Aerospace Risk Management

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Aerospace Risk Management and Analysis Series

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Aerospace Risk Management

  1. 1. Ae erospace Ris M agem nt e sk Mana men and Anal A lysis Series s sAdvannced Quaality Planning andd P Planning and Con nducting theDisciplined Pha Appr ase roach to E Enhanced FAI (Pr d roduction nNew Product Developm P D ment T Trial Run)Risk Assessme A ent,Characcteristics Designation and s R nhanced FAI Reviewing the EnFlow Down D M Measurem ment Sys stemDesign Tools Including SFMEA / n g A AnalysisDFMEA and As A ssociated Tools dProces Tools Including Proces ss g ss S Statistica Process Contro al olFlow, PFMEA, Control Plans and C P (SPC)Work Instructions C Capability Analys and y sisTeam Leader Facilitatio F on A Advanced SPC dC O N S U L T I N G T R A I N I N G S O F T W A R E
  2. 2. 325 E. Eisenhower Pkwy. Suite 4 Ann Arbor, MI 48108 To Register Fax: (734) 761-4966 (734) 761-4940 www.omnex.comAerospace Risk Management and Analysis SeriesAdvanced Quality Planning and Disciplined PhaseApproach to New Product DevelopmentSeminar Content Seminar OutlineThis one-day hands-on seminar is intended to equip participants • Overview: Advanced Quality Planning and Projectwith the skills required to succeed in the application of ManagementAdvanced Quality Planning (AQP) to the product realization and • The Need for ChangeSupplier Quality Management (SQM) process. The approach of • Industry in Transitionthis course is based on best practices by experts in the field. • Project ManagementBy attending this course, participants will also gain insight and • Advanced Quality Planningknowledge regarding the use of prevention-based techniques o Breakout Exercise: Phase 1 Project Planning – Partused for an on-time and low PPM product launch. These Atechniques include Project Planning, Project Reviews, Risk • Risk AnalysisAnalysis and Manufacturing Feasibility Risk Analysis, as well o Breakout Exercise: Phase 1 Project Planning – Partas conducting Project Reviews and planning for overall Project BReviews and Project Scorecards. The use of risk-based and • Project TimingFMEA-based processes, including an enhanced FAI/AQP o Breakout Exercise: Phase 1 Project Planning – Partprocess currently used by companies in the Aerospace industry Csuch as Bombardier, Parker Aerospace and Pratt & Whitney will • Conducting the Project Kick Offbe discussed. o Breakout Exercise: Update the Project Plan • AQP Project ReviewsThis class includes breakout exercise sessions using an example o Breakout Exercise: Project Review Agenda andof an Aerospace sub-assembly project and product launch. This Project Scorecardsrunning example will be used throughout the 16-day Aerospace • Conducting a Design ReviewRisk Management and Analysis Series. o Breakout Exercise: Discussion on Design ReviewWho Should Attend• Project Managers• FMEA Facilitators• All other Risk Management personnelRecommended Training and/or ExperienceParticipants should possess a working knowledge of qualitysystems and methodologies.Seminar MaterialsEach participant will receive a seminar manual and a workbookincluding all team breakout exercises.Seminar Goals• Understand standardized terminology for AQP• Gain insight, knowledge and skill sets required for AQP and Risk Management, including: o Project Planning o Risk Analysis o Project Reviews• Understand the standardized approach for the AQP and best-in-class techniques Driving Worldwide Business Excellence
  3. 3. 325 E. Eisenhower Pkwy. Suite 4 Ann Arbor, MI 48108 To Register Fax: (734) 761-4966 (734) 761-4940 www.omnex.comAerospace Risk Management and Analysis SeriesRisk Assessment, Characteristics Designation andFlow DownSeminar Content Seminar OutlineThis one-day hands-on seminar is addresses the application of • The Improvement Strategythe knowledge captured in S/DFMEAs and PFMEAs related to • Failure History and Risk Assessmentrisk assessment, including the cascading of the risk information o Breakout Exercise: Failure History, Improvementto critical part requirements. Estimation and Developing the GridThis class includes breakout exercise sessions using an example • Risk Classificationsof an Aerospace sub-assembly project and product launch. This o Breakout Exercise: Flow Down and Handlingrunning example will be used throughout the 16-day Aerospace Failures from System FMEA to DFMEA to PFMEARisk Management and Analysis Series. • FMEA Tables and Risk o Breakout Exercise: Tracking Improvement ActionsWho Should Attend• Program Managers• Project Managers• Quality Managers• Design Engineers• AQP Team Members• All other Risk Management personnelRecommended Training and/or ExperienceParticipants should possess a working knowledge of qualitysystems and methodologies.Seminar MaterialsEach participant will receive a seminar manual and a workbookincluding all team breakout exercises.Seminar Goals• Provide an understanding of the Risk Classifications for Special Requirements, Critical Items and Key Characteristics• Provide an understanding of how these risk classifications were developed and how to evaluate at the sub-assembly or component level• Learn how to ensure that historical failures are shared, included in FMEAs and controlled in manufacturing or design Driving Worldwide Business Excellence
  4. 4. 325 E. Eisenhower Pkwy. Suite 4 Ann Arbor, MI 48108 To Register Fax: (734) 761-4966 (734) 761-4940 www.omnex.comAerospace Risk Management and Analysis SeriesDesign Tools Including SFMEA / DFMEA andAssociated ToolsSeminar Content Seminar OutlineThis two-day hands-on seminar is intended to offer insight into, • FMEA Introductionand hands-on experience with, the linkages between various • Putting an FMEA Togetheraspects of the Advanced Quality Planning (AQP) process. • DFMEA PrerequisitesSpecifically, the development and linkage of Block Diagrams, o Breakout Exercise: Customers & FunctionalSystem and Design FMEAs and Design Verification (Test) RequirementsPlans (DVPs) are addressed. o Breakout Exercise: Boundary DiagramsSFMEAs are performed during the Design phase of AQP for • Developing the DFMEARisk Management and Prevention. SFMEAs are used to identify o Breakout Exercise: Starting the DFMEA FormSpecial Requirements, Critical Items and Key Characteristics to o Breakout Exercise: Failure Modesassist in the flow-down to sub-assemblies and components. o Breakout Exercise: Design Causes o Breakout Exercise: Design ControlThis class includes breakout exercise sessions using an example o Breakout Exercise: Effects, Severity and Actionof an Aerospace sub-assembly project and product launch. This Plansrunning example will be used throughout the 16-day Aerospace • DFMEA – Component LevelRisk Management and Analysis Series. o Breakout Exercise: Developing a Component DFMEAWho Should Attend • Test Planning and Reporting• Program Managers• Project Managers• Quality Managers• Design Engineers• AQP Team Members• All other Risk Management personnelRecommended Training and/or ExperienceParticipants should possess a working knowledge of qualitysystems and methodologies.Seminar MaterialsEach participant will receive a seminar manual and a workbookincluding all team breakout exercises.Seminar Goals• Provide a hands-on approach to S/DFMEAs and their relationship to program deliverables and status reporting• Provide the competencies needed to introduce new products and processes smoothly• Gain knowledge and understanding in: o Block Diagrams and Interface Matrix o Linkages between Block Diagrams, SFMEAs, DFMEAs, DVP and other design tools o Linkages between PFMEAs and S/DFMEAs o Using FMEA as an analytical process o S/DFMEAs and DVPs Driving Worldwide Business Excellence
  5. 5. 325 E. Eisenhower Pkwy. Suite 4 Ann Arbor, MI 48108 To Register Fax: (734) 761-4966 (734) 761-4940 www.omnex.comAerospace Risk Management and Analysis SeriesProcess Tools Including Process Flow, PFMEA,Control Plans and Work InstructionsSeminar Content Seminar OutlineThis two-day hands-on seminar is intended to offer insight into, • FMEA Reviewand hands-on experience with, the linkages between various • Putting an FMEA Togetheraspects of the Advanced Quality Planning (AQP) process. • PDFMEA PrerequisitesSpecifically, the development and linkage of Process Flows, o Breakout Exercise: Customers & FunctionalPFMEAs, Control Plans and shop floor documentation are Requirementsaddressed. This information can be used to achieve process o Breakout Exercise: Process Flowstandardization and improvement. • Developing the PFMEAThis class includes breakout exercise sessions using an example o Breakout Exercise: PFMEA Steps, Functions,of an Aerospace sub-assembly project and product launch. This Requirements and FMsrunning example will be used throughout the 16-day Aerospace o Breakout Exercise: PFMEA CausesRisk Management and Analysis Series. o Breakout Exercise: PFMEA Prevention/Detection Controls, Occurrence & Detection Index o Breakout Exercise: PFMEA Effects, Severity IndicesWho Should Attend and RPN• Program Managers • Using PFMEA to Improve the Process• Project Managers o Breakout Exercise: PFMEA Actions• Quality Managers • FMEA and the Product Realization Process• Process Engineers • Evaluating a Process FMEA• Enhanced FAI/AQP Coordinators o Breakout Exercise: Developing a Component• AQP Team Members PFMEA Process• All other Risk Management personnel • Control PlansRecommended Training and/or Experience o Breakout Exercise: Control PlansParticipants should possess a working knowledge of quality • Work Instructionssystems and methodologies.Seminar MaterialsEach participant will receive a seminar manual and a workbookincluding all team breakout exercises.Seminar Goals• Gain knowledge and understanding in: o Process Flows o Linkages between Process Flows, PFMEAs, Control Plans and Work Instructions o Linkages between PFMEAs and S/DFMEAs o Using FMEA as an analytical process o Characteristics Matrix o Process FMEAs and Control Plans Driving Worldwide Business Excellence
  6. 6. 325 E. Eisenhower Pkwy. Suite 4 Ann Arbor, MI 48108 To Register Fax: (734) 761-4966 (734) 761-4940 www.omnex.comAerospace Risk Management and Analysis SeriesPlanning and Conducting the Enhanced FAI(Production Trial Run)Seminar Content Seminar OutlineThis one-day hands-on seminar is intended to address the o Breakout Exercise: What’s Needed?purpose of the First Article Inspection process (FAI) as the • Planning for FAI/AQPculmination of the AQP process and provides a detailed • Preparing for the Initial Production Runexamination of preparation required for the enhanced FAI/AQP • Initial Production Run: MSArequirements. This class focuses on the planning necessary in • Initial Product Run: Production Control Planpreparation of an enhanced FAI/AQP. • Process ReadinessThe Production Trial Run requires that the process • Process Readiness: Work Instructionsdocumentation including Process Flows, PFMEAs, Control • Process Readiness: AssessmentPlans and Work Instructions are completed and that the o Breakout Exercise: Planning and Conducting theoperators are trained. Also, gauging, tooling and the equipment Process Readiness Assessmentmust be made ready. MSA studies and Process Capability • Conducting Initial Production Runstudies should all be completed prior to the enhanced FAI/AQP. • The FAI ReportWarranty preparation and submission is also covered. o Breakout Exercise: Revisiting What’s NeededWho Should Attend• Program Managers• Project Managers• Design, Quality and Manufacturing Engineers• Enhanced FAI/AQP Coordinators / persons who have direct responsibility for preparation, assembly or review of enhanced FAI/AQP components or packages• Auditors and those responsible for supplier enhanced FAI/AQP documentation• AQP Team Members• All other Risk Management personnelRecommended Training and/or ExperienceA general knowledge of quality systems is required.Seminar MaterialsEach participant will receive a seminar manual and a workbookincluding all team breakout exercises.Seminar Goals• Understand the requirements and timing impacts of the enhanced FAI/AQP• Provide examples and lessons learned for use in the hands- on application needed for successful enhanced FAI/AQP submission• Plan for a Production Trial Run, i.e., first production run of a product• Learn how to conduct a Process Readiness Assessment Driving Worldwide Business Excellence
  7. 7. 325 E. Eisenhower Pkwy. Suite 4 Ann Arbor, MI 48108 To Register Fax: (734) 761-4966 (734) 761-4940 www.omnex.com Aerospace Risk Management and Analysis SeriesReviewing the Enhanced FAISeminar Content Seminar OutlineThis one-day hands-on seminar covers the review and auditing o Breakout Exercise: Assessing a FAI/AQP Packageof the documentation required as part of and in support of an • Verifying Initial Production Runenhanced FAI/AQP. This class focuses on determining if all • FAI/AQP Documentation Reviewprogram requirements and documentation have been properly • Review of Each FAI/AQP Submission Itemimplemented and completed, and that the production process has o Breakout Exercise: Assessing a FAI/AQP Packagethe potential to meet these requirements during an actualproduction run at the quoted production rate.This class includes breakout exercise sessions using an exampleof an Aerospace sub-assembly project and product launch. Thisrunning example will be used throughout the 16-day AerospaceRisk Management and Analysis Series.Who Should Attend• Program Managers• Project Managers• Design, Quality and Manufacturing Engineers• Enhanced FAI/AQP Coordinators / persons who have direct responsibility for preparation, assembly or review of enhanced FAI/AQP components or packages• Auditors and those responsible for supplier enhanced FAI/AQP documentation• AQP Team Members• All other Risk Management personnelRecommended Training and/or ExperienceA general knowledge of quality systems is required.Seminar MaterialsEach participant will receive a seminar manual and a workbookincluding all team breakout exercises.Seminar Goals• Learn how to review and enhanced FAI/AQP package for completion• Evaluate two to three complete FAI/AQP packages using an FAI/AQP checklist Driving Worldwide Business Excellence
  8. 8. 325 E. Eisenhower Pkwy. Suite 4 Ann Arbor, MI 48108 To Register Fax: (734) 761-4966 (734) 761-4940 www.omnex.comAerospace Risk Management and Analysis SeriesMeasurement System AnalysisSeminar Content Seminar OutlineThis two-day seminar is designed to provide participants with an • Introduction to MSAunderstanding of the importance of Measurement System • Statistical Properties of Measurement SystemsAnalysis (MSA) in controlling and improving the production • Discriminationprocess, as well as provide a practical knowledge of using • Qualification of Measurement Systemsstatistical methods in analyzing the measurement system. • Bias and LinearityMeasuring devices with low variability as evidenced by use of • GRR StudiesMSA are mandatory before conducting Statistical Process • Attribute MeasurementsControl (SPC) or Process Capability. MSA studies are also • Summarizing MSA Techniquesrequired for enhanced FAI/AQP submission.Who Should Attend• Quality Managers• Quality System and Lab Technicians• Management Representatives• Engineers responsible for process improvements• All other Risk Management personnel responsible for planning, using and maintaining measurement systemsRecommended Training and/or ExperienceA basic understanding of computational mathematics, a partialunderstanding of elementary applied statistics, and a basicbackground in statistical process control are recommended, butnot required.Seminar MaterialsEach participant will receive a seminar manual and a workbookincluding all team breakout exercises.Seminar Goals• Define and understand measurement systems• Define and understand the causes of variation• Be able to qualify the sources of variation• Choose appropriate system for data collection• Ability to maintain measurement systems over the life of the manufacturing process Driving Worldwide Business Excellence
  9. 9. 325 E. Eisenhower Pkwy. Suite 4 Ann Arbor, MI 48108 To Register Fax: (734) 761-4966 (734) 761-4940 www.omnex.comAerospace Risk Management and Analysis SeriesStatistical Process Control (SPC)Seminar Content Seminar OutlineThis two-day hands-on seminar is designed to provide • Introduction to Statistical Process Controlparticipants with an understanding of the importance of SPC in • Process Variationcontrolling and improving the production process and to give • Normal Theory and Central Limit Theoremstudents a practical knowledge of using statistical methods in • Visible Signs of Special Causesanalyzing the production and service processes. • Other Types of ChartsAn additional three-day class is available that covers Capability • Process CapabilityAnalysis and SPC. This three-day hands-on seminar is designed • Control Charts for Non-normal Processesto teach participants how to implement SPC within industriesthat have set up variation, slow and rapid tool wear, andcontinuous processes where adjustments occur on a daily basis.Emphasis on analysis of data and effects on the processes usingeight types of control charts expands the users’ ability to addressnon-normal, multivariate and unilateral variables.Who Should Attend• Individuals who have direct responsibility for defining and developing an organization’s measuring, monitoring and analytical processes using data collection, charts and statistical tools appropriate for its products, processes and business goals and objectivesRecommended Training and/or ExperienceFundamental knowledge of computational mathematics isrecommended for understanding the topics discussed.Seminar MaterialsEach participant will receive a seminar manual and a workbookincluding all team breakout exercises.Please bring a calculator.Seminar Goals• Present a hands-on approach to learning the principles and practices of SPC and process analysis• Understand the uses and benefits of control charts and be able to construct and interpret them• Understand the role that SPC plays in the overall control strategy for a process and/or company Driving Worldwide Business Excellence
  10. 10. 325 E. Eisenhower Pkwy. Suite 4 Ann Arbor, MI 48108 To Register Fax: (734) 761-4966 (734) 761-4940 www.omnex.comAerospace Risk Management and Analysis SeriesCapability Analysis and Advanced SPC • Process Control (Behavior) ChartsSeminar Content o Elements of Control ChartsThis three-day seminar covers Capability Analysis and SPC. o Control Chart ProcessThis three-day hands-on seminar is designed to teach o Control Chart Mechanicsparticipants how to implement SPC within industries that have • Charts for Variables Dataset up variation, slow and rapid tool wear, and continuous o Breakout Exercise: Average and Range Chartsprocesses where adjustments occur on a daily basis. Emphasison analysis of data and effects on the processes using eight types o Breakout Exercise: Seven Additional Rules for Detecting Special Causesof control charts expands the users’ ability to address non-normal, multivariate and unilateral variables. o Breakout Exercise: Average and Standard Deviation Charts o Breakout Exercise: Individuals ChartsWho Should Attend • Charts for Attribute Data• Individuals who have direct responsibility for defining and o Breakout Exercise: p Charts developing an organization’s measuring, monitoring and o Breakout Exercise: np Charts analytical processes using data collection, charts and o Breakout Exercise: c Charts statistical tools appropriate for its products, processes and o Breakout Exercise: u Charts business goals and objectives • The Process Improvement Cycle and Process ControlRecommended Training and/or Experience • Capability AnalysisFundamental knowledge of computational mathematics is o Breakout Exercise: Capability Indices: Bilateralnecessary for understanding the topics discussed. Tolerances o Sampling ProceduresSeminar Materials • Prevention vs. DetectionEach participant will receive a seminar manual and a workbook • Other Types of Control Chartsincluding all team breakout exercises. o Baseline – Random (White Noise) Processes o Breakout Exercise: Probability-based ChartsPlease bring a calculator. o Breakout Exercise: Stoplight Control Charts o Pre-control (Conformance) ChartsSeminar Goals o Breakout Exercise: Zone Charts• Present a hands-on approach to learning the principles and o Breakout Exercise: Short-run Control Charts practices of SPC and process analysis o Breakout Exercise: Charts for Detecting Small• Understand the uses and benefits of control charts and be Changes able to construct and interpret them o Breakout Exercise: Non-normal Charts• Understand the role that SPC plays in the overall control o Breakout Exercise: Multivariate Charts strategy for a process and/or company o Breakout Exercise: Regression Control Charts• Explain optional statistical methods when traditional SPC o Breakout Exercise: Drifting Process Center practices have failed or are inadequate o Breakout Exercise: Residual Charts• Understand the uses and benefits of advanced control charts o Breakout Exercise: Autoregressive Charts and be able to construct and interpret them o Breakout Exercise: Shifting Process Center • Capability AnalysisSeminar Outline o Bilateral Tolerances• Review of Basic Descriptive Statistics o Breakout Exercise: Unilateral Tolerances o Breakout Exercise: Location o Breakout Exercise: Non-normal Processes o Breakout Exercise: Variation o Multivariate Processes o Breakout Exercise: Histogram • Suggested Use of Process Measures• Fundamental of Process Control o Loss Functions o Understanding Process Behavior o Alignment of Process to Customer Requirements o Common and Special Causes • Effective Use and Benefits of Control Charts o Control vs. Capability o Control Limits vs. Specification Limits Driving Worldwide Business Excellence
  11. 11. 325 E. Eisenhower Pkwy. Suite 4 Ann Arbor, MI 48108 To Register Fax: (734) 761-4966 (734) 761-4940 www.omnex.comAerospace Risk Management and Analysis SeriesTeam Leader FacilitationSeminar Content Seminar OutlineThis one-day hands-on seminar is designed to arm facilitators • Facilitation Fundamentalswith the skills necessary to lead their teams. A good facilitator • Essential Meeting Toolsshould be able to understand the various roles of facilitation and o Breakout Exercise: Charter and Team Developmenttheir impact on team performance. This course will help develop • Effective Meetingscompetency in applying facilitative behaviors to prevent and • Interventionsrespond to team member challenges and concerns. The use of o Breakout Exercise: Interventionproblem solving and analytical tools, as well application of the • Conflict Managementfacilitation process across a variety of work settings will also be o Breakout Exercise: Conflict Managementcovered. • Essential Process Tools o Breakout Exercise: Decision Making ExerciseWho Should Attend• Facilitators who are responsible for AQP launch, FMEAs, or problem solving/corrective actionRecommended Training and/or Experience• NoneSeminar MaterialsEach participant will receive a seminar manual and a workbookincluding all team breakout exercises.Seminar Goals• Understand the characteristics of a good facilitator• Learn good facilitation skills• Learn the tools for running an effective meeting Driving Worldwide Business Excellence

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