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© Vibro-Meter Confidential.
© Vibro-Meter Confidential.
GP7200 Project
© Vibro-Meter Confidential.
GP7200 Project
© Vibro-Meter Confidential.
GP7200 Program OverviewGP7200 Program Overview• Definition of the project Team :
– GP7200 MAV Team :• Chris Tose : PM• Andy Watt : SyE• Mark Twain : SwE• Jim Phillips / Leo Madden : HwE
– GP7200 VMSA Team :• Markus Pfaffendorf : PM• Claude Vicidomini : TL & SyE• Fabien Hue : HwE• Christophe Blouët : SwE• Béat Mauron : TSE
PM : Project ManagerTL : Team LeaderSyE : System EngineerHwE : Hardware EngineerSwE : Software EngineerTSE : Test System Engineer
© Vibro-Meter Confidential.
VMSA Team Organisation
Team Leader
C. Vicidomini
Engineering
Chief Engineer
J.Kuenlin
Systems Engineering
C.Vicidomini
Quality Assurance
P.McCann VMSA
Manufacturing
J. Rossier
Purchasing
O. Laurenza
Component Engineering
A. Mozerski
Customer Support
C. Milan
Commercial Manager
VMSA
C.Tose- VMSA/MAV UK
Vibro-Meter SATeam
M.Pfaffendorf
Root Cause/ Industrialization
Y. Conti
© Vibro-Meter Confidential.
Mav UK – GP7200 Hardware and Software
Engineering Manager
Richard Johnson
Quality Assurance
Paul Brooker
Software Engineering
Mark Blay
Mechanical Engineering
Kenny Deans
Configuration / Data Management
Kenny Deans
HardwareEngineering
Leo MaddenJim Phillips
VSMProjectLead
C.Tose
System Engineer
Andrew Watt
© Vibro-Meter Confidential.
Level 1 : Transfer Plan
Jan Feb
2007 2008Mar Apr May Jun Jul Jan Feb Mar Apr May Jun JulAug Sep Oct Nov Dec
P04 Manufacture
P04 Qual TestingP05 RDGT
Engine Cert Software Software Support/Problem Reports
P04 ATP
Survey Phase
PIL Engine Cert
STS Qual
AFDX SW
Qual Reports
SW Update
SW Cert Docs SW Cert Docs
Software Support/Problem Reports
SW Update SW Update SW Update
HW Re-spin (P05) P05 Qual Testing
PM
SOI-1 Review
Final SW Cert Reports
HALT
© Vibro-Meter Confidential.
Achievements This Period Planned Activities/Problems Solved
Escalation/Help Required Obstacles/New Problems
1. AFDX software: RI, SYSGO and VMSA integration session in RI week of 15th Jan
2. PIL Rig software delivery to GE3. Completion of DAT Vibe endurance tests4. Completion of DAT Shock test5. Integration of HSESB into ATP
1. Intermittent CAN failure during Radial vibration endurance tests. This has created a 3 day DAT schedule slip
1. ARINC-664V AIM board integrated into VMSA GTS
2. ATP software update completed including HSESB and enhanced BIT testing
3. DAT Vibration endurance tests completed 2 axis with no failure
4. Breakthrough in AFDX SYSGO/Meggitt integration problems
1. Greenhills certification schedule? This depends on Greenhills responsiveness to Meggitt`s request for a pull.
GENx Status Report Progress
Problems
© Vibro-Meter Confidential.
© Vibro-Meter Confidential.
P03 Delivery status
SER Status DeliveryVBR001AA At GE CompleteVBR003AA At GE CompleteVBR004AA At GE CompleteVBR005AA At GE CompleteVBR006AA At GE CompleteVBR007AA Assembly Complete 19th Jan 07VBR008AA Assembly Complete 26th Jan 07VBR009AA Assembly CompleteVBR010AA In BuildVBR011AA In BuildVBR013AA In BuildVBR014AA Build planned 15th JanVBR015AA Build planned 15th JanVBR016AA Build planned 15th JanVBR017AA Build planned 15th JanVBR018AA Build planned 15th JanVBR019AA Build planned 15th Jan
Room Temp ATP completeRoom Temp ATP complete
CommentsP03AB unit to be returned for upgrade to P03AA
Room Temp ATP completeAwaiting VSM and CPM Modules (due 20th Jan 07)Awaiting VSM and CPM Modules (due 20th Jan 07)Awaiting VSM and CPM Modules (due 20th Jan 07)
© Vibro-Meter Confidential.
P03 Delivery slippage and current status
Original shipment date of mid Sep 06 slipped to mid Nov 06 Risks were identified relating to Software/Test system/hardware integration activities but
these were underestimated Delay and delivery blockage caused by Software migration/integration onto 5554
platform Delays not due to lack of material All production test activities transferred from NH to VMSA in Sep 06 ESS screening procedure and equipment took longer to implement than planned
Current status Flow of material and finished parts from manufacturing is on plan 3 units complete and 9 further units in the pipeline (materials confirmed) Bottleneck and risk area is ESS (Temp and Vibe)
• P03 units are being subjected to temperature testing beyond the current design capability. This has/will continue to cause yield problems
• Only 1 unit can pass through ESS at a time (equipment constraints)• ESS system to pass 5 units at a time is planned for Q3/2007• Current weekly shipping capacity is 1 per week (ESS) and assuming no ESS failures
© Vibro-Meter Confidential.
AFDX – Steering Plan
Aug NovOctSep Dec Jan Feb Mar Apr2006 2007
JunMay
EmbVUE
SYSGOKick-off
AFDX stackwithout EDE
Time Manager Final Cert package
SYSGOofficiallyselected
Jul
deliveries to GE
SepAug Oct
Phase 3Formal testing & Certification
Phase 2Develop Boeing extensions
Phase 1Porting A664 stack
System integration
updatewith EDE Time
Manager
AFDX Stack integrationon CPM
Target HWdelivered to Sysgo
Acceptance tests
SW
up
date
BasicA664 AFDX
stack
AFDX Stack integrationfor ATP and DAT tests
As a minimum, basic A664
transmission
SW
up
date
ICD / API issues
Full EDE (see Note2)
Full BIT (see Note3)
SW
up
date
Draft Cert package
© Vibro-Meter Confidential.
DAT Status
DAT testing as per VMSA document STS-1997-01
Test STS-1997 Ref Test Schedule CommentPin Injection Transient Susceptibility Para 5.6 Test Complete PASSPower Input Para 5.7 Test Complete PASSExplosion Proofness Para 5.8 Test Complete PASS
Vibration Para 5.2 23 Dec to 11th Jan 07
Unit has completed Axial and Tangential endurance tests. CAN bus failure after 3 hours in radial testing - suspect connector intermittent. This is in investigation
Shock Para 5.3 15th Jan 07 Slipped due to radial vibration problemThermal Cycling Para 5.4 17th Jan to 26th Jan
Humidity Para 5.5 29th Jan to 9 Feb 072nd unit has been sourced to pull this forward
Identified Risk: Planned dates exclude Failure investigation and root cause
© Vibro-Meter Confidential.
Qualification Tests ScheduleTest Test Location Proposed Test Date
Test Unit Number
5. VibrationVibro-Meter SA, Fribourg Switzerland
26th Mar 07 to 10th Apr 07 1
6. ImpactVibro-Meter SA, Fribourg Switzerland
12th Apr 07 to 13th Apr 07 1
8. Sand and Dust
RUAGAllmendstrasse 86CH 3602 ThunSwitzerland
23rd Apr 07 to 24th Apr 07 2
10. Salt SprayVibro-Meter SA, Fribourg Switzerland
26th Apr 07 to 1st May 07 2
15. Thermal CycleVibro-Meter SA, Fribourg Switzerland
12th Mar 07 to 16th Mar 07 1
16. Explosion ProofnessCentre d’Essais des PropulseursOrsay, France
3rd May 07 to 4th May 07
3 (Chassis Only)To be
rescheduled to April 07
17. HumidityVibro-Meter SA, Fribourg Switzerland
16th Apr 07 to 2nd May 07 1
18. WaterproofnessVibro-Meter SA, Fribourg Switzerland
19th Mar 07 to 21st Mar 07 1
19. Pin InjectionEmitech, Montigny le Bretonneux, France
17th Apr 07 to 18th Apr 07 2
20. Power InputVibro-Meter SA, Fribourg Switzerland
11th Apr 07 to 13th Apr 07 2
© Vibro-Meter Confidential.
Software Certification Status
Preliminary set of plans provided to GE in Sep 06
Follow-up SOI-1 review to be held at VMI, NH mid Feb 07
SYSGO plans provided and are in VMSA review loop. These will be submitted prior to the SOI-1 review
GreenHills plans received 2 Jan 07
Certification liaison role will be handled by Chris Tose
Identified Software certification schedule risks Current SYSGO plan for final certification documents is end June 2007
• Negotiation started with SYSGO to bring this date forward Current GreenHills plan for final certification documents is Sep 2007
• This will need escalation within Meggitt perhaps with GE support
© Vibro-Meter Confidential.
SDRL Status
Deliverable dates to be jointly reviewed to ensure compatibility with GE program
Microsoft Excel Worksheet
© Vibro-Meter Confidential.
Status of open DDR ChitsChit Title Status Planned
for
#1 Heaters Heater circuits will be depopulated. Components will be up screened. CM235 has been raised.
P04
#2 Connector Chassis Interface
New Design proposed which gives direct metal to metal contact. Initial bonding measurements of new design are not in spec.Alternative design approaches are being reviewed.
Assembly drawings provided to GE for review meeting.
P05
#3 Chassis corrosion Protection
ROM submitted for Alodine 1A chassis with Painted Feet. CM236 has been raised
P04
#4 Flex Chaffing
Initial proposed redesign of flexes rejected during internal design review. Alternative assembly strategy with modified flexes being assessed.
P05
© Vibro-Meter Confidential.
Product Development Strategy Proposed (P03 to P05 Evolution)
P03 P04 P05 P06
Jan 07
DAT Std
Beg Mar 07
Cert Std
Q3 07
1st Flight Std
???
EIS Std
EDPPILDAT(FTB?)
CertHalt1St Flight?
1st FlightRDGT
EIS
Drain holes
PSU Updates
Up-screened Parts
Surface Finish
Bond strap (Nickel)
Flexes
Connector Bonding
VSM Mods (VRT / Strain)
DAT Updates?
Bigger Box & CPM
Cast Box
RGDT
HALT
May need to combine P05 & P06 into one configuration, depending on availability of System EMI test
© Vibro-Meter Confidential.
Larger Box and CPM
Why a larger box? The existing P03/P04 chassis provides ZERO growth contingency on the CPM module
• We have no mitigation if future changes are required due to DAT, CERT, HALT problems, Component obsolesence or functional enhancements
Increase in CPM real estate will allow implementation of enhanced automatic testing Improvement of Flexes is restricted due to insufficient space at front/rear backplanes
Draft outline drawing supplied separatley60mm (2.36 inch) extension in chassis length allocated as follows
30mm (1.18 inch) extension to CPM module 30mm (1.18inch) to improve flex routing/standoffs Extension of VSM not envisaged but further discussion required
Estimated weight increase of 700g (1.54lbs)Lead time of extruded box (proto) 6 weeksLead time for Casted box 4 monthsLead time of CPM approx 6 months
© Vibro-Meter Confidential.
Post P04 (Cert Baseline) Change/Impact/Assessment
Change Impact (S/M/H) Re-Test GE Impact
Flexes Vibe None
Electrical Bonding Bonding/Vibe None
VSM (VRT / Strain) EMI / Thermal
Pin Injection
EMI / Lightning?
Bigger Box Vibe / Thermal
Shock/Impact?
FBO?
Cast Box None (Analysis)
Shock/Impact?
Salt spray?
None
Bigger CPM Vibe / Thermal / EMI
EMI
Bigger VSM? Vibe / Thermal / EMI
© Vibro-Meter Confidential.
P05 Certification Test Matrix
Certification strategy for P05 will be jointly worked with GE using the attached 25 point matrix
Microsoft Excel Worksheet
© Vibro-Meter Confidential.
Production Yield
Based on P03AA data Nov 06 to dateBatch #1 – 6 Units 4 units passed full ESS screening and have been delivered to GE 1 unit failed at 75Degrees C 1 unit supplied on loan (no ESS) Yield of 80%
Batch #2 – 4 units 4 units from 4 passed room temp ATP at first pass Units now due into ESS
Batch #3 Scheduled to start 15th Jan 07
© Vibro-Meter Confidential.
Ball Grid Array soldering process
A BGA repair station is already set up within VMSA manufacturing.
The GENx EMU is the fifth product using Ball Grid arrays
Non GENx products are already being repaired and reworked
The rework process is still to be formalised