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    The document describes a quality circle project to improve the fabrication process of sheet metal components for light combat aircraft. The quality circle identified issues with high rejection rates and mismatches during assembly. Through data collection and root cause analysis, they determined the key causes were related to the hand rolling and wheeling operations. The quality circle developed solutions including converting the checking block to a stretch forming tool and adding anneal and solutionizing processes. Several trials were successful in achieving the desired contour with zero defects. The new process reduced production hours by 48 hours per aircraft, saving an estimated Rs. 3.88 lakhs annually.

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    Stream A - 1 - India

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    21 views5 pages
    The document describes a quality circle project to improve the fabrication process of sheet metal components for light combat aircraft. The quality circle identified issues with high rejection rates and mismatches during assembly. Through data collection and root cause analysis, they determined the key causes were related to the hand rolling and wheeling operations. The quality circle developed solutions including converting the checking block to a stretch forming tool and adding anneal and solutionizing processes. Several trials were successful in achieving the desired contour with zero defects. The new process reduced production hours by 48 hours per aircraft, saving an estimated Rs. 3.88 lakhs annually.

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    The document describes a quality circle project to improve the fabrication process of sheet metal components for light combat aircraft. The quality circle identified issues with high rejection rates and mismatches during assembly. Through data collection and root cause analysis, they determined the key causes were related to the hand rolling and wheeling operations. The quality circle developed solutions including converting the checking block to a stretch forming tool and adding anneal and solutionizing processes. Several trials were successful in achieving the desired contour with zero defects. The new process reduced production hours by 48 hours per aircraft, saving an estimated Rs. 3.88 lakhs annually.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    21 views5 pages

    Stream A - 1 - India

    Uploaded by

    ririn
    The document describes a quality circle project to improve the fabrication process of sheet metal components for light combat aircraft. The quality circle identified issues with high rejection rates and mismatches during assembly. Through data collection and root cause analysis, they determined the key causes were related to the hand rolling and wheeling operations. The quality circle developed solutions including converting the checking block to a stretch forming tool and adding anneal and solutionizing processes. Several trials were successful in achieving the desired contour with zero defects. The new process reduced production hours by 48 hours per aircraft, saving an estimated Rs. 3.88 lakhs annually.

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    of 5

    Title: IMPROVING THE FABRICATION METHOD OF SHEET

    METAL COMPONENT FOR LIGHT COMBAT AIRCRAFT

    DYNAMIC QUALITY CIRCLE

    ARCHITECTS OF DYNAMIC

    FROM RIGHT: A.Shankarnarayan, Master Technician Leader


    C.Srikanth Technician Dy.Leader
    E.Sridhar Technician Member
    A.Mugundan Technician Member
    A.Syed Sadiq Technician Member
    T.H.Raghuraja Manager Facilitator

    DYNAMIC QUALITY CIRCLE


    Sheet Metal Department
    Aircraft Division
    Hindustan Aeronautics Limited
    Bangalore, Pin: 560 017
    Karnataka, India Telephone: 91-80-25225201 Ext 453

    INTRODUCTION:
    DYNAMIC Quality Circle was started in March 2001, to involve personnel in
    Continuous improvement on job related activities etc.

    Circle Name: DYNAMIC QC


    Our QC Circle consists of 6 members
    Average age of our QC Circle members is 32. (Youngest: 24 / Oldest: 41)
    QC Circle meeting takes place after working hours ; during working hours
    QC Circle meeting is usually held 4 time(s) per month. Each takes 1 Hour 30 Minutes.
    Our QC Circle has already completed 28 subjects before this case report.
    Visual aids to be used in this presentation: ; LCD projector

    1
    PROJECT SELECTION PARAMETERS
    Long cycle time.
    Complication in fabrication.
    Assembly held up.
    Quality Improvement
    Customer Satisfaction.

    PROJECT SCHEDULE
    Project plan or schedule is the first step in quality improvement and zero
    Defect in the component of the project. Accordingly, the circle prepared
    the following Milestone Chart, delegating the responsibilities to each member.

    PROBLEM DEFINITION
    PROJECT : LIGHT COMBAT AIRCRAFT.
    PART # : O1L.1E,1180.001/002 AND O1L.1D.1090.002.100/200.
    PART NAME : ENGINE BOTTOM AND TOP CONE.
    SPECIFICATION : L164 T3 2MM THICK AL ALLOY.

    High rejection rate due to mismatching of skin on engine top and bottom cone. Contour of 15mm
    Gap found on assembly
    WHY, WHY, WHY ANALYSIS

    DATA COLLECTION
    Data collection was done primarily through
    Structured questionnaire and interviews with
    Operators and secondarily from database available
    in the assembly and inspection department
    The data collected is as follows.
    It is clear from the table that
    .

    2
    High rejection
    Repeated dressing on assembly.
    Mismatching of the contour on assembly.

    Rejection Analysis
    A/C Work order Qty Accp Rej
    PV1 81424002544 2each 0 2each
    PV2 91051489025 2each 0 2each
    PV3 91051489128 2each 0 2each
    LSP1 91051489264 2each 0 2each
    LSP2 91051489264 2each 0 2each

    FINDING OUT ROOT CAUSE DEVELOPING SOLUTIONS


    Same reasons listed in causes represent in Pareto
    Diagram under VITAL FEW TRIVAIL MANY Converting checking block to
    Concept stretch forming tool.
    Trimming tool has to be
    developed.
    Changing hand roll and wheeling
    opn to ERCO stretch form
    operation.
    Dimension of material should be
    increased for stretch forming.
    Add anneal and solutionise
    process.

    3
    MODIFIED TOOL: REGULAR IMPLEMENTATION

    Tool design modified and approved


    by tooling dept.
    Erco press forming process amended
    by planning dept.
    Process added by form of anneal and
    solutionise.
    Reduced standard man hours were
    amended by MSD
    TRIMMING TOOL: Trimming tool made for final
    trimming.

    Foreseeing probable resistance

    Co-ordination from tool room


    for converting hand rolling to
    stretch form tool.
    Changing. Process with the help
    of planning dept.
    Convincing Erco stretch
    forming operator for trails.
    Requesting raw material store
    for availability of material for
    TRAIL IMPLEMENTATION
    trails.
    TRAIL 1: 1each was carried on T3
    condition (HARD) component got TANGIBLE BENEFITS:
    cracked.
    TRAIL 2:1each was carried in soft Existing hours per aircraft is 80 hrs.
    material by giving 21kg/cm2 contour not Implemented new process smh is
    achieved. 32 hrs.
    Total hrs saved per aircraft is
    TRAIL 3: 1 each was carried by giving
    48 hrs.
    required pressure of 30kg/cm2 contour
    Amount saved per aircraft is
    was achieved.
    Rs19, 440.
    TRAIL 3: 5each was carried on w/o
    Saved for 4 aircraft is Rs77, 760.
    9105148951 and was offered for
    inspection and got confirmed quality. Expected saving for 20 aircraft is
    Rs3, 88,880.

    4
    CONCLUSION
    Suggestion made by our QC members was successfully implemented and observed the
    Rejection rate was reduced to zero defect and saved SMH of 48 Hrs per aircraft.
    We do not believe that our responsibility is over with this achievement. We emphasize the
    Need for maintenance and improvement. Quality improvement is just like never
    Ending waveseach wave adds force to the next wave.

    Dynamic QC has provided a viable platform for maintaining quality, improved group
    Morale and better communication skills.

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