QUALITY MANAGEMENT SYSTEMS

IMPORTANCE OF IDENTIFICATION & TRACEABILITY IN THE AIRCRAFT MANUFACTURING INDUSTRY

ARUNVINTHAN.S NILADRI SHEKHAR DAS VIVEK YADAV PARITOSH GUPTA

AVIONICS

JASKARANDEEP SINGH RAHUL KUMRA

IDENTIFICATION
DEFINITION : WHAT IS MEANT BY IDENTIFICATION?
The action or process of identifying someone or something or the fact of being identified: "tagged with a number for identification". The process of recognizing something or someone by remembering

IDENTIFICATION (CONTD)
WHY IDENTIFICATION USED IN AIRCRAFT MANUFACTURING INDUSTRY?
Selecting products based on functionality, verifiability, supportability, complexity, risk and management activity Determining the structure (hierarchy) of a product and the organization and relationships of its configuration documentation and other product information Documenting the performance, interface, and other attributes of a product Determining the appropriate level of identification marking of product and documentation Providing unique identity to a product or to a component part of a product

IDENTIFICATION (CONTD)
WHY IDENTIFICATION USED IN AIRCRAFT MANUFACTURING INDUSTRY? (CONTD)
Providing unique identity to the technical documents describing a product Modifying identification of product and documents to reflect incorporation of major changes Maintaining release control of documents for baseline management Enabling a user or a service person to distinguish between product versions

IDENTIFICATION (CONTD)
TYPES OF IDENTIFICATION USED IN AIRCRAFT MANUFACTURING INDUSTRY:
Product identification manufacturing order number Process order number Lot number Inspection order number Batch number Bar code Unique item number Manufacturer logo Service provided to any client Project acceptance Project scope

TRACEABILITY
DEFINITION : WHAT IS MEANT BY TRACEABILITY?
The formal definition of traceability is the ability to chronologically interrelate uniquely identifiable entities in a way that is verifiable. Traceability provides the ability to identify and track a product or a component to its point of origin. The point of origin may be a particular lot or batch, production line and time frame, field, or supplier. Product traceability is very important to reliability

Traceability is the ability to verify the history, location, or application of an item by means of documented recorded identification

TRACEABILITY (CONTD)
WHY TRACEABILITY IS USED IN AIRCRAFT MANUFACTURING INDUSTRY?
Promptly locate and remove unsafe products in case of a recall (NON CONFORMING PRODUCTS need to be traceable) Minimize the size of a recall and reduce the cost incurred in recovering or disposing of products in the marketplace Protect brand reputation and to ensure safety Correlating individual product units to warranties and service life obligations Diagnose problems in production and determine liability where relevant and Providing a reference point for defining changes and corrective actions

TRACEABILITY (CONTD)
TYPES OF TRACEABILITY SYSTEMS
Traceability systems can be manual or computer based. Small companies manufacturing limited numbers of products may find paper-based, manual systems adequate. Large companies may find computerized systems more reliable and efficient. Computerized systems can help: speed data and product handling reduce errors reduce paper waste track product movements precisely

SKYJET
(AIRCRAFT MANUFACTURING COMPANY)
OBJECTIVES:
Technical excellence Commitment to integrity Financial strength Capable and focused management Highly skilled and inspired workforce Continuous improvements in quality of products and processes. Safety of facility is paramount Eco friendly

SKYJET
(AIRCRAFT MANUFACTURING COMPANY)
POLICY :

QUALITY AND SAFETY FIRST Focus on the consumer and everything else will follow.
Skyjet Is Committed To Deliver aircraft on time, on cost and on quality getting it right first time drives Skyjets policy with safety as number one priority in the design, building and performance of its aircraft. QUALITY as measured by customer, employee and community satisfaction. PROFITABILITY and GROWTH as measured by increased shareholder value over the long term. We strive to set the standards in safe operations and luxury of aircrafts with continual improvement and achieve excellence in airline industry thereby exceeding the expectations of our passengers.

IMPLEMENTATION OF IDENTIFICATION AND TRACEABILITY

We give top most importance to planning and verification. At least 40% of project time should be spent in this stage. Our planning is based on
Fuel efficiency (SFC) MACH speed Range Endurance Comfortable Capacity Eco friendly Safety Mean life span Availability of components and spare parts All the requirements are met

IMPLEMENTATION OF IDENTIFICATION AND TRACEABILITY(Contd.)

Focus is on long lasting design Identification and traceability of tools and equipment are priority Actuating action should start after full testing and verification Top management shall ensure that the clear implementation route map is provided to each and every level Importance should be given to audit results Each and every dead line should be met

TOOL
Database management tool DATANET
Provided by ORACLE Corporation Include GUI for each kind of identification and traceability tools Dedicated evaluation team

ERP tool SAP

Provide by SAP AG Include full feature for co-ordination between top management and all dedicated workforce Dedicated evaluation team

Stages of Implementation
Identify customer requirements Identify company requirements Validation according to Government rules and regulations Design draft List the components and tools to implement the design Prepare an internal audit Practical simulations (verification and validation) Reviewed design draft Review and validate the audit results Prototype mode Final manufacturing mode Review/recall strategy

Customers requirements
Priority on understanding the customer requirement:
Aircraft range specification Aircraft operating area specification Avionics requirement Spacious and luxurious seats No. of seat and free leg room specification Mood lighting Pets area State of the art safety Customer provided ventilators, respirators and CAPP machines In flight entertainment system Stowage of mobility devices in case of emergency

Customers requirements (Cont.)

Trace the customer satisfaction record Trace customer domain Trace previous performance details of the components provided to customers Trace component availability information

Companys requirements
To make the air travel one of the safest and eco efficient means of operation Reducing a/c noise
Low noise nacelle designs Acoustic treatment Low engine noise technologies

Reducing fuel burn (SFC) Reducing CO2 emissions Cost effectiveness

Companys requirements(Contd.)
Trace the safety equipment parameters Trace the performance parameters of equipment Trace engineering consideration in installation of an equipment Trace customer loyalty details

Validation
Check the universal safety rules and regulations Check the operating country rules and regulations Profit of organization Trace reason for decommissioning of previous projects

Design Draft
Type of aircraft No. and types of engines Landing gear type Tail and wing configuration Avionics installation details Size Payload

Design Draft
Trace the problems faced on different engines and propellant used Trace advantages and disadvantages of different tail and wing configuration and also for the avionics equipment used Trace challenges faced during configuring and dismantling of different equipment

List the components and tools

Self manufactured devices and tool Purchased device and tools Special tools and instruments Information about all components and tools
Part name Part location Electronic tag code Physical id no Manufacturer Last performed test Next overhaul time Problems faced

List the components and tools(Contd.)

Information about manufacturer for purchased items
Lot no. Batch no. Transaction id Manufacturers name and address

Prepare an internal audit

Cost estimation Deadlines Workforce details

Practical simulations
Design virtual simulation: Use MATLAB, CFD,XILINX to determine stability, control, real time performance Wind tunnel test using SJ-007 in R&D Lab Metal Testing: Visual test Ultrasonic Eddy current testing Hammer test Magnetic particle inspection Fluorescent penetration technique Dye penetration testing Radiography

Practical Simulation(Contd.)
Create a proper database to maintain all data All simulations should qualify 3-level testing Any failure should be followed by thorough root cause analysis Emphasis is given on:
Accurate modeling Reliability Mean life time of components Life time of whole aircraft

Reviewed design draft

Simulation performance details Indicate the threshold values of components (Minimum and maximum limits) Any change in design Final list of components details and specification Final assembling information

Review and validate the audit results

Final cost estimation Final deadline details Workforce details Equipment details

Prototype mode
Follow the design specification thoroughly Job track card should be upgraded after each 1 hour Tracing of components should be performed in every session Before every testing stage through tracing of spare parts and all the components should be done

Final manufacturing mode

Finalize assembly Real performance testing Include safety manual Include painted instruction sign Providing customer support detail On time delivery

Review/recall strategy
Design evaluation Audit evaluation Profit evaluation Schedule checking Random checking Replacement strategy Support strategy for major failure All the documents of this stage should be maintained properly for future reference.

MAINTENANCE Of DATA
Paper based documents
Temperature Humidity Salinity Oxygen level Fire protection case Vulnerability to flooding Usage of pesticides and fertilizers Lighting Heat and air conditioning Drainage Windows Encapsulation Shelving

MAINTENANCE (contd)
Electronic documentation
System reliability maintenance Reliability of hardware and software Data backup-Routine backup Disaster recovery Physical & environmental security controls Data & password encryption with document integrity Offline medias store and maintenance Bar codes/ICR and labels are checked for reliable info Dust proof cabinets Temperature control Separated from magnetic field and equipments

CONTINUAL IMPROVEMENT PROCESS

Identify the problem Plan for the future
ACT PLAN

Analyze the process

Standardize the solution

STUDY

DO

Develop the optimal solution

Study the result

Implementation

Continual improvement
We shall ensure that we continually improve our performance based on : Audit results(both internal and external) Analysis of data Customer feedback Corrective action Correction action Preventive action

CORRECTION ACTION
(a) Customer failure returns, complaints, or disruptions, (b) Audit nonconformity findings, (c) Supplier quality issues, (d) Service or support deficiencies, (e) Internal quality problems or alerts, (f) Design deficiencies, (g) Negative trends, and (h) Safety issues.

CORRECTIVE ACTION
Product information (FAILED PRODUCT) Recalling firm Reason for the recall Volume of recalled product Recall strategy Depth of the recall Instructions to the customer Evaluation of the recall Recall status reports Root cause of the problem that resulted in the recall Corrective actions to prevent further occurrences of the problem Termination of the recall

PREVENTIVE ACTION
TO DETERMINE THE POTENTIAL NON CONFORMITIES:
HAMMER TEST VISUAL INSPECTION EDDY CURRENT TESTING RADIOGRAPHY MAGNETIC PARTICLE INSPECTION DYE PENETRANT /FLUORESCENT PENETRATION TECHNIQUE ACOUSTIC EMISSION CRASH TEST FLIGHT TEST ENGINE PRE-RUN WIND TUNNEL TEST ELECTRICAL FLIGHT TEST

PREVENTIVE ACTION
TO DETERMINE THE CAUSE OF NONCONFORMITY ANALYSIS OF DATA CAUSE AND EFFECT CHARTS FAILURE MODE EFFECT ANALYSIS ROOT CAUSE ANALYSIS

PREVENTIVE ACTION FLOW