Trial name: Reduce time to compile the DB Quality Production
Manufacturing Sector: Helicopter OEM
Keywords: Quality, Documentation
The AW Final Assembly Line (FAL) in Vergiate plant is the location in which the trial has been tested. The FAL is the location in which helicopters are manufactured and it is responsible for creating processes that center around reliability and efficiency, both in the supply and management of materials and in guaranteeing Quality during the assembly and delivery to the final customer. In the FAL one of the more important aspects is related to the management and the traceability of documentation that are used to support the workers during helicopter manufacturing (e.g.: Assembly Helicopter Work card, List of Production Baseline, etc.), demonstrate the quality checks occurred (e.g.: Final Assembly and Inspection card, Final Assembly and Inspection record, etc.), trace modification arisen during production. The information provided in these documents is used to create the official documentation necessary to delivery helicopter (H/C logbook) as defined by aviation regulations and company policies.
The AW Digital test case engenders measurable benefits in terms of save time because is the FITMAN application that is in charge to interface the different repositories where document are stored and search information according to user’s requests.
Innovative Services and Functionalities
- Support for management of documentation.
During FAL operations a lot of different documents must be produced linked to the H/C final delivery. The search of some of these documents or some single data is sometimes long and not so easy for other departments. The main functionality implemented is to improve the velocity and the simplicity of search of information with more data informatisation and connection. The improvement of the computerisation process and the possibility to have access and interrogate different sources will make it easier and faster. In particular the following advantages have been achieved:
- Reduction of average time to make data available in a digital format. As a consequence, the users are alleviated by a tedious and repetitive job and can focus their activities and professionalism on quality and production issues.
- Reduction of number of discrepancies between the analysed data from different sources and complied by different persons. FITMAN solution can face these kind of issues linked especially to possible human error of transcription inside the Database of Quality Production for the Helicopter Logbook data compilation.
Impact and Benefits
Two KPIS have been taken into account:
PI1 Reduction of average time
This KPI refers to the reduction of time to search, copy or write data from different sources inside the Database used by Quality Production for the Logbook data compilation. In the AS-IS situation the medium time used for manually search data is 50÷65 min for each person for monthly. The expected target is 5÷10 min with a reduction of 45÷55%.
PI2 Average number discrepancy reduction
This KPI refers to the reduction of average data discrepancies due to human errors in data transcriptions. In the AS-IS situation there are 30÷40 number of discrepancy per each helicopter. The expected target is 5÷10 with a reduction of 25÷30%. This result is due to automation in searching the information, to the reduction of typing errors and to automatic consistency check that the system performs when searching for information.
In the “as is” situation, the information is manually searched by users by consulting the documents stored in different repository and sources (Interactive Electronic Technical Publication, SAP, Helicopter Flight Planning, Manufacturing Execution System, etc.), the information founded (N/C Helicopter, P/N & s/n Installed Components, Time limit, etc.) are then transcribed or copied into the Quality Production DB that is the starting point to prepare the Helicopter Logbook. This process takes a lot of tome and could introduce errors. The business objective is to reduce the time necessary to collect data and the trial relates to the possibility of provide users with a tool able to query different databases automatically. As input the user inserts the tail number that uniquely identifies the helicopter which data are required. The system takes care of the request and interrogates the various databases providing access accounts and formulating the correct query. At the same time a check is made of the data by highlighting any discrepancies. The user can visualize the results by means of the Client Graphic User Interface and the data can be exported in a CSV file to be used by office tool such as Excel.
Technical Challenges & Trial Platform
The GE (Generic Enabler) /SE (Specific Enabler) / TSC (Trial Specific Components) used to develop the Digital platform for the trial are:
- GE: PUB –SUB.
- GE: Application Mashup.
- GE mediator (client soap).
- SE: Metadata and Ontologies Semantic Matching.
- TSC db –SERVICE SOAP – GUI – Gadgets.
Moreover the following Trial Integration Components have been developed:
- DB (support DB for the results exposition display).
- Gadgets (for query/search).
- Client GUI.
- Db Quality Production.
- Data Sources.
AgustaWestland was created by the merger of two helicopter Companies, both with long and rich histories dating back to the formative days of aviation manufacturing in the early 20th century. Agusta’s and Westland’s pedigrees as helicopter manufacturers dates back to the 1950s. The two Companies first collaborated in the 1960s when Westland began producing the Agusta AB47G, known as the ‘Sioux’, under licence. From 1964 Westland built 250 of these small helicopters at Yeovil, UK. The relationship between the two Companies continued to evolve for more than 20 years through collaboration on the development and production of the 16-ton multi-role EH101 (now AW101) helicopter. This association enabled Agusta and Westland to integrate quickly and smoothly when Finmeccanica S.p.A. of Italy and GKN Plc of the UK signed an agreement for the formation of a 50:50 joint venture company named AgustaWestland in 2001. In December 2004 Finmeccanica acquired GKN’s 50 per cent stake in AgustaWestland.
AgustaWestland is leader in the global helicopter industry. It offers a wide commercial/military product range encompassing all main weight categories that can perform a full variety of missions such as offshore, passenger and VIP transport, air ambulance, law enforcement, SAR or utility missions. The advantage of this family of helicopters is that they share a common design approach, common parts, common training and the same maintenance philosophy. In the military sector, AgustaWestland has the most capable helicopters in production today for naval, attack, utility and combat SAR missions.
Research and Development is an essential part of the business, and represents the Company’s commitment to improving existing products as well asto developing innovative solutions. AgustaWestland is particularly focused on providing customers with effective logistic and maintenance support to increase their operational capabilities, whilst reducing overall operating costs.The worldwide headcount at AgustaWestland exceeds 13,000, with major manufacturing facilities located in Italy, UK, Poland and USA. Revenues in 2013 stood at €4,076 million with a cumulative order backlog amounting to almost €12 million, and new orders worth €4,384 million.
Point of contacts for FITMAN
Mrs. Elena Rossi
Mr. Roberto Sanguini
TXT e-solutions is the FITMAN coordinator.
Founded in 1989, TXT e-solutions is an international software products and solutions vendor, leader in “Strategic Enterprise Solutions”. The company has been listed on the Italian Stock Exchange – STAR segment (TXT.MI) – since July 2000 and has about 600 employees. Consolidated 2014 revenues are € 55.9 million. TXT is based in Milan and has branches in Italy, Paris (F), Lyon (F), Wynyard (UK), Leicester (UK), Chemnitz (D), Halle (D), Barcelona (E), Toronto (CDN) and Sydney (AUS).
TXT is specialized in the most dynamic and agile markets with the highest degree of innovation and renewal that require state-of-the art solutions, where process and business play a fundamental role in growth and competiveness. To answer to customer’s needs TXT has always invested in technology and in business processes innovation, making this a cornerstone on which to build its success. Research and Development therefore holds a primary role in TXT, with important investments in both business areas:
- TXT PERFORM: End-to-end solutions for Fashion, Retail, Consumer Goods and Manufacturing sectors;
- TXT NEXT: advanced Software Engineering Services for companies in the Aerospace, Automotive, High-Tech and Banking sectors.
Point of contacts for FITMAN
Mr. Michele Sesana