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Let's look at some statistics
Quality and Safety In The Aerospace Industry
Top Ten Human Fears
The Book of Lists reports the Top Ten Human Fears as:
Speaking before a Group
Insects and bugs
Six Sigma Defects Percentage = 0.0003%
The odds of dying in a plane crash are equal to quadruplets being born -- but not just any quadruplets, naturally conceived quadruplets. And not just any naturally conceived quadruplets, but naturally conceived identical quadruplets.
Even if you have an accident...
National Transportation Safety Board www.ntsb.gov
How is this achieved?
Development of an Aerospace Industry Standard
There was a proliferation of standards used to define quality system requirements.
These slightly differing requirements caused suppliers to be constantly audited to different criteria for the same basic top level standard.
ISO 9001:1987 was accepted as the commercial equivalent quality system.
ISO 9001 neither fulfills all the needs of the industry nor covers the regulatory requirements.
Product and service quality becomes equally important to price, delivery and performance.
Uniform supplier requirements.
More consistent verification methods and fewer verification audits.
Why is an aerospace standard necessary?
Aerospace industry customers expect and demand that quality systems employed by manufacturers assure that products are safe and reliable.
Supplier community is an extension of its own processes and procedures and therefore must be tightly controlled to reduce variation.
Any variations from the specified requirements can build in latent defects that cannot be tolerated in service.
Industry Specific Requirements
AS9000 added 31 new requirements in the areas of:
• Quality system and planning.
• Document and data control.
• Process control.
• Control of nonconforming material.
Industry Specific Requirements
Some examples of the additions to AS9100 include:
• Reliability, maintainability and safety (in design).
• Documentation of design verification and validation.
• Design verification and validation testing.
• Production documentation.
• Control of production process changes.
AS9100 provides the essentials of an effective traceability program.
Lean Six Sigma in Aerospace
Model: AH-64D Apache Longbow Helicopter
Problem: They experienced a heavy downfall in the overall
operational performance and high cycle time.
Solution: They decided to use Lean concepts
and use statistical tools (Six Sigma).
Results: Internal defects reduction by 58% and the cost associated with it by 61%.
Since 1999 they have a 100% on-time delivery rate and have reduce the number of hours required to build an aircraft by 48%.
Boeing’s success story represents a visible evidence of the benefits that can be expected from the implementation
of lean initiatives in an assembly unit.
High level of traceability on all materials, products and processes.