KEYED IN
FIGURE 1
and develops a control for those pro- cess parameters by using tools such as process maps, failure modes and effect analysis, design of experiments, capa- bility studies and statistical process control.
PM CAS PILOT PROJECT Te first pilot project was the M31 Fin Assembly, which is used on the 120 mm Mortar Family of Munitions (FOM) to provide flight stability and to transfer energy for propulsion. Tis project was selected because of producibility con- cerns, and because the industry partner was a willing participant in the process, which is very important to the success of the effort. Te first four phases of the KPD&M process identified a feature that was not listed on the technical drawing or specification but significantly impacted safety and performance of all mm FOMs.
the 120
Incorporating this feature into the drawing and specification significantly reduced the performance and safety risks, and freed up resources for other areas of concern. Te pilot project also revealed the
increased costs resulting from a
feature that did not have a significant impact on performance. Tis feature had very tight difficult
tolerances that made it very to manufacture, reducing the
potential supplier base and boosting its cost. Increasing the tolerance on this fea- ture by twice its previous limits improved its producibility and cost-effectiveness. Eliminating seven nonessential inspec- tions and reclassifying inspection levels for more than 57 percent of the major characteristics further reduced costs.
Te KPD&M process also devel- oped mature aerodynamic models that expedite the response to requests for
variations, malfunction investiga- tions and future design changes, using
40 Army AL&T Magazine January–March 2015
Phase 1 KP Project Planning and Requirement Clarity, Stability, Rank and Priority
STEP 1: Create a KP project charter. STEP 2: Create a cross-functional team of experts to help identify a thorough set of candidate KPs. STEP 3: Generate and assess requirement clarity, classification and allocated flow-down.
Phase 2 Construct Diagrams to Identify Candidate KPs and Specific Areas of Focus
STEP 4: Structure a KP tree and functional flow diagrams. STEP 5: Generate input-output-constraint diagrams, parameter diagrams, noise diagrams and boundary diagram.
STEP 6: Identify unique subareas of focus; lean out, rank and prioritize the KP work areas. Phase 3 KP Measurement and Designed Experimentation
STEP 7: Prove measurement systems can be trusted and are capable. STEP 8: Design and conduct experiments (sequential flow of design of experiments). STEP 9: Analyze data using analysis of variance and other statistical methods to identify sensitivities and capability indices.
Phase 4 Identify KP Sensitivities and Balance KP Tolerances
STEP 10: Establish and verify tolerance ranges and percentage contribution to variation of key Ys and sub-Ys.
Phase 5 KP Implementation, Transfer and Control Plan for Manufacturing Supply Chain
STEP 11: Manufacture and production implementation plan for KPs. STEP 12: Evaluate the seven KP metrics and implement changes in control plan.
PHASES OF KPD&M
In five phases encompassing 12 steps, KPD&M rigorously identifies the design factors (key parameters) that have the most influence on desired performance and the associated manufacturing parameters requiring process control, then translates these into a manufacturing and production plan. (SOURCE: Clyde Creveling, PDSS Inc.)
fact-based decisions. Te risk of unfore- seeable outcomes affecting performance or safety is present even during manu- facturing or after the product has been accepted. Te mature aerodynamic models provide helpful information to address those issues.
To reduce costs further, the engineering team supporting the project developed a new acceptance methodology that will reduce the number of inspections by more than 70 percent while ensuring objective and measurable evidence of product conformance through process and statistical controls.
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