Measurable Six-Sigma and Quality Performance Improvement ...fm.sap.com/pdf/8182/09_Poliquin_Cadotte.pdf · Measurable Six-Sigma and Quality Performance Improvement with ... certification’s

P&WC Proprietary Information

Measurable Six-Sigma and Quality Performance Improvement with SAP QM and SAP xMIIAdaptive Manufacturing Summit

September 28th, 2006, Denver, CO

C. PoliquinBusiness Development Manager – Pratt & Whitney Canada

R. CadottePrincipal Business Consultant – Pratt & Whitney Canada


Solution Implementation and Benefits

Lessons Learned and Next Steps

Company Background and Challenges

Solutions Considered and Selected

SAP AG 2006, Measurable Performance Improvements / R. Cadotte & C. Poliquin /


Commercial Engines

P&W Aftermarket Services

Military Engines

Space Propulsion

P&W Power Systems

UNITED TECHNOLOGIES CORPORATION (42.7 Billion$)

Pratt & Whitney Canada has a world mandate to design, develop, manufacture, market and support turbofan, turboprop and turboshaftengines in a wide range of power ratings to meet the diverse needs of the marketplace - regional, business, general aviation, utility and military aircraft, and helicopters, as well as turbines for auxiliary power units and industrial applications



Company Background: Product

Turboprops

Turboshafts

Turbofans

Auxiliary Power Units (APU)

Industrial applications

Beech King Air C90

Bell 412

Citation Bravo



Worldwide Facilities



Customers



Business Opportunities

Competitive landscape

� Significant increase in production volume with General Aviation

� Need to transition to a lean production flow line

– the quality issues across the supply chain must be minimized to deliver

quality parts on-time



Manufacturing Issues before deploying SAP xMII

� No central system to gather SPC data

� No real-time data processing (15 minutes to days)

� Software maintenance nightmare (in house developed)

� No integration with the ERP system (SAP)

� Difficulty in extracting data for six sigma analysis. So, not getting full

benefits from:

– Lean initiatives

– Rework reduction

– Repair reduction

– Reduction in non-conformity (QN)



Challenges for the project

� For Engineering to identify all Engine Models Critical to Quality Parts (CTQ) and associated Key Part Characteristics (KPC) to be placedunder process control / certification

� For Manufacturing to update the Manufacturing Operation Sheet and ROUTINGS to include the KPC and ensure that they are monitored and controlled

� For Suppliers the KPCd & KPCm are displayed in the supplier portal via the Inspection Plan

� To get involvement from all organizations (Change management)

� To train more than 7000 people (Cultural change) and involve over 200 suppliers

� To put in place a user friendly IT system in support of data gathering from the shop floor operators and suppliers

� To transfer data in real-time from various model of Computer Measurement Machines (CMM) to SAP



The challenge: get data to decisions

DATA

Exploration,

transformation &

analysis

Without data,

there is no hope.

INFORMATION

KNOWLEDGE

DECISIONS / ACTION

Comprehension &

extrapolation

Investigation &

interpretation

Data rich,

information poor.

A good decision, made

in the absence of

knowledge, is merely a

lucky one.

Knowledge inspires

confidence.

Ce

rt

Gets

Yo

uT

he

re



SAP xMII

DATA

INFORMATION

KNOWLEDGE

DECISIONS / ACTION

IT solution to get data to decisions

Planner dashboard

Supplier dashboard

CMMGauge

Manager dashboards

Procurement dashboard

Operator dashboard



Identifies CTQsincluding

Customer MFA

Pratt & Whitney Canada ProCert Process

Planner &

Procurement

Shop Floor

Operator

Or supplier

Engineering

Procurement &

Plant Manager

Roles

SAP R/3 Routings & Insp. Plans

Modifies Process Sheets & Identifies measuring devices

MFA on CTQs

Monitor CTQ & Mfg. Control

SAP R/3 Release Production Order & Inspection lot

Use Measuring devices and

Record ResultsSAP xMII SAP xMII

SAP xMII

SAP xMII

Analyze data recorded

(SPC / Six Sigma)SAP xMII SAP xMII



Deployment timeline

START

Operator

dashboard

Supplier

dashboard

D J F M A M AJ J OS N D J F M

2004 2005 2006

Planner

dashboard

Operator

dashboard

CMM

Agile development

Procurement

dashboard



Objectives for deploying SAP QM and SAP xMII

The objective of the project is to implement tools to address Process in Control and capability (Cpk => 1.33)

Upon completion of this project,

� Manufacturing unit will be able to:– Record results

– Monitor results via raw data & run chart

– Live update on Cp/Cpk value to help steer his manufacturing processes

– Extract raw data to be displayed for first level analysis, download raw data for detail analysis

� Suppliers will be able to:– Enter Cp/Cpk value, process type, number of points used for calculation

– See previous data entry (Cp/Cpk, etc)

– See traffic light status for data entry per characteristic

Anticipated Qualitative Benefits

� Will improve quality of parts

� Will improve customer perception in the market and free up cash for future funding

� Will increase customers satisfaction

� Will help deliver quality parts on time








Solutions considered and selected

4 systems were analyzed:

– 3 commercially available off-the-shelf systems

– 1 in-house development

Evaluation was conducted in 2 steps:

� A general evaluation of the software vendor, the software capability and

the software fit with PWC infrastructure/UTC guidelines

� A detailed fit/gap analysis was done for 2 short-listed solutions

SAP xMII was confirmed as the one solution being

� More mature system

� Featuring the best fit with PWC IT strategy and infrastructure

� Lower total cost of ownership

� Meeting timeframe requirements



System requirements overview

Support the creation of control plans

Recording of data

Provide Pratt & Whitney Canada Manufacturing with� an input/display screen via the web, to upload the Key Part

Characteristics data with run chart(s) in real time

� Transfer CMM data in a timely fashion to the operator

� Enable QN(s) to be generated from Operators web page

Provide Suppliers with an input/display screen via the web, to upload the Key Part Characteristics

Provide data analysis capabilities to Planners, Procurement Quality analysts and Designers

Make data available for special analyses using Minitab

Provide dashboards to deliver visibility to management








DATA

INFORMATION

KNOWLEDGE

DECISIONS / ACTION

Dashboard’s feature review

Planner dashboard

Supplier dashboard

CMMGauge

Manager dashboards


Operator dashboard



Shop floor Operator dashboard

Run Chart display in real time

Capability to enter comments on each data points

Calculation and display of CP/CPK value for each SPC characteristics

Data is saved in SAP QM Result Recording

Automatic operation confirmation (CO11)

Validation of Production Order with Part Number and Operation

Capability to enter data for serialized or non-serialized parts

Can update data value as long as Inspection lot is not closed

Automatic calculation of average value

Multi-entry capability

CMM data integration with dashboard



Confirm operation (replace CO11)

Operator enters:

� Information in the fields

He clicks the green check box

System will provide feedback, error message or confirmation

CO11



Supplier dashboard

Can enter Cp/Cpk value, process type, number of points used for calculation

Display previous data entry (Cp/Cpk)

Display traffic light status for data entry overdue per characteristic

Data is saved in customer table

Validation of Purchase Order with Part Number and vendor



Planner dashboard

Capability to extract data using material, operation and date range

Display statistical information Cp, Cpk, Ppk, Cpu, Cpl and number of points

Detail information of data point (machine number, operator identification, etc.)

Graphic display selectable as a run chart or histogram

Capability to add comments to data points

Capability to insert a breakpoint

Capability to identify outlier points

Download capability to Excel spreadsheet




Capability to select multiple vendors and/or multiple materials

Download capability to Excel spreadsheet

Display characteristic data entry overdue status using traffic light

Display characteristic history

Capacity to display latest or historical data

Graphic can display Cp and/or Cpk historical value

Graphics can be printed with all associated information

Search capability by material



Manager dashboard’s requirements

The solution will provide a centralized repository of ProCert data used for information and decision making. This data must come from manufacturing, engineering, suppliers and engine centre

The solution will provide an information tool to enable the alignment of design requirements (tolerances) to process capability (including assembly and test capability) for new program or newpart design

The solution will provide a centralized repository for monitoring part/process certification

M IL E S T O N E S S T A T U S - A L L P R O G R A M SM ile s to n e C (D ra w in g r e le a s e d )

0

1 0 0

2 0 0

3 0 0

4 0 0

5 0 0

6 0 0

7 0 0

8 0 0

Oct

-05

Nov-05

Dec-

05

Jan-

06

Feb-0

6

Mar

-06

# o

f part

s

P T 6 A - 68 3 07 A 3 0 8C 6 10 6 15

T o ta l = 7 3 5 pa r ts

M ile s to n e 1 (P R I + M O S)

6 0 8

0

1 0 0

2 0 0

3 0 0

4 0 0

5 0 0

6 0 0

7 0 0

8 0 0

Oct

-05

Nov

-05

Dec

-05

Jan-0

6

Feb-0

6

Mar

-06

# o

f part

s

P R I M O S M /S 1 : P T 6 A -6 8 30 7 A 3 08 C 61 0 61 5

To ta l = 7 3 5 p a r ts

5 5 %

M ile s t o n e 2 (G a u g e R & R + C o n tro l P la n )

2 9 5

0

1 00

2 00

3 00

4 00

5 00

6 00

7 00

8 00

Oct

-05

Nov-0

5

Dec-0

5

Jan-

06

Feb-

06

Mar

-06

# o

f p

art

s

G ag e R & R C o ntr o l P lan M /S 2: P T 6 A -6 8 30 7 A 3 08 C 6 10 6 15

To ta l = 7 3 5 p a r ts

2 8 %

M ile s to n e 3

1 3 5 1

0

5 0 0

1 0 0 0

1 5 0 0

2 0 0 0

2 5 0 0

3 0 0 0

3 5 0 0

4 0 0 0

Oct

-05

Nov

-05

Dec

-05

Jan-

06

Feb-0

6

Mar-0

6

# o

f K

PC

d

C p k ba s elin e C p k > 1.0 0 C p k > 1 .33

T ota l = 3 4 5 5 K P C D

5 7 .2 %



How it was done

� Created new custom tables to store Process

certification’s information (Cp, Cpk, count of points,

etc.)

� Use standard result recording from SAP QM

� Use standard dynamic modification rule in the PP routing

� Operator dashboard web page linked to SAP ERP with

SAP xMII

� Use standard SAP BAPIs and we had to customize a

few one

� Created new RFC features such as “Remain to Record”

� Created ABAP and Java code for validation purposes



How SAP xMII was used to link Operator Dashboard and SAP ERP

� Screen created

using HTML and JavaScript

� Information passed to Visualization

Services

� Information passed to Transaction

Services

� Information passed to SAP

Operator Dashboard

Visualization Services

Transaction Services

SAP

Applets

Data query

Web service

SAP xMII



Additionalinspections

Warranty

Leaks

Scrap

Rework

Hidden

(?) % of sales

Engineering change

Long cycle time

Additional setups

Cost of re-launching

Lost Sales

Lead-time Penalty

Loss of customer trust

Supplier Quality

Invisible

5 to 8 % of sales

Repair

Recurring Service Bulletins

Recurrent

EngineeringNotices

Non-contractual

guarantee

Inventory Surplus

Loss of credibility

Visible

2 to 3% of sales

SAP Solution Benefits

Reduction in what is under and over water level



Value from the SAP Solution:

� Savings from Quality Cost Avoidance will be realized in six major areas:

� Lower level of rework and repair

� Improve quality resulting in lower material prices

� reduction in QN (quality notification) items

� reduction in warranty expense caused by manufacturing escapes

� improvement in engine retest ratio, and

� shop floor productivity improvement.

� The ROI is fully in line with Pratt & Whitney Canada objectives

SAP Solution Benefits








Lessons learned

� Hiring of a SAP xMII consultant has speeded up the development and knowledge transfer to the programmers

� Time must be provided to the programmers to experiment and explore the BAPI for QM

� May need to custom code an RFC because a BAPI is not providing the full functionality

� Sit down with your users to confirm their needs and the features for your dashboards

� Change management must not be neglected for success

� Certain SAP BAPIs can be detrimental to transaction performance. Function modules can be used to improve response time



Lessons learned

Expect evolution of the product



Questions


Measurable Six-Sigma and Quality Performance Improvement with SAP QM and SAP xMIIAdaptive Manufacturing Summit

September 28th, 2006, Denver, CO

C. PoliquinBusiness Development Manager – Pratt & Whitney Canada

R. CadottePrincipal Business Consultant – Pratt & Whitney Canada



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SAP Adaptive Manufacturing Summit 2006

Colorado Convention Center

Denver, Colorado

September 27-28, 2006

Documents

Measurable Six-Sigma and Quality Performance Improvement ...fm.sap.com/pdf/8182/09_Poliquin_Cadotte.pdf · Measurable Six-Sigma and Quality Performance Improvement with ... certification’s