Module 3: PRODUCTION PLANNING AND CONTROL: A400M FAL 2011-2012.
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Transcript of Module 3: PRODUCTION PLANNING AND CONTROL: A400M FAL 2011-2012.
Module 3:
PRODUCTION PLANNING AND CONTROL: A400M FAL
2011-2012
Máster GSC & AIO 2011-2012GLOBAL SUPPLY CHAIN & AERONAUTICAL INDUSTRY OPERATION
Module 3: PRODUCTION PLANNING AND CONTROL
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Production Planning and Control: A400M FALBy: Gloria Vicente Vicente
H/O Operative Planning and Performance Management FAL A400M
Máster GSC & AIO 2011-2012GLOBAL SUPPLY CHAIN & AERONAUTICAL INDUSTRY OPERATION
Module 3: PRODUCTION PLANNING AND CONTROL
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• Planning Starting conditions Programme Planning
• Work Breakdown Structure (WBS)• Development phase. Integrated Planning. Follow up• Series phase
Planning criteria Development phase. Planning Integration Series phase. Production plan
• Planning parameters Real Operative planning: SAP
• Visual management
Máster GSC & AIO 2011-2012GLOBAL SUPPLY CHAIN & AERONAUTICAL INDUSTRY OPERATION
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Programme Directive
Contract
Product definition
Manufacturing conditions
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Module 3: PRODUCTION PLANNING AND CONTROL
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PLANNING CONCEPTS
• Planning = time management
• Programme level planning: Master plans
• Task level planning: Operative planning
• Development phase Series phase
Máster GSC & AIO 2011-2012GLOBAL SUPPLY CHAIN & AERONAUTICAL INDUSTRY OPERATION
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PROGRAMME PLANDEVELOPMENT PHASE
Integrated plann linked to a WBS according to programme milestones
• Master PlanL1: Programme milestones plan• TDBU Milestones: Cascaded through several programme levels. Milestones
imposed by the top organizations.• P2P Milestones: To stablish relationships between two organizations at same
or diferent levels.• Internal milestones: To stablish the plan inside one organization.• All milestones have to be linked to activities.
•
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Legend:
• “Planning only” WP
• “Budget only” WP
PLO
BDO
Industrial & Delivery Centre (MDT)
NOGUERAS R
A400M Head of Programme(MD)
GAUTIER C.
Systems & integration(MDEY)
RICHARD R.
Power Plant(MDEV)
RABIET C.
FAL(MDTT)
SILVA CAMPOS JJ
HTP(MTA)
MEDINA RIVAS J.
Flight Test(MDET)
GUEVARA-MARTINEZ P.
Programme Performance Management
(MDM)ALBERIDO A.
Programme Management(MD)
GAUTIER C.
Customer Services(MDS)
MIEGEL A.
Delivery Centre(MDTT)
N.N.
Industrial Operation(MDTI) BAILEY S.
Design Integration(MDEI)
BOUCHERAT P.
VTP (incl. Rudder)(TTD)
BRENKE M.
Fuselage(TBD)
BRUEGGEMANN K.
CWB(TMB)
DROUVROY S.
Certification & Airworthiness/Q. Dem.
(EIAM)GABET S.
Integrated planning
GERAT M.A.(MDMP)
Conf. ManagementDEHAESE K.(MDMM)
Avionics(MDEY5)
TAURIAC JM.
MIT Military System(MMCM1)KALAK P.
System Engi. Support(MDEYE)
COHEN-BACRIE J.
Cockpit(MDEY1)
PLASSE JY.
Communication(MEY)
SIERRA-BEJARANO F.
Flight Dynamics / Energy(MDEY2)
GODARD E.
Utilities(MDEY3)THEISS V.
Fuel(MDEY4)DAVIS C.
Prog. Mngt(MDEY)
RICHARD R.
Procurement(MDEY)
RICHARD R.
Customer interface & Qualification Mngt.
(MDEC)LLAMAZARES-ALONSO S.
Overall Engineering(MDE)
CASSIER A.
Statics(MDEI)
GROSJEAN E.
Supportability(MDEI)
ROLLAND PC.
Fatigue(MDEI)
GROSJEAN E.
Aerodynamics KITSON B.
OAD(MDEO)
ROBIN D.
PLO
Systems ILS(MDEYS)
BOULANGER A.
Manufacturing Engineering(TMDASM)
SCHIMMELMANN. O
Leading & Trailing Edge(MTA)
MEDINA RIVAS J.
Industrial(TTTN)
VIRKUS U.
Engineering(TTE)
REERS B.
CWB Manufacturing(TMB)
DROUVROY S.
CWB Design Integration (TBEMT)PAGES G.
Continuous Product Dev.(TWMI)Allen J.
Programme Management(TWM)
WOOD G.
Certification(TWMM)
BUSHNELL M.
FAL / Flight Test support(TWMB)GRIER C.
Industrial Operations(TWMB)GRIER C.
Programme Management(TTD)
BRENKE M.
Rudder(TMB)
DROUVROY S.
Cargo Hold(MDEY6)HAHN P.
CoC Struc. Sup. To CoE(MDEI)
GROSJEAN E.
Tech. Data Integrity(MDEI)
ARISTE-ZELISE O.
Programme Quality & Maturity(MDQ)
SCOTT J.
Evac. Test(MDEB)
STUEBEN J.
Loads KORNFUEHRER
Aaeroelastics LAPORTE A.
Performance THEZELAIS S.
Weigh/Balance PONS L.
TBB Assembly(TBBM)
SIEFKEN C.
Engineering Definition Dossier NF (TBEM)
PAGES G.
Programme Management(TBD)
BRUEGGEMANN K.
Industrial Partner Supplier IFA(TBDI)
FOERSTER R.
Engineering Definition Dossier IFA (TBEM)
MECHLER H.
Nose Fuselage Assembly(TBSM)
LEMAITRE O.
Acoustics PERRIN-DECROUX
Test Pyramid(MDEI)
GROSJEAN E.
TECH. INFO & DATA(MDSI) HOWES P...
ILS Technical(MDSI) CURA M.
MATERIAL SUPPORT(MDSI) COLL P.
TID (MSED)GUTIERREZ J.
TID (SEDX)MORAND B.
FLIGHT OPS (STIB)GRESSE
MAINT. ENG. (MSES)GRANDE D.
MAINT. ENG. (SEME)SAFRA JM.
IN-SERVICE SUPPORT(MDSS) BURGAZ J.
INITIAL PROV. (MSTT)KAUFHOLD M.
INITIAL PROV. (SEDX)MORAND B.
SUPPLY PREP. (SMV2)RADMACHER M.
GROUND SYSTEMS(MDSI) TANNER J.
GSS - MDS (MDEYS)BOULANGER A.
GSS - MPRS (MDEYS)BOULANGER A.
TRAINING & TRAI. AIDS(MDSI) GOMEZ R.
T & TA (MSTT)CORCHON JL.
T & TA (STIB)GRESSE JL.
T & TA-S&IT (MDEYS)BOULANGER A.
CS INF SYS(MDSS) LAURENT P.ILS INT. CONF.
(MDSI) VILLARES D.
GND TOOLS (MDEYS)BOULANGER A.
MAINTENANCE PL.(SEMS1) WEBSTER D.
PLO
PLO
AC GND EQUIP.(MDSI) CURA M.
SUPP. ASS.(MDSI) DELPECH S.
ILS CONF LIS. (MSEM)CEREN M.GSS REF.(MSEM)
CEREN M.
LIS & INF SYS. (MSO)LABLANCA J.
INFO SYS. (SVA)LEFLOCH H.
AGE (MSES)GRANDE D.
AGE (SEMS)RAYNAUD O.
PLO
Procurement Management
(PYD)CHRETIEN L. PLO
BDO
BDO
BDO
BDO
BDO
BDO
BDO
PLO
FT & Operations(MDET)
GUEVARA-MARTINEZ P.
Flight Test analysis(MDET)
BARRERE M.
FT Installation(MDET)
VILCOT T.
Ground Support(MDET)
GUEVARA-MARTINEZ P.
BDO
BDO
BDO
BDO
Test Integration(MDEYE)
COHEN-BACRIE J.
PLO
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Module 3: PRODUCTION PLANNING AND CONTROL
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MP L1
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P2P Milestones: Clashes reviewFUSELAGE–FAL milestones:
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Module 3: PRODUCTION PLANNING AND CONTROL
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LONG TERM: PRODUCTION PLAN (APC)
MID TERM(3 YEARS): INTEGRATED PLAN (UP SERIE)
SHORT TERM (3 MONTHS- 1 YEAR): PLANT PLAN (SAP)
PROGRAMME PLAN
SERIES PHASE
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Job card
Work order
A/C / STATION
MP (UP)/APC / A/C Chart (UP)
DPE
Start time /Precedences
SAP PROGRAMMER AVLVISUAL LINE
RE-PROGRAMING
KPI´S
MASTER PLAN
THEORETICAL OPERATIVE PLAN = BUILD PROCESS REAL OPERATIVE PLAN
FAL A400M PLANNING CRITERIA
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Module 3: PRODUCTION PLANNING AND CONTROL
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Production plan parameters
Working Time
Calendar
Manpower Factor
FAL Lay-out
FAL Lead Times
FAL Learning Curves
FAL Working Party slots
Logistic cycles
Delivery phase
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Module 3: PRODUCTION PLANNING AND CONTROL
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- Calendar assumes decisions including Spanish Authorities and Trade Unions commitment.- Calendar formal approval will be done by December for coming year.- As average:
- 224 working days- National Holidays: 11- Local Holidays: 3
- Summer Holidays are typically two weeks around first half of August.- Typical working time:
- 2 shift, 8 hrs. per shift- timetable:
shift 1 7:00-15:10. Break : 11:30-11:40
shift 2 15:00-23:10. Break 19:30-19:40
Working time
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Module 3: PRODUCTION PLANNING AND CONTROL
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Calendar
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Module 3: PRODUCTION PLANNING AND CONTROL
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Module 3: PRODUCTION PLANNING AND CONTROL
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Process to plan
FAL A400M
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Module 3: PRODUCTION PLANNING AND CONTROL
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St. 60 Fuselage joint up 27 27 25 8
St. 50 Empennage joint up 19 19 19 8
St. 72/70 St. 72 Wing joint up- struct. 34+ 5,5 34 34 16St. 70 Wing joint up- equip. 15+1,5 15 15 8
St. 40 A/C integration & equipping 26 26 25 8
St. 35 Indoors Ground Tests 54 54 54 16
St. 30 Outdoors Ground Tests 20 20 20 8
St. 25 Powerplant equipping 25 25 15 8
St. 20 Furnishing & Powerplant install. 15 15 15 8
Cargo Hold customer inspection n/a 1 1 1
Structural Ground Tests 44 n/a n/a
EMI/EMC 3 3 n/a n/a
St. 15 Fligth Line 19 19 19 14
St. 10 Painting 6 12 12 10
Handover 10 8 8 2
Customer acceptance n/a n/a 30 15
OPTIONS n/a ? ? ?
FAL A/C Lead Time (working days)
rate 2,5Station no. Sta. description MSN 1* MSN 6 MSN 7
St. 45 Software Loading 10+10 10 10 8
MSN 2
27
1934+3,515+1,5
26
54
20
25
15
1
3
19
12
8
n/a?
10
MSN 4
27
1934+3,515+5
26
54
20
25
15
1
3
19
12
8
n/a
10
MSN 3
27
1934+3,515+1
26
54
20
25
15
1
3
19
12
8
n/a?
10
MSN 5
27
1934+3,515+1
26
54
20
25
15
1
3
19
12
8
n/a
10
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• Tn= Tref* c (ln n/ref)/ ln3
comparacion curvas entrenamiento
0
5
10
15
20
25
30
35
1 6
11 16 21 26 31 36 41 46 51 56 61 66 71 76 81 86 91 96
rank
wd
84% 21 wd en 1
80% 29 wd en 1
72% 21 wd en 9
65% 29 en 9
66% 25 en 9
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old 5.1 & 25
old 4.1 old 4.2 old 5.2 old 6 old 7
old 1.3.1/1.3.2
50
60
40 30 2035 1015 8
72/70
FuselageAD-Bremen
Nose FuselageAF-St. nazaire
SponsonsSOCATA-Tarbes
NLGM.Dowty
MLGM.Dowty
WFF Set 1& 4DENEL
OWAUK-Filton
CWBAF-Nantes
PYLONS EQUIPPING
(MTAD)
PODDING (MTAD )
Engine CowlsMTAD-Cadiz
PylonsAF-St. Eloi
Engine Cowls
HTPMTAD-Seville
VTPAD-Stade
PowerplantEPI
WFF Set 2,3,5&6DENEL
MLG DoorsSONACA
NLG DoorsSOCATA
Pylons
FAL Scope
WFF ongletsDENEL
old 1.1
old 1.2
old 2/3
Engine Dressing (MTAD)
45 Software loading
PropellersRatier-Figueac
Parts to plan (CAP)
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Module 3: PRODUCTION PLANNING AND CONTROL
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All A/C
FAL on dock FAL in jig(*)
Logistic cycle time
FAL Station installation Logistic cycle time40 20 wd45 10 wd20 15 wd
All other stations 10 wd
In jig: FAL Ref Station
1
2 - Transport
5 - in jig
6
3Availability at supplier On dock:Latest arrival at FAL
FAL
3 to 6
Transport
2
SupplierCalendar
1Milestone
4 – Inspection
max. 5 w.d.
3 w.d.
2 w.d.
Main CA´s
Equipment & LI
LOGISTIC CYCLES (CAP)
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Production plan L1 = FAL Production Plan
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Module 3: PRODUCTION PLANNING AND CONTROL
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Theoretical build process
Station duration
Job cards
Workers by job card: max-min
Job card LT
Workload
Work station/Skill/Competences
Workshop exceptionsResources availability
Skills and CompetencesCalendar exceptions
Missing parts
Operative planning per A/C
Needs of:
Resources
Training,
etc
Changes in:
Precedences
Times
Work station/Skill
LT
WORKSHOP PROCESS
OPERATIVE PLANNING
Out of Sequence Works
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WORK ORDERS AT WORKSHOP
Máster GSC & AIO 2010-2011GLOBAL SUPPLY CHAIN & AERONAUTICAL INDUSTRY OPERATION
Módulo Nº: 21
Máster GSC & AIO 2010-2011GLOBAL SUPPLY CHAIN & AERONAUTICAL INDUSTRY OPERATION
OUT OF SEQUENCE WORKS
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DPE SAP APC
PLANIFICATRON
Start Times
Precedences
Work Order
OsW
Calendar
MSN Location
Capacity
Stations dates
PLANNING SET UP
PLANIFICATRON “AVL”JOB CARDS PLAN
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Module 3: PRODUCTION PLANNING AND CONTROL
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Planificatron-1
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Planificatron-2
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Planificatron-3
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TASKS MONITORING
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BACK UP
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RTD Curve
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0500
100015002000250030003500400045005000
18/01/201120/01/201124/01/201126/01/201128/01/201101/02/201103/02/201107/02/201109/02/201111/02/201115/02/201117/02/201121/02/201123/02/201125/02/201102/03/201104/03/201108/03/201110/03/201114/03/201116/03/201118/03/201122/03/201124/03/201128/03/201130/03/201101/04/201105/04/201107/04/201111/04/201113/04/201115/04/201119/04/201125/04/201127/04/201129/04/201104/05/201110/05/201112/05/201116/05/2011
Closed
Ongoing
Pending
Operations Status Per Date
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% RTD FAL% RTD FAL until Current Station
0% < RTD < 5%
5% =< RTD < 10%
RTD >=10%
0% < RTD < 3%
3% =< RTD < 5%
RTD >=5%
Legend of colors : indicator % RTD Global
Legend of colors : indicator % RTD per Station
2,87%
ST92 ST72 ST70
0,00% 0,00% 1,15%
ST93 ST50 ST40 ST35
0,00% 0,00% 0,66%
ST91 ST60
0,00% 0,99%
% RTD FAL hasta Estación actual
2,1%6,9%
2,9%
Tipo de Operaciones lanzadas
EstandarAOC
TOTALES
0,0%
2,0%
4,0%
6,0%
8,0%
10,0%
12,0%
14,0%
16,0%
INDICADOR GRADO DE AVANCE FAL
RTD FAL Total hasta Estación Actual
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Máster GSC & AIO 2010-2011GLOBAL SUPPLY CHAIN & AERONAUTICAL INDUSTRY OPERATION
Módulo Nº: 21
Follow up: Planning Robustness
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Módulo Nº: 21
Follow up :TOP 10 on the route to TC / IOC
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Máster GSC & AIO 2010-2011GLOBAL SUPPLY CHAIN & AERONAUTICAL INDUSTRY OPERATION
Módulo Nº: 21
Follow up : TOP 10 on the route to TC / IOC
Máster GSC & AIO 2010-2011GLOBAL SUPPLY CHAIN & AERONAUTICAL INDUSTRY OPERATION
Módulo Nº: 21
Follow up : TOP 10 on the route to EIS
RACI for planningMilestones MDTI FAL DC MCA RemarkAll customer inspections for MSN 7 achieved A R C R At section and at FAL level
FCO Quality gate L for MSN 7 achieved A R C QG L: A/C ready for H/O to delivery centre
All SCN-CI for IOC fully functional and installed on MSN 7 A R I R
All SCN-CI provisions up to SOC3 fully installed, certifiable and set inoperationable A R I R
R ResponsibleC ConsultedI Informed
Pending to be included in UP:
Available in UP: