9102 FAIR Production Process Run
4. Product & Process
Validation
AS9102
FAIR
Production Process Run

2. Product Design & Development

Production Process Run 2. Product Design & Development 3. Process Design & Development Production Readiness
Production Process Run 2. Product Design & Development 3. Process Design & Development Production Readiness

3. Process Design & Development

Design & Development 3. Process Design & Development Production Readiness Review Design Process Flow Diagram

Production

Readiness

Review

Design

Process Flow Diagram

Packaging,

MSA

Records

PFMEA Control Plan

Preservation &

ICS

& DRA

   

Labelling

FAI

AS13004 Process FMEA & Control Plan

AS13003 Measurement Systems Analysis

- Problem Solving Requirements for Suppliers - 8D

Supplier Management

PPAP

1. Planning

AS13000

AS13007

Approval

1. Planning AS13000 A S 1 3 0 0 7 Approval AS13006 – Process Control Methods
AS13006 – Process Control Methods AS13002 – Qualifying Alternate Inspection Plans
AS13006 – Process Control Methods AS13002 – Qualifying Alternate Inspection Plans

AS13006 Process Control Methods

AS13002 Qualifying Alternate Inspection Plans

Control Methods AS13002 – Qualifying Alternate Inspection Plans © Smallpeice Enterprises www.smallpeice.com
Control Methods AS13002 – Qualifying Alternate Inspection Plans © Smallpeice Enterprises www.smallpeice.com

© Smallpeice Enterprises

Control Methods AS13002 – Qualifying Alternate Inspection Plans © Smallpeice Enterprises www.smallpeice.com

www.smallpeice.com

In Summary

In Summary • Our customers are demanding Zero Defects. • Zero Defects is needed to meet

Our customers are demanding Zero Defects.

Zero Defects is needed to meet our Quality, Cost and Delivery targets

Zero Defects can only be achieved through Defect Prevention not Defect Detection

The Aerospace Industry currently has low maturity in the effective application of these Defect Prevention tools

Will only improve if Senior Leadership understand what is

required and drive it as a priority

We must raise the skill level of our people

© Smallpeice Enterprises www.smallpeice.com
© Smallpeice Enterprises
www.smallpeice.com

Strive for perfection in

everything.

Accept nothing nearly

right or good enough.

Sir Henry Royce

in everything. Accept nothing nearly right or good enough. ” Sir Henry Royce Part of our

Part of our heritage.

Part of our future.

in everything. Accept nothing nearly right or good enough. ” Sir Henry Royce Part of our