Company Private

CH-148 Crab Analysis/ DIVEGeorge Bowman

Mfg Supervisor

Anthony GrandaQE

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Team Charter

Event Name: Electrical Crab Count reduction DIVE CH-148Event Location: SikorskyWest Palm Beach, FL FAFOEvent Type: DIVEEvent Dates: May 20, 2010 to May 25, 2011

Project Charter

Problem Statement: Electrical Crab Count on Ch-148 program in the cabin exceeds target of 500. Currently Electrical Cabin Crab Count is at 1189 Objective: To standardize electrical install on CH-148 program and to reduce electrical Crab Count to less than 500 per Aircraft

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Business Impact: To ensure electrical crab count is less than 500 in cabin area to meet scope, schedule and budget of development program needs.

Scope and Boundaries: CH-148 Line.  Executive Sponsor(s): Rob Von Stralendorff (Operations Manager) Team Members: Anthony Granda (Leader), George Bowman (Implementation Leader & Co-Leader), Bob Dolberg (T-tool manager), Craig Cunningham (ME), Bill Callahan (Tech), Syed Ashan (Tech)  Pre-Work Plan / Activities: CH-148 electrical crab Count Breakdown, AOS reveiw Benefits / Measures of Success: Upon completion of event will reduce cabin electrical crab count, show cost savings for man hour reduction and to create standard work for electrical installation of CH-148 line.

Project Charter (CONTD)

Team Charter

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Define Investigate

EnsureVerify

CH-148 Shake Crab Reduction

Harness Routing Aids• LH Rack Template - (Complete)• ESM Cable Template – (T-tool # 92551-20903-011T027 created and will be added to AOS #92551-20903-011)• Wire Pull-Thru Guide – (Prototype in place, awaiting ME to cut work order)

Solutions:- Standard Work

• Released Photo Books – (Engineering – 9/20)• No more Install per Old rev Inspect per New

• Production AOS Standard Work – (ME – On-Going)• No more Install per Print – Capture Learnings

- Harness Routing Aids• LH Rack Template - (Complete)• ESM Cable Template – (Work Order cut, PO placed 9/9)• Wire Pull-Thru Guide – (Prototype in place, awaiting ME to cut work order)

Problem – CH-148 Shake Crab count exceeds target of 500 need to improve lead time and lower cost on the CH-148 line. High drivers must be identified and addressed

Team Members:

George Bowman ( Implentation Leader) Bob Dolberg

Anthony Granda (co-lead) Bill Callahan

Gary Clayton Syed Ashan  

Root Causes:

Electrical crabs in the Cabin area are the highest driver

and are created through an absence of standard work

and an a lack of routing tools

Owner: George Bowman

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CH-148 Shake Crabs per A/C

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CH-148 CRAB COUNT LOCATION

298

1189205

24348

64

LANDING GEARS

81

MAIN GBOX & ROTOR HEAD - 28Mech 22 / Elec 6

Mech 368 / Elec 821

Mech 179/ Elec 119

Mech 59 / Elec 184

Mech 40 / Elec 41

Mech 32 / Elec 16

Mech 40 / Elec 165

Mech 33 / Elec 31

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CH-148 ALL POSITION CRABS BY A/C

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CMHP CRABS BY POSITION & BY A/C

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CH-148 TOP 5 DRIVERS BY POSITION

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CH-148 TOP 5 A/C LOCATIONS

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CH-148 CRAB REDUCTION PLAN

Data Pareto Suggests Cabin Station 6 Electrical Install Focus

- Standard Work• Released Photo Books – (Engineering – 9/20)

• No more Install per Old rev Inspect per New • Production AOS Standard Work – (ME – On-Going)

• No more Install per Print – Capture Learnings - Harness Routing Aids

• LH Rack Template - (Complete)• ESM Cable Template – (Work Order cut, PO placed 9/9)• Wire Pull-Thru Guide – (Prototype in place, awaiting ME to cut work order)

- Training • DANS Report - Crab Creator is Crab Fixer (On-Going)

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CH-148 CRAB REDUCTION PLAN

Data Pareto Suggests Cabin Station 6 Electrical Install Focus

- Standard Work• Released Photo Books – (Engineering – 8/30)

• No more Install per Old rev Inspect per New • Production AOS Standard Work – (ME – On-Going)

• No more Install per Print – Capture Learnings

      

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Kaizen NewspaperKaizen Newspaper

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Kaizen Newspaper

Team Date

% Complete

Electrical Crab reduction CH-148 10/3/2010

Activity Owner Due Date

DANS Report Training Bowman 10/15/10

Crab Count Analysis Granda/ Bowman 10/15/10

Released Photo Books Electrical ENG 10/15/10

Production AOS standard Electrical ENG/ ME 10/15/10

Harness Routing Aids Dolberg/ Bowman/

Cunningham10/15/10

L/H Rack Template ENG 10/15/10

Companion Way Step Bowman/ Clayton/ Dolberg 10/15/10

Wire Pull Through Guide Cunningham/ Bowman 10/15/10

Add Template to AOS ENG/ Bowman 10/15/10

Granda/Bowman 10/15/10Event Outbreif

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Summary of Event

Pre-Event No Standard T-tooling for electrical installNo Photo Books for electrical installationExceeded Crab Count of 500 crab count targetNo standard work for assembly orderEmployees not using DANS report to fix there own discrepancy

Post Event Created four T-tool templates to be used during installationPhoto books released55% reduction in crab count from A/C 801 to 803Standard work added to assembly orderDANS report used daily to fix owners crabs