2. 2
Team Charter
Event Name: Electrical Crab Count
reduction DIVE CH-148
Event Location: Sikorsky
West Palm Beach, FL FAFO
Event Type: DIVE
Event Dates: May 20, 2010 to May
25, 2011
Project Charter
Problem Statement: Electrical Crab Count on Ch-148 program in the cabin
exceeds target of 500. Currently Electrical Cabin Crab Count is at 1189
Objective: To standardize electrical install on CH-148 program and to reduce
electrical Crab Count to less than 500 per Aircraft
3. 3
Business Impact: To ensure electrical crab count is less than 500 in cabin area
to meet scope, schedule and budget of development program needs.
Scope and Boundaries: CH-148 Line.
Executive Sponsor(s): Rob Von Stralendorff (Operations Manager)
Team Members: Anthony Granda (Leader), George Bowman (Implementation
Leader & Co-Leader), Bob Dolberg (T-tool manager), Craig Cunningham (ME),
Bill Callahan (Tech), Syed Ashan (Tech)
Pre-Work Plan / Activities: CH-148 electrical crab Count Breakdown, AOS
reveiw
Benefits / Measures of Success: Upon completion of event will reduce cabin
electrical crab count, show cost savings for man hour reduction and to create
standard work for electrical installation of CH-148 line.
Project Charter (CONTD)
Team Charter
4. 4
Define Investigate
EnsureVerify
CH-148 Shake Crab Reduction
Harness Routing Aids
• LH Rack Template - (Complete)
• ESM Cable Template – (T-tool # 92551-
20903-011T027 created and will be
added to AOS #92551-20903-011)
• Wire Pull-Thru Guide – (Prototype in
place, awaiting ME to cut work order)
Solutions:
- Standard Work
• Released Photo Books – (Engineering – 9/20)
• No more Install per Old rev Inspect per New
• Production AOS Standard Work – (ME – On-Going)
• No more Install per Print – Capture Learnings
- Harness Routing Aids
• LH Rack Template - (Complete)
• ESM Cable Template – (Work Order cut, PO placed
9/9)
• Wire Pull-Thru Guide – (Prototype in place, awaiting ME
Problem – CH-148 Shake Crab count exceeds target of 500
need to improve lead time and lower cost on the CH-148
line. High drivers must be identified and addressed
Team Members:
George Bowman ( Implentation Leader) Bob Dolberg
Anthony Granda (co-lead) Bill Callahan
Gary Clayton Syed Ashan
Root Causes:
Electrical crabs in the Cabin area are the highest driver and
are created through an absence of standard work and an a
lack of routing tools
Owner: George Bowman
11. 11
CH-148 CRAB REDUCTION PLAN
Data Pareto Suggests Cabin Station 6 Electrical Install Focus
- Standard Work
• Released Photo Books – (Engineering – 9/20)
• No more Install per Old rev Inspect per New
• Production AOS Standard Work – (ME – On-Going)
• No more Install per Print – Capture Learnings
- Harness Routing Aids
• LH Rack Template - (Complete)
• ESM Cable Template – (Work Order cut, PO placed 9/9)
• Wire Pull-Thru Guide – (Prototype in place, awaiting ME
to cut work order)
- Training
• DANS Report - Crab Creator is Crab Fixer (On-Going)
12. 12
CH-148 CRAB REDUCTION PLAN
Data Pareto Suggests Cabin Station 6 Electrical Install Focus
- Standard Work
• Released Photo Books – (Engineering – 8/30)
• No more Install per Old rev Inspect per New
• Production AOS Standard Work – (ME – On-Going)
• No more Install per Print – Capture Learnings
13. 13
Kaizen NewspaperKaizen Newspaper
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Kaizen Newspaper
Team Date
% Complete
Electrical Crab reduction CH-148 10/3/2010
Activity Owner Due Date
DANS Report Training Bowman 10/15/10
Crab Count Analysis Granda/ Bowman 10/15/10
Released Photo Books Electrical ENG 10/15/10
Production AOS standard Electrical ENG/ ME 10/15/10
Harness Routing Aids
Dolberg/ Bowman/
Cunningham
10/15/10
L/H Rack Template ENG 10/15/10
Companion Way Step Bowman/ Clayton/ Dolberg 10/15/10
Wire Pull Through Guide Cunningham/ Bowman 10/15/10
Add Template to AOS ENG/ Bowman 10/15/10
Granda/Bowman 10/15/10Event Outbreif
14. 14
Summary of Event
Pre-Event
No Standard T-tooling for
electrical install
No Photo Books for electrical
installation
Exceeded Crab Count of 500
crab count target
No standard work for assembly
order
Employees not using DANS
report to fix there own
discrepancy
Post Event
Created four T-tool
templates to be used during
installation
Photo books released
55% reduction in crab count
from A/C 801 to 803
Standard work added to
assembly order
DANS report used daily to
fix owners crabs
