PROCESS IMPROVEMENTS IN AEROSPACE MANUFACTURING INDUSTRY USING VALUE STREAM MAPPING AND PROCESS CERTIFICATION

Abstract

The aerospace and defense industry is a major source of innovation and technological advancements. It plays a critical role in national defense, enables safe and efficient air travel, increases communication and the dissemination of knowledge, and contributes to increased consumerism and the globalization of supply chains. Aerospace Manufacturers face several manufacturing process challenges, like any other manufacturing or process Industry. Order and delivery cycles for transport aircraft since 1958 are fairly regular, between 10 and 12 years long, but are always out of phase. During periods when the airline industry reaps profits, orders for new transport aircraft are placed. However, due to the length of time required for manufacturing, by the time the planes are ready, the airline companies are often facing a low market and therefore withdraw their orders. The ability of aerospace manufacturers to shorten the manufacturing and design build time is a critical challenge. Manufacturing optimization goals often include an evaluation of the existing process for its value add components and process capability to ensure predictable output. Value stream (VSM) and process certification strategies are extensively utilized in aerospace manufacturing industry to enhance the effectiveness and capability of the manufacturing processes. Value Steam Mapping is a special type of process flow chart that uses symbols as “the language of Lean” to depict and improve the flow of inventory and information. VSM provides optimum value to the customer through a complete value creation process with minimum waste in:  Design (concept to customer)  Build (order to delivery)  Sustain (in-use through life cycle to service)

vi | P a g e Value stream mapping is a tool that allows to see waste, and plan to eliminate it. It is different than the localized process improvements in that it ties the process elements together from end to end (cradle to grave) and determines how the value is delivered to customers with the identification of waste or liabilities within the process elements. Liabilities are those activities which are non-value added activities for which the customer doesn’t pay for. “VALUE” is defined as a capability provided to a customer and as what the customer is buying and as defined by customer.  of the highest quality  at the right time  at an appropriate price Applications of VSM are also presented by a practical implementation on an assembly process and reduction in Lead time, cycle time, processing time, and work in process inventory and manpower requirement at individual stations in an assembly process of any business process. Variation, the law of nature, while it is true, is bad for Quality. It affects equally both manufacturing and administrative processes. In a manufacturing set up variation would mean unpredictable processes leading to waste generation and hence it is treated as an enemy. Variation in a process is defined as a change or slight difference in condition, amount, or level, typically within certain limits. The variation in the quality of product in any manufacturing process are due to two reasons, Chance causes and Assignable causes. A process with only chance causes is said to be in a state of statistical control. This means, chance causes results in only minor variation in the process whereas assignable causes results in major variation in a process. Therefore, the main aim of process certification activity is to identify and rectify the assignable causes as soon as possible for an acceptable quality and control the effects of chance causes to a bear minimum.

vii | P a g e Process Certification is the process variability reduction strategy utilized within Aerospace Manufacturing OEM’s and their supplier bases. It is the application of statistical thinking to critical measures of a process’s performance so that rational, data-driven decisions are made to improve and manage the process. It is a tool that helps to optimize the efficiency, effectiveness and quality of processes by reducing variation in products and services. The objective of this project is to evaluate aerospace manufacturing process for effectiveness and process certification using various tools of VSM & Process certification, with following quantifiable measures.  Reduction in Lead time  Reduction in Cycle time  Reduction in manpower Requirement  Improvements in Process Capability