WELCOME

AESQ SUPPLIER FORUM

10 Oct 2018
Tokyo, Japan

AESQ – Aerospace Engine Supplier Quality Strategy Group

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Ä
Ä

LOGISTICS
TETSUYA MIZUTANI
IHI CORPORATION - HOST

AESQ – Aerospace Engine Supplier Quality Strategy Group 2

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WELCOME FROM IHI
HIDEO MORITA
VICE PRESIDENT OF AERO ENGINE,
SPACE ＆ DEFENSE
BUSINESS, IHI

AESQ – Aerospace Engine Supplier Quality Strategy Group 3

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INTRODUCTION TO THE
SUPPLIER FORUM
MARTIN SCHAEFFNER
MTU AERO ENGINES AG

AESQ – Aerospace Engine Supplier Quality Strategy Group 4

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Agenda
8:15 Welcome to IHI and AESQ – Tetsuya Mizutani, IHI & Hideo Morito, IHI
8:30 Introduction to the Supplier Forum – Martin Schaeffner, MTU
8:45 Introduction to AESQ - Martin Schaeffner, MTU
9:05 Voice of the Customer – Toshihiko Noguchi, ANA
9:45 Supplier Survey Results - Olivier Castets, Safran
10:00 Break
10:30 Published Standards (facilitated session)- Barrie Hicklin, Honeywell
10:35 Overview of AESQ Standards - Olivier Castets, Safran, Helen Djäknegren, GKN
10:45 AS13000 Problem solving – Olivier Castets, Safran
10:50 AS13000 Feedback – Barrie Hicklin, Honeywell
11:05 AS13001 Delegated product release verification training – Earl Capozzi, P&W
11:10 AS13001 Feedback – Barrie Hicklin, Honeywell
11:25 AS13002 Inspection frequency – Erika Grimm, GE
11:30 AS13002 Feedback – Barrie Hicklin, Honeywell
11:45 AS13003 Measurement System Analysis – Ian Riggs, Rolls-Royce
11:50 AS13003 Feedback – Barrie Hicklin, Honeywell
12:00 Lunch
AESQ – Aerospace Engine Supplier Quality Strategy Group 6
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Agenda
1:00 AS13004 PFMEA & Control Plans – Ian Riggs, Rolls-Royce
1:05 AS13004 Feedback– Barrie Hicklin, Honeywell
1:20 AS13006 Process Control methods – Peter Amsden
1:25 AS13006 Feedback – Barrie Hicklin, Honeywell
1:45 Benefits of AS13001 DPRV Training Requirements - Catherine Catarina-Graça,
Safran
2:05 Benefits of AS13004 PFMEA & Control Plans incl. Voice of Supplier
- Ian Riggs, Rolls-Royce and Zhu Hong Lei, SAM Suzhou
2:55 Break
3:10 Benefits of AS13003 MSA - Martin Schaeffner, MTU
3:30 Future Initiatives – Dan Eigenbrode, Pratt & Whitney
3:40 AS13005 Quality Audit Requirements – Helen Djäknegren, GKN
3:50 AS13007 Supplier Management – Barbara Negroe, GE
3:55 AS13005 & AS13007 feedback - Barrie Hicklin, Honeywell
4:10 Closing remarks – Tetsuya Mizutani, IHI and Martin Schaeffner, MTU

AESQ – Aerospace Engine Supplier Quality Strategy Group 7

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Introduce Yourself

1. Take the Attendee Name Sheet from your table

2. Introduce yourself to as many people as possible in 5 minutes
3. Share your name, position, company and how far you have
travelled to be here today
4. By the time you go home today we hope you can complete the
whole sheet.
AESQ – Aerospace Engine Supplier Quality Strategy Group 7
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Code of Conduct

• No Commercialism
• No discussion of cost, pricing plans, pricing policies,
product usage surveys, marketing plans or any related
topics
• Presentations must focus on technical issues (not on
marketing aspects of products) and relate to or support
the development or maintenance of G-22 Committee work
• Be aware of and follow ITAR & EAR rules and regulations
governing export control
• Discussions should be open and follow the agenda or
other legitimate direction agreed upon by consensus of
the committee - avoid unauthorized or ‘private’ meetings

AESQ – Aerospace Engine Supplier Quality Strategy Group 8

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Code of Conduct

• Respect basic meeting etiquette:

–Only one person speaking at any given time
–Attack the issue, not the person
–Be on time…returning from breaks/lunch
–Respect all ideas & comments
–No silent skepticism, be candid
–Do not dominate discussions
–Stay focused on the meeting & agenda
• Strive for high-quality standards to benefit all stakeholders
– users, customers, suppliers and the industry as a whole
• Strive for an open atmosphere that promotes a free-
flowing interchange of standards technical information

AESQ – Aerospace Engine Supplier Quality Strategy Group 9

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INTRODUCTION TO THE
AESQ
MARTIN SCHAEFFNER
MTU AERO ENGINES AG

AESQ – Aerospace Engine Supplier Quality Strategy Group 10

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Commercial Aviation – A Growth Market

In 2036
4.5%/yr Increase in
Passenger Traffic

2 X active aircraft
=
worldwide

7,100 billion passenger km in 2016 23,000 active aircraft in 2016

17,000 billion passenger km in 2036 45,000 active aircraft in 2036
Quelle: Ascend, IATA, MTU

AESQ – Aerospace Engine Supplier Quality Strategy Group 11

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Aviation Safety
The Quality of our products and services are extremely important
Quality and continuous improvement are an absolute must!

AESQ – Aerospace Engine Supplier Quality Strategy Group 12

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Chain of Events
In many cases, it is not a single malfunction, error
or failure that leads to a crash.
It is a sequence of events involving
• hidden (latent) failures
• errors of judgment/action
• a failure of the failure prevention systems

AESQ – Aerospace Engine Supplier Quality Strategy Group 13

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Manufacturing Quality Escapes in Turbine
Engines
-->An FAA proposal for further investigation and action – January 2018

• The trend of manufacturing quality escape safety board issues that resulted
in at least one operational event has been increasing.
• The percentage of total turbofan ADs associated with manufacturing quality
escapes has been cyclic since 2004, but 2016 (37%) was the highest
percentage in the prior four years, and second only to 2011 (44%).
• The top drivers in turbofan manufacturing quality escape ADs were related to
issues with surface finish, incorrect dimensions, and forging (all with 8),
followed by incorrect assembly (7). Manufacturing Quality Escapes

• Life limited parts (32) made ECO Safety Board Issues That Included at Least One Operational Event
7

up the vast majority of the turbofan 6

6

manufacturing quality escape ADs, 5

more than three times the next

5

closest part type.

4

3
3

2 2 2
2

1
1

0
2009 2010 2011 2012 2013 2014 2015 2016

AESQ – Aerospace Engine Supplier Quality Strategy Group 14

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AESQ Vision

To establish and maintain a common set of

Quality Requirements that enable the Global Aero Engine
Supply Chain to be truly competitive through lean, capable
processes and a culture of Continuous Improvement

AESQ – Aerospace Engine Supplier Quality Strategy Group 15

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AESQ Vision
In detail
• Create common standards within the engine manufacturers (OEM’s)
in regard to quality
• Deploy together the written standards throughout our supply chain
• Establish capable quality processes and a culture of continuous
improvement

Main targets
• To improve quality within the supply chain
• Improve on time delivery and minimize costs through a reliable
quality performance
• Gain efficiency by standardized processes

AESQ – Aerospace Engine Supplier Quality Strategy Group 16

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AESQ Key Quality Elements
 also aligned to AS9145 APQP & PPAP
Design Risk
Assessment

Product KCs

Risk analysis and Capable Process Control

control required measurement required
Product and systems required
Production risks identified Measurement systems Manufacturing processes
Process KCs
& mitigated ensuring are capable & repeatable under variation control
capable & stable ensuring effectiveness of produce consistent
manufacturing processes inspection processes product at rate

AS13004 - PFMEA AS13003 Measurement AS13006 Process

and Control Plans System Analysis (MSA) Control Methods

Supporting Standards: AS13000 Problem Solving; AS13001 DPRV Training; AS13002 Inspection Frequency;17
In process  AS13005 Audit; AS13007 Supplier Management

AESQ – Aerospace Engine Supplier Quality Strategy Group 25

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AESQ Will Drive Progress
• AS13000, AS13001, AS13002, AS13003, AS13004 have all been flowed
down by all AESQ members and are part of your Purchase Order.
AS13006 is accepted by all members and will be flowed down shortly.
AS13005 and AS13007 will follow soon.

AESQ – Aerospace Engine Supplier Quality Strategy Group 26

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VOICE OF THE CUSTOMER
TOSHIHIKO NOGUCHI, ANA

AESQ – Aerospace Engine Supplier Quality Strategy Group

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SUPPLIER SURVEY
RESULTS
OLIVIER CASTETS, SAFRAN

AESQ – Aerospace Engine Supplier Quality Strategy Group

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Supplier Survey Overview

Collaboration
• Working together to drive quality
performance

Feedback
• Provide input on developing standards

Integrated Supply Chain

• Drive efficiency, maximize resources,
create synergies

Training
• Coordinated training efforts

AESQ – Aerospace Engine Supplier Quality Strategy Group 21

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Are you Aware of the Published Standards?

We still have some work to do

AESQ – Aerospace Engine Supplier Quality Strategy Group 22

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 Which Standards Have You Heard Of?
AS13000 Problem Solving (8D)

AS13001 DPRV Training

AS13002 Inspection Frequency

AS13003 Measurement Systems Analysis

AS13004 PFMEA & Control Plans

AS13005 Quality Audit Requirements

AS13006 Process Control Methods

AS13007 Supplier Management

AS9145 APQP & PPAP

AS9146 FOD prevention

AS9117 Delegated product release

verification

AESQ – Aerospace Engine Supplier Quality Strategy Group 23

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 Which Standards are in YOUR Contracts?

AS13000 Problem Solving (8D)

AS13001 DPRV Training

AS13002 Inspection Frequency

AS13003 Measurement Systems Analysis

AS13004 PFMEA & Control Plans

AS9145 APQP & PPAP

AS9117 DPRV

AS9146 FOD Prevention Program

AESQ – Aerospace Engine Supplier Quality Strategy Group 24

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AESQ STANDARDS
OVERVIEW
OLIVIER CASTETS, SAFRAN

HELEN DJÄKNEGREN, GKN

AESQ – Aerospace Engine Supplier Quality Strategy Group

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AESQ Website - aesq.saeitc.org

AESQ – Aerospace Engine Supplier Quality Strategy Group 39

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AESQ Guiding Principles

• 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

AESQ – Aerospace Engine Supplier Quality Strategy Group 17
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AESQ Standards – Global Deployment
Vision
To establish and maintain a common set of Quality Requirements that enable the Global
Aerospace Engine Supply Chain to be truly competitive through lean, capable processes and a
culture of Continuous Improvement

AESQ Standards - Global Deployment Status

AS13002 AS13004
AS13000 AS13003
Developing and Process Failure Mode AS13006
Problem Solving AS13001 Measurement
Qualifying Alternate and Effects Analysis Process Control
Requirements for DPRV Systems Analysis
Inspection Frequency (PFMEA) and Control Methods
Suppliers Requirements for
Plans Plans
AESQ Member Accepted Accepted Accepted Accepted Accepted Accepted
Arconic (P&P) May-15 Feb-16 May-17 Mar-16 Aug-17 Sep-18

GE May-14 Oct-14 Jan-15 Jan-16 Aug-17 Sep-18

GKN Jun-14 Mar-15 Apr-15 Mar-15 Aug-17 Sep-18

Honeywell Jan-16 Mar-15 Oct-15 Jan-16 Aug-17 Sep-18

MTU Aug-15 Jan-16 4Q16 Jan-16 Aug-17 Sep-18

PCC Structurals Mar-15 Jan-15 May-15 Jun-16 3Q 18 Sep-18

Pratt & Whitney Jan-15 Mar-15 Apr-15 Mar-15 Aug-17 Sep-18

Rolls-Royce Dec-14 Oct-15 Jan-15 Jan-15 Aug-17 Sep-18

Safran Jan-15 Jan-15 Jan-15 Jan-15 Aug-17 Sep-18

AESQ – Aerospace Engine Supplier Quality Strategy Group 28

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Progress Forward

AESQ is now well established and is

gathering momentum

Supplier feedback is very positive &

they want us to move faster

Broader supplier engagement is being

sought to apply more resources

Stronger links with IAQG & PRI are

being developed

Stakeholder engagement essential for

progress & direction

AESQ – Aerospace Engine Supplier Quality Strategy Group 29

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PUBLISHED STANDARDS

BARRIE HICKLIN, HONEYWELL

AESQ – Aerospace Engine Supplier Quality Strategy Group

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Feedback Questions

1. Has the Standard been flowed down by your Customer(s)?

2. Do you have any problems with or suggestions for the Standard?
3. Have you had problems flowing down the Standard to your suppliers?
4. Are there any commodity specific considerations?

AESQ – Aerospace Engine Supplier Quality Strategy Group 31

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AS13000 PROBLEM
SOLVING
OLIVIER CASTETS, SAFRAN

AESQ – Aerospace Engine Supplier Quality Strategy Group

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 AS13000 Problem Solving
Original State Future State
GLOBAL 8D

7-Step DIVE/Red-X® 7-Step 8DDIVE/Red-X®

AESQ Principles Expected Benefits

 Standardise • Reduced need for Customer training & support

 Simplify • Improved access to training & consultancy

 Adopts Existing Industry Standards • Removal of complexity of reporting

Prescriptive, Auditable
• Improved problem solving skills
 Common Language
 Supported by 3 Party Training & Consultancy
rd

AESQ – Aerospace Engine Supplier Quality Strategy Group 41

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AS13001A DPRV TRAINING
EARL CAPOZZI, PRATT & WHITNEY

AESQ – Aerospace Engine Supplier Quality Strategy Group

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 AS13001A Delegated Product
Release Verification Training
Original State Future State
3 days

3 days 3 days
• One Common Training Requirement
3 days • Industry-wide DPRV database through SAE

• Delivered globally by SAE

Total 12 days
• Refresher training every 3 years
3 days

AESQ Principles Expected Benefits

 Standardise • Reduced costs for customers & suppliers

 Simplify • Reduced training time for DPRV personnel

 Adopts Existing Industry Standards* • Training provided in region of DPRV personnel

 Prescriptive, Auditable • Customer training limited to on-site

 Common Language
 Supported by 3 Party Training & Consultancy
rd
* Rev A aligns with AS9117 - DPRV
AESQ – Aerospace Engine Supplier Quality Strategy Group 42
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AS13002 INSPECTION
FREQUENCY
ERIKA GRIMM, GE

AESQ – Aerospace Engine Supplier Quality Strategy Group

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 AS13002 Inspection Frequency
Original State Future State
Common Method for
100% Inspection
•
100% Inspection Planning
• Guidance on commodity

Inspection Level
REDUCED Sample specific planning

Error Proof AQL Capability

AESQ Principles Expected Benefits

 Standardise • Standardised Process

 Simplify • Improved compliance
Adopts Existing Industry Standards
• Improved Product Quality
 Prescriptive, Auditable
 Common Language
 Supported by 3 Party Training & Consultancy
rd

AESQ – Aerospace Engine Supplier Quality Strategy Group 43

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AS13003 MSA
DR IAN RIGGS, ROLLS-ROYCE

AESQ – Aerospace Engine Supplier Quality Strategy Group

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AS13003 Measurement Systems Analysis
Attribute
Agreement
Original State Analysis? Future State

AESQ Principles Expected Benefits

• Improved knowledge of Measurement
 Standardise
Capability
Simplify
• Clarification of minimum acceptance standards
 Adopts Existing Industry Standards • Mandates replaces guidance
 Prescriptive, Auditable • Adopts Automotive Industry Action Group
 Common Language ‘Blue Book’ on MSA

 Supported by 3 Party Training & Consultancy

rd
• Improved Quality Performance

AESQ – Aerospace Engine Supplier Quality Strategy Group 44

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AS13004 PFMEA &
CONTROL PLANS
DR IAN RIGGS, ROLLS-ROYCE

AESQ – Aerospace Engine Supplier Quality Strategy Group

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 AS13004 PFMEA & Control Plans
Original State Future State

In Scope: Risk Mitigation requirements with execution

guidance & recommended timing, supporting AS9145
Out of Scope: DFMEA requirements, any duplication
Varying standards and approaches of related Aerospace Standards (e.g. AS9145)

AESQ Principles Expected Benefits

 Standardise • Standardised process

Simplify • Increased pace of adoption

 Adopts Existing Industry Standards • Improved compliance to a better standard

 Prescriptive, Auditable • Reduced quality risks

 Common Language • Ultimately improved quality & delivery

 Supported by 3 rd Party Training & Consultancy

AESQ – Aerospace Engine Supplier Quality Strategy Group 45

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AS13006 PROCESS
CONTROL METHODS
PETER AMSDEN,
PRATT & WHITNEY

AESQ – Aerospace Engine Supplier Quality Strategy Group

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 AS13006 Process Control Methods
Original State Future State
Common standard & approach
Aligned with AS13002, 13003, 13004,
AS9103, AS9145 & AIAG “Blue Books”
Varying standards &
approaches

PC requirements not clearly defined/understood

Inconsistent application/flowdown to sub-tiers
Lack of commitment/belief in benefits In scope: Process Control for all characteristics
Belief low volume environments not applicable Out of scope: Foundational requirements

AESQ Principles Expected Benefits

• Improved variation control & reduction
 Standardise techniques, broad-based belief in benefits
 Simplify • Common prescriptive standard fully aligned
 Adopts Existing Industry Standards with AESQ, AS9103 & AIAG Blue Book Stds
 Prescriptive, Auditable • Focus on accurate data analysis and proactive
 Common Language problem resolution

 3 Party Training & Consultancy

rd • Improved Quality Performance, reduced risk
AESQ – Aerospace Engine Supplier Quality Strategy Group
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Relationships to other industry standards

AS9100

Design Risk
Analysis

Feedback

Key Product
Characteristics
AS13003 AS13002 AS13004 AS13006
Measurement System Alternate Inspection Process
Analysis Frequency Plans Process Flow Process Control Process Analysis
PFMEA Control Plan Monitoring &
(MSA) Diagram Method Selection and Improvement
Control

Product and
Foundational
Process Key
Activities
Characteristics

AS13006 designed to align and work closely with other industry standards

AESQ – Aerospace Engine Supplier Quality Strategy Group

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AS13004 & AS13006 Standard Relationships

Related Standards
AS13000: Problem Solving Requirements (8D)
AS13002: Developing & Qualifying Alternative Inspection Frequency Plans
AS13003: Measurement Systems Analysis Requirements
AS9103: Variation Management of Key Characteristics
AS9145: Advanced Product Quality Planning & Production Part Approval Process
AESQ – Aerospace Engine Supplier Quality Strategy Group 89
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BENEFITS OF THE STANDARDS &
SUPPLIER CONTRIBUTIONS TO
AESQ

AESQ – Aerospace Engine Supplier Quality Strategy Group

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AS13001 DPRV
TRAINING
REDUCING NON QUALITY EVENTS BY DEPLOYING DPRV AT
SAFRAN SUPPLIER FACILITIES

CATHERINE CATARINA-GRACA,
SAFRAN

AESQ – Aerospace Engine Supplier Quality Strategy Group

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PROCESS TO BECOME A DPRV
2017 Update

DPRV Certification following AS9117 DPRV & AS13001

DPRV course

PROCESS TO BECOME A DPRV

2017 Update

Setting up the function

On site audit Granting the SAFRAN DPRV stamp

By Safran QE And the SAFRAN certificate if the
audit is conclusive
AESQ – Aerospace Engine Supplier Quality Strategy Group 48
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DPRV DUTIES

AESQ – Aerospace Engine Supplier Quality Strategy Group 55

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 RECORD MANAGEMENT
On Safran Aircraft Engines Quality ERP
Check over more than 1000 claims

FAULT DEFINITION
C00 CONDITIONING PACKAGING
P00 DOCUMENTATION
T00 MARKING / IDENTIFICATION / TRACEABILITY / MANAGEMENT (GENERIC)
V00 APPEARANCE / VISUAL / FINISH ( GENERIC)

AESQ – Aerospace Engine Supplier Quality Strategy Group 56

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 NON QUALITY EVENTS
2016/2017 update

Safran Aircraft Engines Claims : DPRV Deployed

Diminishing despite the LEAP ramp up

AESQ – Aerospace Engine Supplier Quality Strategy Group 57
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 NON QUALITY EVENTS
2016/2017 update

Comparing deployed and non deployed sites

83% of DPRV deployed sites

17% of DPRV undeployed sites
AESQ – Aerospace Engine Supplier Quality Strategy Group 58
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WHAT ABOUT MARKING EVENTS ?

DEPLOYED UNDEPLOYED
AESQ – Aerospace Engine Supplier Quality Strategy Group 59
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 IMPROVEMENT ACTION PLAN

• Communicating on metrics : going ahead with DPRV

Deployment
• Specific improvement action plan on « top 10 » SAFRAN
impacting suppliers
• Raising awareness on SAFRAN and Safran Aircraft Engines
requirements for DPRV managers (8 workshops worldwide)
focused on SAFRAN & AESQ standards
• SAFRAN and Safran Aircraft Engines Communication kit are
updated twice a year
• Promote Benefits of DPRVs as 9 SAFRAN companies are
going live

AESQ – Aerospace Engine Supplier Quality Strategy Group 60

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BENEFITS OF AS13004 –
PFMEA & CONTROL PLANS
DR IAN RIGGS,
ROLLS-ROYCE

AESQ – Aerospace Engine Supplier Quality Strategy Group

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Core Product Defect Prevention Tools

Product Design Process Design Production & Service

Advanced Product Quality Planning (APQP) &

Production Part Approval Process (PPAP)
AS9145

Process Control Error Process Control

Design FMEA MSA Capability
FMEA Plan Proofing (SPC)

AS13004 AS13003 AS13006

8D Problem Solving
Must be applied as a ‘system’ of tools
Must be applied at part number level AS13000
Effectiveness relies on Cross Functional working
AS13004 Process FMEA & Control Plan

What’s New
1. A Process FMEA for every part
number
2. A Process FMEA that covers all
Process Steps (those that
transform the product)
3. A Process FMEA that covers all
design features /
characteristics*
4. Failure Modes that describe how
the PRODUCT can fail to meet
Design Intent
5. A Control Plan for every part
Number
* Rolls-Royce Deployment Requirement
AS13004 Process FMEA & Control Plan

DON’T PANIC!
It is an achievable task, thanks to ;

Computer Software e.g. xFMEA,

DataLyzer, etc.

The use of Reference PFMEAs (see later)

Being part of a Large Network – sharing

lessons learnt

59
SAM SUZHOU CASE STUDY
Deploying AS13004 to Achieve Zero Defects

Honglei Zhu
Production Manager
SAM (Suzhou) Co. Ltd.

AESQ – Aerospace Engine Supplier Quality Strategy Group

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Agenda

Introduction of SAM Group and SAM Suzhou

Zero Defect and PFMEA (AS13004)

RFT improvement

Benefits

Lessons learnt

AESQ – Aerospace Engine Supplier Quality Strategy Group 61

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 SAM Suzhou Profile

SAM is a subsidiary of Accuron Technologies and headquartered in Singapore. With

nearly 2,000 employees across Asia and Europe servicing the precision and
equipment markets, we are equipped with the design and cutting edge
manufacturing capabilities to service leading global companies.

Our precision business segment focuses primarily on niche products such as engine
mounts, airfoils, engine cases and structural parts. Our equipment business
segment is vertically integrated to offer unique engineering solutions from
collaborative design and development, to finished equipment assembly.

As an AS9100 certified company, our quality system conforms to the quality

requirements of major companies in the aerospace and industrial industries. Our
products are supplied from our facilities in China, Germany, Malaysia, Singapore and
Thailand to customers world-wide.
62
 Geographical Presence
Sitec Aerospace SAM Suzhou
Germany – Bad Tölz / China / Suzhou

Headquartered in
Singapore

Staff Strength (non-Aerospace)

China 410 Thailand –
Europe 264 Ayuttaya
SAM Aviatron
Malaysia 1027
Singapore 259 Meerket Precision
Thailand 50 SAM Precision
Malaysia – Penang SAM Avitron
Total 2,010
Singapore
AESQ – Aerospace Engine Supplier Quality Strategy Group
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 SAM Suzhou Business

AEROSPACE

Contract
OEM Products
Manufacturing

EQUIPMENT

64
 SAM Suzhou
• Geographical Location: Suzhou, China, 2
hours to Shanghai
• Incorporated in 1995, 2004 relocated in EPZ
• Factory Size: 150,000 sq ft
• Land Size: 250,000 sq ft
• Location: Export Processing Zone, SIP
• Manpower: 410
• Machine capabilities:
5 Flexible manufacturing system Lines
Milling 49,Turning 9,Grinding 4,CMM 5,
others(SP) 35
Manager
9
Engineer
60

Production Support Staff

294 47

65
 Drive For Zero Defects

In Dec,2016
SAM was Invited to join the movement

Working Together…

to deliver a competitive supply chain

DRIVE FOR ZERO DEFECT

 DfZD Work Stream PFMEA using AS13004
Error Proofing
Awareness
Training
…

PFMEA output
RFT

Achieve:
100% RFT
0 Escape
Concession Reduction

PFMEA Drives RFT& Scrap reduction & Productivity Improvement

 √
√
√

31st July, 2017 √

“Zero Defect” part
√ (KH17504) delivery
kick off event
√
On 7th – 10th March, 2017 √
PFMEA workshop @ SAM
Facilitator: T.Slater / R.Kelsey

On 5th April, 2017 √

High Level PFMEA Training
√ at Rolls Royce Singapore
Facility
Working Together
On 20th April, 2017 √
On 6th April, 2017 Team Celebrated By end of May, 2017
1st Feature PFMEA completed PFMEA completed
AESQ Forum
PFMEA AS13004 √ Part Number: Part Number:
KH41760 (2) √
In Singapore KH17504 (1)
KH28381 (3)
PFMEA Roadmap to XWB Engine Mounts KH17496 (4)
 RFT improvement case study
RFT Tracking for p/n: KH17504
1. ZD delivery part kick off event end of Jul, 2017;
2. Achieve the 100% RFT by end of Q3, 2017;
3. Achieved 100% RFT in Sep 17 – Apr 18 (7 months) & Jun 18 – Aug 18 (3 months)

100% 100% 100% 100%

95% 96% 95% RFT100%

93% 93% 93%
92%
91% 91%
90% 89% 90%
88% 89%
88% 88%
87%
85% 85% Cutting Tool Broken
82% 82% Go back PFMEA review
80%

Recommend Actions:
1. Change cutting method to Reaming;
2. Move to H M/C (with RFID, less human touch, close door machining);
3. Enhance 5S management; Handling Trolley Improvement Project;
4. Enhance Supplier Engagement;
5. Case study for cutting tools improvement;
Proprietary Information of SAM
 Lessons learnt from AS13004
P/N: KH17504 Pareto Chart P/N: KH17504 Pareto Chart
by NON-Conforming Chart by Rejection Code

The cause of non-conformance effect are the input of PFMEA.

Action & Action Result

 Lessons learnt from AS13004
Process Failure Mode and Effects Analysis (PFMEA)
Key Contact / Phone Date Date
Production - SAM Suzhou 2017/3/9 2018/4/19
(Orig.) (Rev.)
Custom
er
Part Number KH17504 Core Team
Approv
al Date
Proces
s
Requirements Responsi Action Results

Classification
Functi
Potenti Potential bility&

Severity
Feature on/ Recomm
Drg Sheet Operatio al Potential Effect(s) of Cause(s) Target
Num Step Prevent RPN ended

Occurrence

Occurrence
(A2) n Failure Failure of Completio Actions

Detection

Detection
Severity
(A3) ion Action
Descri Mode Failure Detection n Date Taken
Dim Control RPN
ption Controls Completi
(B1) Tol (-) Tol (+) s
on Date
(B2) (B3)
[Customer Effect]5
Increased wear of pin - tool ID
early scrappage/repair visual
bore gauge
CCF Ø Above [Manufacturing / Assembly wrong check,
SH3 38 & 45 170 Reaming E 0.0125 0.0125 5 CCF 3 in station by 5 75
37.0215 top limit Effect]5 A proportion of tooling tool
operator
production run may have to presetter
be reworked off line and check,
accepted
CCF
j│ Ø 0.05 Move to
0.05m│E Heller M/C Action
tool
to Owner
presetter in station
wrong tool implement Xu Hua
SH3 39 & 46 170 Reaming E NA 6 routine, 3 dimensional 5 90 6 5 2 60
setting automated Target date
qualified check
tooling December-
CCF j│ Ø operators,
0.10m│A 0.1 control 2018
│Bm-Cm routine

Key success factors:

• Supporting from Design engineer for Design Risk Analysis
• Update PFMEA frequently (nonconformance data as an input)
• Create action plan to mitigate risks
• Refer to previous product history, customer feedback, etc
 Lessons learnt from AS13004

Vendor
Code:228537
Supplier Name:SAM
(Suzhou) Co., Ltd. PROCESS CONTROL PLAN
Document No. Part No.(s) Issue number Issue date Approval (stamp/sign)
KH17504 CP001 KH17504 1 24/05/2018
Document Category (circle / delete) Part Classification
Pre-Prod. Prod. Sensitive

PROCESS MACHINE, CHARACTERISTICS METHODS

FIXTURE, SPECIA REACTION
PROCESS NAME / TOOLS FOR L / KEY PRODUCT / EVALUATION / CONTRO PLAN /
EC/M OP. MFG / CHAR. PROCESS SPEC. MEASUREMENT SAMPLE SAMPLE RESP. REFERENC
OPERATION NO. PRODUCT PROCESS L
EC NUMBER SIZE FREQ.
DESCRIPTION MEASUREME CLASS / TOLERANCE TECHNIQUE METHOD E
NT
38&4 CCF Ø Free of damage /
EC 170 Milling MC-MN4H69 Tip condition CCF Visual All 100% Operator MOM Inform leader
5 37.0215±0.0125 wear
EC 170 Milling MC-MN4H69 39 CCF j│ Ø 0.05m│E Work offset CCF Within 0.03mm Probe check All 100% Operator MOM Inform leader

EC 170 Milling MC-MN4H69 42 CCF i│ 0.50│ B-C Work offset CCF Within 0.03mm Probe check All 100% Operator MOM Inform leader

EC 170 Milling MC-MN4H69 46 CCF j│ Ø Work offset CCF Within 0.03mm Probe check All 100% Operator MOM Inform leader
0.10m│A│Bm-Cm
Coolant
EC 170 Milling MC-MN4H69 49 Ra 0.8 10%+/-5% test paper All 100% Operator MOM Inform leader
concentration

Key success factors:

• Control the process inputs to obtain the desired product outputs
• Use of error proofing
• Verify output at the earliest possible operation within the process
SAM SUZHOU CASE STUDY
Deploying AS13004 to Achieve Zero Defects

Honglei Zhu
Production Manager
SAM (Suzhou) Co. Ltd.

AESQ – Aerospace Engine Supplier Quality Strategy Group

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SAM Suzhou Success

Picture
SAE INTERNATIONAL

HOW TO BE EFFICIENT BY
USING REFERENCE PFMEA
How to Create and Manage Part Specific
Process FMEAs using a Reference FMEA
Database

AESQ – Aerospace Engine Supplier Quality Strategy Group

This document slide does ©
Copyright not
SAEcontain ITAR or
International. EAR use
Further technical data. The
or distribution is notcontent ofwithout
permitted this presentation slide
permission from SAEis proprietary and
confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ.
Using Reference PFMEAs

Potential S O D R
Potential Potential Prevention Detection
Process Requirements Failure E C E P
Effects V Causes Controls C Controls N
Modes T

Fuel leak 2
Oversize Tool pre- Bore mic
leading to 9 4 7 5
OP10 Drill Fuel Hole explosion tool setting at OP 50 2
Hole too
CNC 50mm Diameter Big
+/- 1.0 mm Spindle Asset Care Weekly 2
Drilling
Scrap part 6 alignment & 3 ball bar 8 1
error Calibration check 6

Slight
Oversize Tool pre- Bore mic 5
increase in 3 2 7
OP20 Drill Air Hole noise level tool setting at OP 50 6
Hole too
CNC 50mm Diameter Big
+/- 3.0 mm Spindle Asset Care Weekly
Drilling 3
Concession 4 alignment & 1 ball bar 8 2
error Calibration check

Blue Boxes show the (partial) content of a Reference PFMEA for Hole Drilling where the
Failure Mode is ‘Hole Too Big’

76
Creating a Part Specific PFMEA using
Reference FMEAs

‘Shell’ Part Number PFMEA

A ‘shell PFMEA is created for each operation and every

feature / specification required to produce a specific
part number using the Process Flow Diagrams,
Characteristics Matrix and Drawing / Specifications.
Completing the Part Number Specific PFMEA

The team may need to add in additional Failure Modes, Potential Causes and/or Control
information based on their knowledge of the specific part numbers. Some information in the
Reference PFMEA may not be relevant so can be deleted.
How long does it take to complete an AS13004 Process FMEA?

Estimates are for a medium complexity machined part (1000 features)

Reference PFMEAS once created will be used for all future PFMEAs and only updated
when necessary. This is a ‘one off’ activity.
Initial Part Specific PFMEAs will take longer as the cross functional team discuss issues
for the first time e.g. what would happen if….?
Initial PFMEAs should be treated as a learning exercise.
It will probably take 3 – 5 PFMEAs for the team to optimise the process.
How Rolls-Royce can help

Process PFMEA Practitioner Guide for

developing PFMEAs & Control Plans to
AS13004 including the creation and use of
Reference FMEAs is available free of charge
(electronically or hard copy) from Rolls-Royce

Rolls-Royce will make its Reference PFMEAs

available to external businesses to promote
the deployment of AS13004.

We recommend that suppliers invest in a

suitable FMEA software tool to manage the
level of data created efficiently

We have developed Global PFMEA training to

support this approach with Smallpeice
Enterprises and Industry Forum (see AESQ
website for details)
Supplier Success Examples

GKN Newington
Trent 7000 Fan Case
Defect Free at Product
Introduction

SAM Suzhou
XWB Engine
Mounts
Defect Free
It really is that easy…..

It really is that effective…..

Good luck.
AS13003 MSA

MARTIN SCHAEFFNER, MTU

AESQ – Aerospace Engine Supplier Quality Strategy Group

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MSA@MTU
Experiences from using the Measurement System Analysis method at MTU

4/4/2017
Proprietary Notice

This document contains proprietary information of the MTU Aero Engines AG group
companies. The document and its contents shall not be copied or disclosed to any third
party or used for any purpose other than that for which it is provided, without the prior
written agreement of MTU Aero Engines AG.

4/4/2017 85
© MTU Aero Engines AG. The information contained herein is proprietary to the MTU Aero Engines group companies.
 General Approach

What is the intent?

The goal is to make sure that every measurement system (gage + outside influences) used is suitable
for the intended task  representing “real” part quality!
The AS13003 method summarizes different tools and delivers a standardized approach.
Mainly used in: PPAP; approval of new measurement technology; stabilizing production processes

Guiding Questions

“Method 1” “Method 2”
Is the gage precise and accurate enough to What happens in real production line
rely on it? conditions?
What happens if the same inspector measures the
How big is the variance of my Calculation of the
same part without knowing the results from his last
measurement? value cg >1,33
measurements?
%
GR&R
Total
What happens when a different inspector measures Variance
Is there a systematic error in the Calculation of the
the same part without knowing the results from his
measurement? value cgk >1,33
coworker?

3/28/2017 MSA@MTU 86
© MTU Aero Engines AG. The information contained herein is proprietary to the MTU Aero Engines group companies.
Hands-on Example Case, Turbine

3/28/2017 MSA@MTU 87
© MTU Aero Engines AG. The information contained herein is proprietary to the MTU Aero Engines group companies.
Actions defined due to results from the MSA Case, Turbine

3/28/2017 MSA@MTU 88
© MTU Aero Engines AG. The information contained herein is proprietary to the MTU Aero Engines group companies.
Lessons Learned up to now

• By using the MSA method you get a reliable and understandable statement if you can rely
on your results or not
 don’t touch your production processes before you are sure about your measurement
• Cg & Cgk database is a great support to discuss drawing requirements with the design
organization
• An MSA helps to eliminate influences coming from different measurement strategies

• A CMM measurement is not always reliable – accuracy and inspector variance matters
• High quality of existing measurement programs as in most cases only a few characteristics
show a significant variance
• A comparison to an independent reference measurement gives a valuable insight into the
production line measurement;
 not easy to achieve due to the small tolerances and the expectation to be more precise
• For tighter tolerances the method is very challenging and even a difference of 1/10 µm
between reference & production results can be the reason for an incapable system -> Rules
for these special cases are necessary
3/28/2017 MSA@MTU 89
© MTU Aero Engines AG. The information contained herein is proprietary to the MTU Aero Engines group companies.
FUTURE INITIATIVES
BARRIE HICKLIN, HONEYWELL

AESQ – Aerospace Engine Supplier Quality Strategy Group

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Feedback Question

What topics would you like us to work on in the future?

AESQ – Aerospace Engine Supplier Quality Strategy Group 91

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FUTURE INITIATIVES
DAN EIGENBRODE,
PRATT & WHITNEY

AESQ – Aerospace Engine Supplier Quality Strategy Group

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Product Life Cycle & Document Interaction
AS9145 (APQP/PPAP) & AESQ Standards
AS9145 Kick Off
End of Concept Design Release Initial Prod. Production
(PDR) (CDR) Approval Launch
(PDP)
5. Ongoing Production, use and
1. Planning
Post Delivery Service
4. Product & Process
AS9145 2. Product Design & Development
Validation
APQP Phases
3. Process Design & Development
Production AS9102
AS9145 Key FAIR
PPAP
Readiness
PPAP Events Review Production Process Run
Approval

Design Process Flow Diagram Packaging, MSA

AS9145 PPAP PFMEA
Records Preservation & ICS
Element Timing & DRA
Control Plan
Labelling FAI

AS13004 – PFMEA & Control Plans

AESQ
AS13003 – Measurement Systems Analysis
2nd Level
Documents AS13006 – Process Control Methods

AS13002 – Inspection Frequency

AS13000 – Problem Solving Requirements for Suppliers - 8D

AESQ
AS13001 – Delegated Product Release Verification Training Requirements
Systems
Documents AS13005 – Quality Audit Requirements

AS13007 – Supplier Management

AESQ – Aerospace Engine Supplier Quality Strategy Group 86

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 Existing & Future Workstreams
Quality Planning Process Control Quality Assurance

Customer /
IAQG APQP & PPAP – AS9145 Audit 3rd party
audits
Process Planning
NC Material
Process Control Problem
PFMEA Source &
Flow Plan Inspection Solving
Method Supplier
Frequency (Subtier)
Change
Management
FOD
MSA Counterfeit
FAI Process Control Parts /
(Variation Management) Ethics
Production Compliance
Readiness Tooling /
SPC incl. KPIs incl.
Assessment Ppk / Cpk fixture
short run RFT DPRV
mgmt NDT
Training

Published Standard AESQ working in IAQG Team Current Workstream Potential future workstream

AESQ – Aerospace Engine Supplier Quality Strategy Group

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AESQ Strategic Process Map

Comparative
Analysis

Next
Priority & White
Supplier Input Work
Feasibility Paper
Stream

Member
Input

Assimilation & prioritization of future AESQ initiatives for

standardization and step improvements in quality
AESQ – Aerospace Engine Supplier Quality Strategy Group 95
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White Paper Projects
Work in Progress
FAI Non-Conforming Material
Study Topics Study Topics

Interpretation
Guidance (8D)
(partial / full FAI)

Form 3 Standardize Forms

Ballooning Common IT Hub

Submission Common processes

for repair and
repetitive concession
Planning FAIR requests

AESQ – Aerospace Engine Supplier Quality Strategy Group

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96
confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ.
AS13100 AS9100 Supplemental Requirements
Original State Future State

AESQ Principles Expected Benefits

 Standardise
• Reduces/Eliminates top level OEM Requirements
 Simplify

 Adopts Existing Industry Standards

• “Raises the Bar” for Quality Expectations
 Prescriptive, Auditable

 Common Language • Common Aero-Engine Manufacturer Language

 Supported by 3rd Party Training & Consultancy

AESQ – Aerospace Engine Supplier Quality Strategy Group 87
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SUPPLIER CONTRIBUTION
TO AESQ WORK

AESQ – Aerospace Engine Supplier Quality Strategy Group

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 How You Can Participate

• Attend our AESQ Supplier Forums

• Provide feedback on current
standards & those in development
• Share best practice deployment
stories and impact of standards
via the AESQ Website
• Help identify new areas of
standardization & future work
aesq.saeitc.org/

Challenge your customers about deployment of standards

AESQ members are committed to deploy
AESQ – Aerospace Engine Supplier Quality Strategy Group 18
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AS13005 QUALITY AUDIT
REQUIREMENTS
HELEN DJÄKNEGREN, GKN

AESQ – Aerospace Engine Supplier Quality Strategy Group

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 AS13005 Quality Audit Requirements
Original State Every Customer Audits Every Future State Risk Based Supplier Audit
Internal and supplier audit Supplier
requirements in many
documents Aerospace Standard
AS13005
– Audit types & checklists
 System
 Production process
 Product
 Special process
– Auditor qualification, KPI´s
– Supplier Surveillance Audit
 Selecting suppliers
Internal Audits for Many  Selecting scope, approach One Common Requirement
– Audit outcome
Requirements for Internal Audit

AESQ Principles Expected Benefits

Standardise • Lean & effective internal audit process provides confidence
 in state of compliance throughout Aero-Engine supply
Simplify chain

• Improved rigor of audit approach
 Adopts Existing Industry Standards • Suppliers chosen for audit based on performance and risk
Prescriptive, Auditable • Reduced and/or eliminated unnecessary and/or duplicate
 audits => Cost reduction / resources liberated by customer
Common Language and supplier.

• Reduced supplier audits for performing suppliers (low risk)
 Supported by 3rd Party Training & Consultancy that demonstrate compliance to internal audit
requirements
• Recognizes existing 3rd party certification
AESQ – Aerospace Engine Supplier Quality Strategy Group 87
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AS13007 SUPPLIER
MANAGEMENT
BARBARA NEGROE, GE AVIATION

AESQ – Aerospace Engine Supplier Quality Strategy Group

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AS13007 Supplier Management

• Lots of sub-tier surprises?

• Is the variation and risk
understood?
• Is the risk owned?
• How is it managed?
• How will it be improved?

AESQ – Aerospace Engine Supplier Quality Strategy Group 90

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 AS13007 Supplier Management
Original State Varied Future State
Fewer Customer-Specific
Customer-Specific
Requirements
Requirements
Single
Industry
AESQ
Standard for Tier X Standard
Supplier/Tier Flow
Management down
??? In scope: Raw material & finished hardware
Out of scope: Distributors & MRO suppliers

AESQ Principles Expected Benefits

• Simplify language for organizations to
 Standardise manage suppliers
 Simplify • Ability to use the standard throughout all
 Adopts Existing Industry Standards tiers of the supply chain
 Prescriptive, Auditable • Standard will simplify and reduce the
number of methods the suppliers must use
 Common Language to meet Customer requirements (i.e.
Supported by 3rd Party Training & Consultancy simplify/make common the “how to”)
AESQ – Aerospace Engine Supplier Quality Strategy Group 91
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 CLOSING REMARKS
MARTIN SCHAEFFNER &
TETSUYA MIZUTANI

AESQ – Aerospace Engine Supplier Quality Strategy Group 105

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confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ.
AESQ Vision

To establish and maintain a common set of

Quality Requirements that enable the Global Aero Engine
Supply Chain to be truly competitive through lean, capable
processes and a culture of Continuous Improvement

AESQ – Aerospace Engine Supplier Quality Strategy Group 106

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confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ.
AESQ Vision
In detail
• Create common standards within the engine manufacturers (OEM’s)
in regard to quality
• Deploy together the written standards throughout our supply chain
• Establish capable quality processes and a culture of continuous
improvement

Main targets
• To improve quality within the supply chain
• Improve on time delivery and minimize costs through a reliable
quality performance
• Gain efficiency by standardized processes

AESQ – Aerospace Engine Supplier Quality Strategy Group 107

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confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ.
AESQ Will Drive Progress

Spread the Word

Provide feedback on the AESQ website

AESQ – Aerospace Engine Supplier Quality Strategy Group 106

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confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ.
RETURN HOME SAFELY

AESQ – Aerospace Engine Supplier Quality Strategy Group 109

This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and
confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ.