CARGO DOOR’S DEPRESSOR SEAL

Depressor Seal

Damaged Depressor Seal

DAMAGED DEPRESSOR SEAL

Damaged Depressor Seal

Background

Six Sigma is data – driven business process optimization methodology which aims to reduce variation, elimination non-value added activities and significantly improve process quality.

How does it work ?

Define What is important to the organization ?8-Blocker, Fishbone, CTQ, Process Flow

MeasureHow much can the existing process improve ?

Capability analysis

AnalyzeWhat are the critical factors ?

Hypothesis testing, Regression

ImproveHow to reduce variation, time, cost, defects ?

DOE, Simulation

ControlHow to maintain improvement ?

SPC

(DMAIC)

Y

Xs

Y

Y

YX

Y = f(X)

DEFINE & MEASURE

Project DefinitionProject Definition

Objective Reduce depressor seal damage (DSD) by more than

50%Defect Definition FWD & AFT Cargo Doors Depressor seal damage

(DSD)Benefits Reduce maintenance repair cost Reduce flight delays Minimize operation interruptionsConstraints Non-availability of detail data regarding the damage Non-availability of maintenance repair cost

Team Members Saad Nujaim Adel Sait Mohammad Fayoumi Khaild al ghomari

Master Black Belt Saad NujaimProcess Sponsor GS, MD- GS Strategic Unit

Team MembersTeam Members

Hardness of depressor seal

Guiders set up of Hi-Loaderweather

Condition of container

Temperature

.

Training DPU

Supervision

Materials Environment Methods

DepressorSeal

Damage (DSD)

Manpower Machine

Position Hi-Loaders

Fatigue

License

Light

Measurements

Shipment Size

A/C Door size

Rush Operation

Using of stoppers inCargo compartment

A/F Protection Guiders

Condition of stoppers in a/c Cargo comprtment

Different natis

Qualification

Cause and EffectCause and Effect

Check for External &

Internal Dep. Seal Damage

Offload Containers from CGO

compartment to H/L

Offload Containers from H/L to Transporter

Wait for Loading

Load Containers from transporter to

H/L

Load Containers from H/L to CGO

Comartment Stow Safety Rails Close CGO door

Hi-loader positioned properlyOffloadLoad

Existing Loading/ Offloading Existing Loading/ Offloading ProcessProcess

Descriptive Statistics for all DSDDescriptive Statistics for all DSD (2001 – 1st Qtr of 2008)

Process Capability

Run Chart (2001 – 1st Qtr of 2008)

Upper Specification Limit (LSL) = 2 dsd/qrt N (LT) = 28

N (ST) = 6

Z (ST) = [ USL - Avg DSD (ST) ] STDEV(ST) Z (LT) = [ USL - Avg DSD (LT) ] STDEV(LT)

Avg DSD (ST) = 1.17 Avg DSD (LT) = 3.17 STDEV (ST) = 0.98 STDEV (LT) = 2.59

** Z (ST) = [ 2 – 1.17 ] 0.98 = 0.85 ** Z (LT) = [ 2 – 3.71] 2.59 = - 0.66

Z (SHIFT) = Z(ST) – Z(LT) = 0.85 + 0.66 = 1.51

Calculation of Z-ST & Z-LT

Zst =0.85Zlt =- 0.66Zshift = Zst - Zlt = 0.85+0.66 =1.51

Control is fineImpove factoryor technology

World class

Need better controlTechnology is fine

Poor controlPoor technology

3.0

1.5

0.0

Con

trol

(Zsh

ift)

0.0 3.0 6.0 Technology

(Zst)

Where we are now

Goal

Control Vs Technology

ANALYSIS

86 % of DSD is related to B-747 ,while 14 % is related to other fleet type.

Depressor Seal Damage Based on A/C Type

53% OF DSD took place in Jeddah and Riyadh stations

Depressor Seal Damage by Station

Variables R-value Interpretations

(No of DSD) and ( No of Revenue Departure For All Fleet) 0.277 Weak relationship

(No of DSD) and ( No of Revenue Departure Form JED&RUH Stations) 0.844 Strong

relationship

(No of DSD) and ( No of Revenue Departure For B-747) 0.698 Good relationship

Determination of the existence relationship between the number of DSD and some other variables is measured by the value of the correlation coefficient “R”. The Correlation Analysis and its “R” value is shown in the table below:

Based on the above table , it is clear that the total number of DSD is linearly correlated to JED & RUH operation and B-747 fleet.

Note: Data Source :ARP-TSV

Relationship Between DSD And Other Variables

One of the major causes of DSD incident is loading and off loading operation on the A/C. B-747 A/C and B-777 A/C are very identical in terms of :1- Loading / off-loading operation2- Shipment types and size (ULD’S & Pallets)3- Equipment used for loading/off-loading operation.

Factor B-747 B-777 Interpretations

Hardness of DS MAT.7075-T6.Thichness0.05

MAT.2024-T42.Thichness0.063

Not significat,T6 is harder

Door size FW& AFT (264 cm by 168 cm)

FW (269 cm by 170 cm). AFT (A-J 177.8 Cm by 170.2//

OTHERS 269.2 Cm by 170Cm)

B-777 is bigger by 5 cm X 2 cm except for A-J

AFT door

Protection guide fitted in A/C Not Available Available

Help offloading Operation

Drive Power Unit

PDV2101(1,5,3,6).UNT2218(0).DRV2100(0,1,1,2).DV2300(3,0,4,3)

KUNT251(3,5,3,2).KUNT252(0,0,0,1).

KUNT250(0)

Both reliable, not a sensitive

cause*

Analysis of DSD Causes

* Components Removals for years 2003,2004,2005,2006,2007 data Source :ARP-TSV

Question :- Does the operation volume of A/C B-747 and A/C B777 is significantly Different ?Test of Hypothesis is used to compare the mean of B-747 NO. revenue dept and the mean of B-777 NO. revenue dept.Analysis of VarianceSource DF SS MS F PFactor 1 47383681 47383681 60.17 0.000Error 54 42525739 787514Total 55 89909420 Individual 95% CIs For Mean Based on Pooled StDevLevel N Mean StDev -------+---------+---------+---------B-747ALL 28 4086.8 851.0 (---*----) B-777 28 5926.5 922.4 (----*---) -------+---------+---------+---------Pooled St Dev = 887.4 4200 4900 5600

Answer : YesBecause the P-value = 0.000 , < 0.05 , we conclude that there is a statisticaldifference between the two means and the mean of B-777 NO. revenue dep. is higher.

Operation Volume Analysis

Following observations were made during the inspections performed in Jeddah and Dhaka (may2008) stations:No adjustment for Hi-loader’s protection guiders was made during loading and off-loading operation.

Analysis of Loading/offloading and Hi-loader Operation

Analysis of Loading/offloading and Hi-loader Operation

The operator stands on the right side of A/C door.

A lot of damaged ULDs were used.

Analysis of Loading/offloading and Hi-loader Operation

Some of heavy ULDs were handled by the operator alone.

Inadequate supervision

33 % OF DSD was located on the left side of A/C CGO doors, while 14 % of DSD was On right side of A/C CGO doors.

Depressor Seal Damage By Door Location

The analysis revealed that:1- Hi-loader’s protection guiderssetting is considered as

the major cause of DSD.

2- Damaged and heavy ULDs are another cause of DSD in the absence of proper setting of Hi-loader’s protection guiders and the operator stand alone on the right side of A/C cargo door.

Conclusion

Conclusion

3- Cargo door of B-777 has less DSD due to :

A- Bigger door size in width.

B- It has protection guide fitted in A/C’s cargo door (help in offloading).

B-777 B-747

RECOMMENDATIONS

1. Hi-loader protection guiders must be adjusted within A/C Cargo door width.

2. Damaged ULD’S should not to be used.

3. ULD’S weight must be controlled to avoid loading of heavy ULD’S.

RECOMMENDATIONS4. Assistance must be requested by the operator in case of facing stuck/heavy ULD’s.

5. Damaged ULD’s should not be loaded side door.

6. Any failure of PDU should be reported by the operator.

IMPROVE & CONTROL

Check for External &

Internal Dep. Seal Damage

Offload Containers from CGO

compartment to H/L

Offload Containers from

H/L to Transporter

Wait for Loading

Load Containers from transporter

to H/L

Load Containers from H/L to CGO

Comartment Stow Safety Rails Close CGO door

heavy container

stuck/damaged?

Hi-loader positioned properly

NO

YES

Call for assistance

/fix

Heavy containers

stuck/damaged?

NO

YES 1)Call for assistance/fix2) don’t place on door

sides

OffloadLoad

Adjust the protection

guiders

IMPROVED Loading/ Offloading ProcessLoading/ Offloading Process

Depressor Seal damaged Trend

Process Fixes & Control

Causes of Variation

- The Adjustment of Hi-loader’s protection guiders was not performed

-A lot of ULD’S were damaged.

- Inadequate Supervision.

Process Fix -Review & study the processes of loading and offloading.

-Update GSPM to include the recommendations.

-To enhance safety awareness by explaining correct practices to the concerned staff.

- GS established licensing & training programs.

Control System

- Monitor the processes of loading and offloading.

- Perform the random inspection.

- Monitor DSD trend.

Project Closure

Financial Eliminate the maintenance repair cost Eliminate any related cost to operation interruption and flight delays

Operation Minimize operation interruption Minimize unexpected flight delays Improve A/C safety.

Implementation of project recommendations will yield the following :-