Drive for Zero Defects

Dr Ian Riggs

Quality Executive,

Civil Aerospace

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2What would your normal working day be like if there were

Zero Defects?

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We do amazing things…. but

Are our Customers satisfied with our Quality &

Reliability?

Are we Efficient?40 – 60% of people’s time spend ‘putting things right’

Rework & Remaking uses up capacity

What is it Costing us?

Benchmarking studies estimate true Cost of Quality at 20%–25% of

sales. It is always cheaper to do it ‘right first time’

Can we Deliver?

60% of our delivery issues result from Quality issues somewhere in

the supply chain. Significant ramp up in volume ahead – Opportunity

or Risk?

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Zero Defects Context

Metrics continuing to improve, but…

Customer disruption is always unacceptable

Customers’ quality expectations are

increasing

What are we doing to prevent the next big

Quality Disruption?

Zero Defect Principles : The Four Absolutes of Quality

Philip B. Crosby

Quality is Free1979

Quality has to be defined as conformance to

requirements, not as goodness or elegance.

The System for assuring quality is Prevention, not

Appraisal.

The performance standard must be Zero Defects, not

‘that’s good enough’.

The measurement of quality is the price of non-

conformance, not indices.

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Leadership & Culture

OrganisationalCapability

Technical Capability

ZD

Do we have the right tools to prevent the

creation of defects?

Do we know how to use these tools effectively?

Do we create the right environment to

support our Zero Defect Goal and

engage everyone?

Defect Prevention Approach

MINDSET

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Core Product Defect Prevention Tools

Product Life Cycle

8D Problem Solving

Product Design Process Design Production & Service

Design FMEAProcess FMEA

Control Plan

MSA CapabilityError

ProofingProcess Control

(SPC)

Advanced Product Quality Planning (APQP) &

Production Part Approval Process (PPAP)

Must be applied as a ‘system’ of tools

Must be applied at part number level

Effectiveness relies on Cross Functional working

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Aerospace Defect Prevention Maturity Baseline

DFMEA PFMEA Control

Plan

Gauge

R&R

Attribute

Agreement

Analysis

Capability SPC

Variables

Attribute

SPC

100%

50%

10%

75%

25%

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Zero Defects Leadership Program in Rolls-Royce 10

Overview:

• Aimed at the top 1000 leaders in Civil

Aerospace Operations

• 3-Day Program covers;

• Training in the Defect Prevention Tools

• Review of real examples of current practice

• Reflections on how we can improve the

current situation

• Creation of prioritised action plans

• Leaders capable of having coaching

conversations with their teams and suppliers

Success factors :

• Teams from same business

• Cross functional

• Focus on ‘what we can do’ not on ‘what

others need to do’

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Leadership Program – Supplier Forum

IndianapolisDerby Shanghai

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LEAN Leadership Behaviours for ZD Maturity

1. Cross-functional

leadership Team

2. Focus on Key

Part Numbers

3. Agree

Go-Look-See Schedule

4. Assess

Defect Prevention Maturity

Baseline / Status

5. Business Improvement

Plan created / updatedREPEAT

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Success Stories

16 Part Specific

FMEAs in 3 months

Introduction of error

proofing and

prevention controls.

Defect Free since

September 2017

30 of 35 DARs

requests cancelled

after process centering

was introduced

Also improvement in

RFT seen as a result of

removing concession

process. (Operators

took more time to set

up process to avoid

scrap). Zero Defects

Mindset.

Trent 700 in-load to

Indianapolis using

Real Time SPC.

98% of features Cpk

>2, the other 2% Cpk

>1.67

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AESQ Objectives

• Simplify & Standardize supplier

requirements

• Build on existing industry standards

• Common language for Quality

• Standards are simple, prescriptive &

auditable

• Promote standardized 3rd party

training

• Easy to adopt within existing

process/systems

• Deliver results rapidly, through

focused activitieshttp://aesq.saeitc.org/

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AS9145 PPAP

Element Timing

Design

Records

& DRA

Process Flow Diagram

PFMEAControl Plan

Packaging,

Preservation &

Labelling

MSA

ICS

FAI

1. Planning

Initial Prod.

Approval

AS9145 Key

PPAP Events

Design Release

(CDR)

End of Concept

(PDR)Kick Off

Production

LaunchAS9145

(PDP)

AS9145

APQP Phases

AS9102

FAIR

Production Process Run

PPAP

Approval

4. Product & Process

Validation

3. Process Design & Development

2. Product Design & Development

5. Ongoing Production, use and

Post Delivery Service

Production

Readiness

Review

AESQ

Process

Documents

AESQ

Systems

Documents AS13007 – Supplier Management

AS13004 – Process FMEA & Control Plan

AS13003 – Measurement Systems Analysis

AS13002 – Qualifying Alternate Inspection Plans

AS13006 – Process Control Methods

AS13000 - Problem Solving Requirements for Suppliers - 8D

AS9145 (APQP/PPAP) & AESQ Standards

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In Summary

• Our customers are demanding Zero Defects.

• Zero Defects is needed to meet our Quality, Cost and

Delivery targets

• Zero Defects can only be achieved through Defect

Prevention not Defect Detection

• The Aerospace Industry currently has low maturity in the

effective application of these Defect Prevention tools

• Will only improve if Senior Leadership understand what is

required and drive it as a priority

• We must raise the skill level of our people

Strive for perfection in everything.

Accept nothing nearly right or good enough.

”

“Sir Henry Royce

Part of our heritage.

Part of our future.