How to Effectively Deploy Defect Prevention Methods in the Aero Engine Supply Chain

October 9th 2019, Toulouse

An AESQ Supplier Forum Event

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and Copyright © SAE International. Further use or distribution is not permitted without permission from SAE confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. Ian Riggs Olivier Castets Global Quality Executive Quality Manager Component & Accessories Rolls-Royce Civil Aerospace Safran Aircraft Engines Chairman - AESQ

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. Agenda

Safran 08:00 Case Welcome & Voice Studies Overview & Introductions of the Maxime Heinisch Overview Olivier Objectives Ian Olivier Customer Barbara Lisa BREAK Barrie Riggs Castets Balmat Safety Negroe Claveloux Hicklin

Process FMEA Measurement Systems Process Control Problem Solving (8D)

GROUP Welcome Ian Martin LUNCH Back Olivier FACC PHOTO Pete E Teti PW Kalisz Riggs Schäffner Mechachrome 12:00 12:45 Castets Meggitt

Human Let’s Talk Closing Deployment Remarks Factors A380 FAL 17:00 Catherine Ludovic BREAK Erika Helen Ian Barbara Tour Information CLOSE & Catarina-Graca Chevet Grimm Djäknegren Riggs Negroe DEPART

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. Toulouse Supplier Forum Delegate Pack

Delegate Pack Contents 1) Agenda 2) Using PollEV and Wifi Details Defect Prevention in the 3) Presentation Material Aero Engine Supply Chain 4) Case Studies 5) Speaker Biographies 6) AS13xxx Standard Training Provider Information an AESQ SUPPLIER FORUM EVENT 7) AESQ Website Details Radisson Blu Hotel, Toulouse Airport October 9th 2019 8) Airbus A380 Tour Details

4 AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. The AESQ Steering Group Members

Barbara Negroe Lisa Claveloux Ian Riggs Olivier Castets Executive Sourcing Quality Leader Director Supplier Quality Global Quality Executive Quality Manager Component & Accessories GE Aviation Pratt & Whitney Rolls-Royce Civil Aerospace Safran Aircraft Engines

Helen Djäknegren Barrie Hicklin Martin Schäffner James Clifton Osa Omoruyi Director Global Supplier Quality Director, Quality Systems Senior VP Corporate Quality VP Quality Director of Quality GKN Aerospace & Regulatory Compliance MTU Aero Engines PCC Structurals Arconic Honeywell

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. AESQ Members Introduction

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. Who is in the Room Today?

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. Voice of the Customer

Olivier Balmat VP Industrial Quality

Safran Aircraft Engines

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. AESQ SUPPLIER FORUM IN TOULOUSE SAFRAN INTRODUCTION

October 8th, 2019

Ce document et les informations qu’il contient sont la propriété de Safran. Ils ne doivent pas être copiés ni communiqués à un tiers sans l’autorisation préalable et écrite de Safran. C2 - Restricted

SAFRAN: TECHNOLOGY THAT BENEFITS OUR DAILY LIVES

1 SINGLE-AISLE MORE THAN 80+ COMMERCIAL 62,000 LANDINGS SUCCESSFUL JET TAKES OFF a day using our ARIANE 5 every 2 SECONDS, equipment LAUNCHES powered by our in a row*** engines**

3,000 MILITARY 1 OUT OF EVERY OVER 40,000 AIRCRAFT fitted 3 HELICOPTER POWER with our inertial TURBINE TRANSMISSIONS navigation systems ENGINES totalling over 1 billion sold worldwide flight-hours

MORE THAN MORE THAN 1 MILLIONSEATS 21,500 NACELLE 100 KM OF in service in airline COMPONENTS ELECTRICAL fleets worldwide in service WIRING on an Boeing 787 Dreamliner

**in partnership with GE, through CFM International ***in partnership with Airbus, through ArianeGroup 10 Safran name of the activity / Date / Department (menu "Insert / Header and footer") Ce document et les informations qu’il contient sont la propriété de Safran. Ils ne doivent pas être copiés ni communiqués à un tiers sans l’autorisation préalable et écrite de Safran. C2 - Restricted

A COMPREHENSIVE RANGE OF AIRCRAFT PROPULSION SYSTEMS

AND EQUIPMENT Cabin interiors Power & data wiring Cockpit Lavatories, water Seats & waste Oxygen systems Control systems IFEC – In-flight entertainment & connectivity Panel & displays Seats Flight actuators Auxiliary Power Unit (APU)

Avionics sensors Aircraft condition monitoring systems

Exit slide

Anti icing & de-icing Galleys & equipment Exterior lighting

Inerting & fuel systems

Landing gears Engines Braking & landing control systems Nacelles & components Engine control systems (FADEC) Wheels and carbon brakes Power transmission systems Power distribution and generation

11 Ce document et les informations qu’il contient sont la propriété de Safran. Ils ne doivent pas être copiés ni communiqués à un tiers sans l’autorisation préalable et écrite de Safran. C2 - Restricted

PROPULSION: THE BROADEST POWER RANGE

(1) Rolls-Royce Turbomeca Ltd, a 50/50 joint company between Safran Helicopter Engines and Rolls Royce

(2) PowerJet is a 50/50 joint company between Safran Aircraft Engines and UEC Saturn (Russia)

(3) CFM International is a 50/50 joint company between Safran Aircraft Engines and GE (USA)

(4) By Europrop International (EPI), a consortium of Safran Aircraft Engines, Rolls- Royce, ITP and MTU Aero Engines

(5) In collaboration with GE (USA)

(6) Through the Engine Alliance (Safran Aircraft Engines 10%, Safran Aero Boosters 7.5%)

(7) In collaboration with GE (Safran Aircraft Engines 23.7%)

(8) Through Europropulsion, a 50/50 joint company between Safran and Avio (Italy)

12 Safran name of the activity / Date / Department (menu "Insert / Header and footer") Ce document et les informations qu’il contient sont la propriété de Safran. Ils ne doivent pas être copiés ni communiqués à un tiers sans l’autorisation préalable et écrite de Safran. C2 - Restricted

CFM® – A French-American alliance

No. 1 engine supplier worldwide for mainline commercial jets (over 100 seats)

More than 570 customers worldwide

Safran Aircraft Engines & GE, 50/50 joint company All activities are equally split: design, Partnership extended successful partners for over 40 years development, production, sales and support. to 2040

13 Safran Aircraft Engines / 2018 Ce document et les informations qu’il contient sont la propriété de Safran. Ils ne doivent pas être copiés ni communiqués à un tiers sans l’autorisation préalable et écrite de Safran. C2 - Restricted

LEAP® – Combining the best technologies from Safran Aircraft Engines and GE

A320neo 737 MAX C919 More than 17,000 orders and commitments as of July 2018

-15% lower fuel consumption*

LEAP-1A LEAP-1B LEAP-1C Entry into service Entry into service Entry into service -15% reduction in August 2016 in May 2017 2018 in CO2 emissions*

14 Safran Aircraft Engines / 2018 Ce document et les informations qu’il contient sont la propriété de Safran. Ils ne doivent pas être copiés ni communiqués à un tiers sans l’autorisation préalable et écrite de Safran. C2 - Restricted

How can we manage the LEAP ramp up and ensure safety at the same time?

By fully endorsing the APQP process and the corresponding AESQ standards through 3 projects

SPI SPOC SPRED To manage the APQP and its To ensure the right level of To ensure the capability of tollgates requirements over the the production processes To ensure maturity at each control plan steps of the development Supported by Supported by Supported by • AS9145 for APQP • AS13002 to qualify • AS13006 for Process • AS13004 for PFMEA alternate inspection Control • AS13003 for MSA frequency plan

15 Safran nom de l’activité / Date / Direction (menu "Insertion / En-tête et pied de page") Ce document et les informations qu’il contient sont la propriété de Safran. Ils ne doivent pas être copiés ni communiqués à un tiers sans l’autorisation préalable et écrite de Safran. C2 - Restricted

16 Safran nom de l’activité / Date / Direction (menu "Insertion / En-tête et pied de page") Ce document et les informations qu’il contient sont la propriété de Safran. Ils ne doivent pas être copiés ni communiqués à un tiers sans l’autorisation préalable et écrite de Safran. AESQ Overview

Barbara Negroe Lisa Claveloux Executive Sourcing Quality Leader Director Supplier Quality

GE Aviation Pratt & Whitney Vice Chair - AESQ

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. Commercial Aviation – A Growth Market

In 2036

4.5% / yr Increase in Passenger Traffic = 2 X active aircraft worldwide

7,100 billion passenger km in 2016 23,000 active aircraft in 2016

17,000 billion passenger km in 2036 45,000 active aircraft in 2036

Quelle: Ascend, IATA, MTU

18 AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. Aviation Safety

The Quality of our products and services are extremely important. Quality and continuous improvement are an absolute must!

19 AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. Aero Engine Supplier Quality (AESQ)

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. Aero Industry Requirements Flowdown 2012 Industry Requirements Regulator Customer Requirements Requirements NADCAP AS Standards (AS9100, AS9145, AS9103, etc.)

AERO Engine Manufacturers

Rolls-Royce GE P&W Safran SABRe S-1000 ASQR-01 SAFe

Aero Engine Supply Chain

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. AESQ Vision

To establish and maintain a common set of Quality Requirements that enable the Global Aero Engine Supply Chain to be truly competitive through lean, capable processes and a culture of Continuous Improvement.

22 AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. AESQ Vision

In detail • Create common standards within the engine manufacturers (OEM’s) in regard to quality • Deploy together the written standards throughout our supply chain • Establish capable quality processes with a focus on Defect Prevention and a culture of continuous improvement Main targets • To improve quality within the supply chain • Improve on time delivery and minimize costs through a reliable quality performance

• Gain efficiency by standardized processes

23 AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. Aero Industry Requirements Flowdown 2019

Industry Requirements Regulator Customer Requirements Requirements NADCAP AS Standards (AS9100, AS9145, AS9103, etc.)

AERO Engine Manufacturers AESQ AS13xxx Rolls-Royce GE P&W Safran Standards SABRe S-1000 ASQR-01 SAFe

Aero Engine Supply Chain

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. Product Life Cycle & Document Interaction AS9145 (APQP/PPAP) & AESQ Standards

End of Concept Design Release Initial Prod. Production AS9145 Kick Off (PDP) (PDR) (CDR) Approval Launch 5. Ongoing Production, use and 1. Planning Post Delivery Service 4. Product & Process AS9145 2. Product Design & Development Validation APQP Phases 3. Process Design & Development

Production AS9102 AS9145 Key PPAP Readiness FAIR Approval PPAP Events Review Production Process Run Process Flow Diagram AS9145 PPAP Design Packaging, MSA PFMEA Preservation & ICS Records Control Plan Element Timing & DRA Labelling FAI AS13004 – PFMEA & Control Plans

AESQ AS13003 – Measurement Systems Analysis 2nd Level Documents AS13006 – Process Control Methods

AS13002 – Inspection Frequency Plans

AESQ AS13000 – Problem Solving Requirements for Suppliers - 8D Systems Documents AS13001 – Delegated Product Release Verification Training Requirements

86 AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. Aero Industry Requirements Flowdown Vision Industry Requirements Regulator Customer Requirements Requirements NADCAP AS Standards (AS9100, AS9145, AS9103, etc.)

AERO Engine Manufacturers

AESQ Quality Management Requirements (Supplemental to AS9100)

Aero Engine Supply Chain

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. AESQ Website

Access AESQ Website to;

• Provide feedback on current and developing standards

• Share best practice deployment stories

• Get clarification of Standard deployment & interpretation

https://aesq.sae-itc.com

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. AESQ Will Drive Progress

AS13000, AS13001, AS13002, AS13003, AS13004 and AS13006 have all been flowed down by all AESQ members and are part of your Purchase Order.

29 AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. Deployment Case Studies

AS13xxx Series Standards

Barrie Hicklin Director Quality Systems & Regulatory Compliance Honeywell

1 AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. 2

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. Supplier Case Studies

Case Study 1 Case Study 2 Case Study 3 Case Study 4

AS13003 AS13000 AS13004 AS13002 & AS13006 Measurement Systems Problem Solving using PFMEA & Control Plan Process Control Analysis (MSA) 8D

Standard Highlights Standard Highlights Standard Highlights Standard Highlights Dr Ian Riggs Martin Schäffner Peter Teti Olivier Castets

FACC Mechachrome PW Kalisz Meggitt Case Study Case Study Case Study Case Study

Q&A Q&A Q&A Q&A

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. Case Study AS13004 Process Failure Mode & Effects Analysis (PFMEA) & Control Plans

Dr Ian Riggs Global Quality Executive Rolls-Royce Civil Aerospace

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. AS13004 Process FMEA & Control Plan Overview

2. Process FMEA

1. Process Flow Diagram

3. Production Control Plan

Keep Updating

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. AS13004 Process FMEA & Control Plans : Maturity Checklist

AS13004 Assessment Checklist

Ref Clause Complies Category Question Comments Editable file linked from the # Ref. Yes No standard AS13004. 4.1 Have the tools and methods defined within this standard been 1 4.1.1 Process Risk deployed using a cross functional team? Identification, Assessment, Has the design organization completed a Design Risk Analysis 2 Mitigation and 4.1.2 (DFMEA) that identifies risks associated with safe and proper Prevention operation of the product? Overview Has AS13004 been applied to all New Product Introduction 3 4.2.1 programmes? Has AS13004 been applied to products and/or services currently used in production following manufacturing process 4 4.2.2 changes, transfer to a new location or being addressed for 4.2 improvement?

Applicability Once invoked, is AS13004 being applied throughout the lifecycle of a product, process risk being reviewed on a 5 4.2.3 continual basis and mitigation actions being taken and actioned on a frequent basis? Has AS13004 been flowed to all suppliers that manufacture 6 4.2.4 and/or supply products and services?

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. What is a PFMEA?

Potential S D Potential Potential Prevention O Detection Process Requirements Failure E C E RPN Effects Causes Controls Controls Modes V C T

Fuel leak Oversize Tool pre- Bore mic leading to 9 4 7 252 OP10 Whattool wouldsetting need to Howat OP will50 you Drill FUEL Hole explosion fail in the process to HoleHow too could you get detect the CNC 50mm Diameter Big Cause and/or Spindlecause theAsset Failure Care Weekly WhatDrilling are you+/- 1.0trying mm the Requirements 6 Mode? Failure to create? wrong?Scrap part alignment & 3 ball bar 8 189 error Calibration checkMode? Slight How could this be Defined by Engineering How bad would it be Oversize Tool pre- HowBore likelymic are Drawings & increase in 3 prevented? 2 7 56 OP20 Drill AIR Hole if was noisenot level to tool setting youat OP to 50 detect Specifications Hole too the Cause or CNC 50mm Diameter Bigspecification? SpindleHow likelyAsset is Care it to WeeklyFailure Drilling +/- 3.0 mm Concession 4 alignmenthappen? & 1 ballMode? bar 8 28 error Calibration check

Product Focussed Process Focussed

Risk Profile (RPN) = Severity x Occurrence x Detection

8 AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. Process FMEA & Control Plans : Critical Success Factors

Must be created & Maintained by a PFMEA must be done at the CROSS FUNCTIONAL TEAM RIGHT TIME

AS13004 Deployment

PFMEA Failure Modes must Required for EVERY part number* describe PRODUCT DEFECTS

PFMEAs must DRIVE ACTIONS Include ALL Process Steps to reduce risk

EVERY Design Characteristic Keep up to date – They are LIVE included in the PFMEA** documents

*Typical deployment for NPI, Key Changes (Design or Process), Source Changes as well as Major Quality Issues Corrective Actions **Rolls- Royce Requirement

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. Process FMEA Case Study

Juergen Klinglhuber Andre Haertelt Director, Quality VP Operations Manufacturing Quality FACC Aerostructures FACC Aerostructures

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. AS 13004 (PFMEA & CONTROL PLAN) BENEFITS OF DEPLOYING PREVENTION TOOLS AS PART OF APQP AND ZERO DEFECTS

AGENDA

1) WHO WE ARE 2) WHERE WE ARE NOW 3) HOW WE GOT THERE 4) WHERE WE WANT TO GO 5) HOW WE CHANGED 6) WHAT WE LEARNED AESQ DEFECT PREVENTION SUPPLIER FORUM OCT 9TH 2019 WHO WE ARE

OUR PARTS PORTFOLIO OUR CUSTOMERS AESQ DEFECT PREVENTION SUPPLIER FORUM OCT 9TH 2019 WHO WE ARE FACC OVERVIEW – FIGURES & FOOTPRINT AESQ DEFECT PREVENTION SUPPLIER FORUM OCT 9TH 2019 WHERE WE ARE THE EFFECT OF BIQ – THE HARD FACTS AESQ DEFECT PREVENTION SUPPLIER FORUM OCT 9TH 2019 WHERE WE WERE PFMEA TO AS13004 AS AN ENABLER – THE SOFT FACTS

PFMEA Control Plan

FOR CUSTOMER SATISFACTION ONE-OFF CHARACTER RATHER INSPECTION FOR THE RECORDS PLANS

DONE IN ISOLATION NOT ALIVE (QUALITY) NOT DERIVED FROM PFMEA

Late after FAIR AESQ DEFECT PREVENTION SUPPLIER FORUM OCT 9TH 2019 WHERE WE WANT TO BE PFMEA TO AS13004 AS AN ENABLER – THE SOFT FACTS

PFMEA AS A “SCHOOL OF THOUGHT“

FROM ONE-OFF TICK EARLY ENGAGEMENT CROSS FUNCTIONAL BOX EXERCISE TO WITH EFFECT ON COLLABORATION – CULTURALLY DRAWING BY-OFF COMMON GOALS EMBEDDED PLM PROCESS ELEMENT

PFMEA AS A TOOL

BUILDING BLOCKS FOR FORMAL STANDARD INCREASED PRODUCT RECORDING AND ALLOWING MORE UNDERSTANDING DEVELOPMENT OF EFFICIENT (DESIGN SEVERITY PORTFOLIO APPLICATION WITH SCORING) COMMODITY EVERY TURN KNOWLEDGE AESQ DEFECT PREVENTION SUPPLIER FORUM OCT 9TH 2019 HOW WE GOT THERE THE CHALLENGING STARTING POINT

?? AS13004 FOR EVERYTHING AND NOW AESQ DEFECT PREVENTION SUPPLIER FORUM OCT 9TH 2019 HOW WE GOT THERE DEPLOYMENT OF AS13004 @ FACC

RIED ZERO DEFECTS SABRe³ RELEASE OF AS13004 WORKSHOP SELF-ASSESSMENT SABRe³ GO LIVE

2017 2018 2019

DERBY ZERO DEFECTS PILOT PFMEA SUB-TIER REVISION OF FACC PEP EVENT GOLD STANDARD FLOW-DOWN AESQ DEFECT PREVENTION SUPPLIER FORUM OCT 9TH 2019 WHERE WE WANT TO GO FULL PORTFOLIO COVERAGE – “INFECTION” LIGHTHOUSE PROJECT TO GAIN EXPERIENCE KNOWLEDGE TRANSFER COMMODITY COMMONALITIES (PART FAMILIES) FLEET & DOMINO/SNOWBALL EFFECT LEGACY NPI RR FLEET & LEGACY NPI RR FLEET & LEGACY FIRST DEFINED PART OF RR NPI RR FLEET & LEGACY AESQ DEFECT PREVENTION SUPPLIER FORUM OCT 9TH 2019 HOW WE CHANGED AS13004 – THE QUALITY OF PFMEA

OLD VS. NEW FACC PFMEA → MORE DETAILED FUNCTIONAL NET AESQ DEFECT PREVENTION SUPPLIER FORUM OCT 9TH 2019 HOW WE CHANGED AS13004 EMBEDDED IN THE ORGANISATION

EXT & INT COLLABORATION

PRODUCT UNDERSTANDING MORE FOCUS ON ZERO DEFECTS MINDSET SPREAD THROUGHOUT ELIMINATION OF PFMEA AMBIGUITY THE COMPANY (FEATURE VS PROCESS)

CROSS-PEOPLE AND CROSS-PROCESS INTERACTION

MGMT UNDERSTANDING OF BENEFITS (UPFRONT INVESTMENT VS CoNQ) AESQ DEFECT PREVENTION SUPPLIER FORUM OCT 9TH 2019 WHAT WE LEARNED STRONGER TOGETHER

> COLLABORATION IS KEY > NEW DEPARTMENT WITH DEDICATED AND SKILLED FMEA HOST FOR FMEA SESSIONS > GOOD MODERATION DRIVES > GROWING DATABASE (REFERENCE FMEA FOR RESULTS COMMON PROCESSES, FEATURE BASED FOR > COMMODITY DRIVES SCOPE PRODUCT SPECIFIC ASPECTS → BUILDING (FEATURE & PROCESS) BLOCKS / LEGO® SYSTEM FMEA) > AS13004 BY MS EXCEL BEARS RISKS > UNIFYING SOFTWARE SOLUTION COVERING AND MEANS MANUAL EFFORT FULL CIRCLE FMEA–CP–SPC IN EVALUATION AESQ DEFECT PREVENTION SUPPLIER FORUM OCT 9TH 2019 WHAT WE LEARNED OBSERVATIONS ON AS13004

AS13004 IDEAL FOR “ONE STOP SHOPS“ – MAKE2PRINT/OEM/SUB-TIER COORDINATION EFFORTS - FEATURE FOCUS – RISK OF OMITTING COMMODITY RELATED PROCESS ASPECTS - DEFINED STANDARD CREATES CLARITY, SUPPORTS RFT AND REDUCES EFFORT +

HELPS TO IDENTIFY CRITICAL MANUFACTURING FEATURES AND DRIVES PROCESS CONTROL VIA CONTROL PLAN – SUPPORTS ON TIME PRODUCTION READINESS +

ACTS AS TOOL KNOWLEDGE MGMT AND SHEDS LIGHT ON SIMILAR PRODUCT AND PROCESSES + AESQ DEFECT PREVENTION SUPPLIER FORUM OCT 9TH 2019 WHAT WE LEARNED RECOMMENDATIONS

SHARE RESPONSIBILITIES PLAN IN ADVANCE (NOT QUALITY ONLY)

GO STEP BY STEP PPAP AND ADHERE TO STRUCTURES SUCCESS CHANGE MGMT DEFINE LIGHTHOUSE PARTS EARLY COORDINATION GRADUALLY WITH DESIGN OWNER INCREASE SCOPE THANK YOU

24.10.2019 AS13004 Success Stories

RR XWB Stub Shaft Sam Suzhou make Engine Trent 7000 Fan Case Delivered Hanwha is a Structures & Deployed AS13004 Mounts for XWB. Defect Free at PPAP after Transmissions supplier. PFMEA on all 16 Part Specific FMEAs in 3 applying ZD Toolkit. Feature based PFMEA using Characteristics months Parts now delivered Defect Free Reference PFMEAs Cross-functional Introduction of error proofing Manufactured by GKN, Cross-functional team (design, teamwork and prevention controls. Newington. manufacturing & Hanwha) Zero Defects at Product Defect Free since September PPAP completed in 6 months This led to DPU reduction: Launch 2017 instead of the usual 18 months. Trent XWB A-Frame: to 0.00. APQP / PPAP Delivered in Trent 7000 A-Frame DPU 50% of the time scheduled improved to 0.0.

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. Using REFERENCE PFMEAs to improve Effectiveness & Efficiency

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. Potential S O D Potential Potential Prevention Detection Process Requirements Failure E C E RPN Effects Causes Controls Controls Modes V C T

Fuel leak Oversize Tool pre- Bore mic leading to 9 4 7 252 OP10 tool setting at OP 50 Drill FUEL Hole Hole too explosion CNC Hole too Big / Too DrillingCNC 50mm Diameter Big DIAMETER Small Spindle Asset Care Weekly Drilling +/- 1.0 mm Scrap part 6 alignment & 3 ball bar 8 189 error Calibration check

Stress on Fuel Incorrect CMM at pipe leading to 9 manual None 2 7 126 OP10 OP120 Drill FUEL Hole cracks offset CNC Out of DrillingCNC Position X, Y Position POSITION Machine Asset Care Weekly Drilling +/- 0.05 mm Concession 4 calibration & 1 ball bar 8 28 out of limit Calibration check

Fuel leak Incorrect CMM at leading to 9 offset None 2 7 126 OP10 OP120 Drill FUEL Hole Hole too explosion used CNC Hole too Deep / too DrillingCNC Hole Depth 120 Deep DEPTH Shallow Spindle Asset Care Weekly Drilling mm +/- 1.5 mm Concession 4 alignment & 1 ball bar 8 28 error Calibration check Creating a Part Specific PFMEA using Reference FMEAs

Reference PFMEA Database ‘SHELL’ Part Number PFMEA

Drawing & Specifications

Characteristic Matrix

Part Specific Design and Process Documentation

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. Completing the Part Number Specific PFMEA

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. Using the ‘Bridge Tool’ to create the SHELL PFMEA Real Time Demo

Developed by Rolls-Royce Bangalore

Equivalent Processes available from Quest Engineering Consultancy and Tata Consultancy Services (TCS)

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. How long does it take?

Create Reference 30 man hours per PFMEAs REF PFMEA

30 man hours per Shell PFMEA (manual method): Create Shell PFMEA <2 Hours using Bridge Tool

Complete 1st - 3rd Part 400 man hours per PFMEA Specific PFMEAs

<100 man Complete future Part hours per Specific PFMEAs PFMEA

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. SOURCES OF FURTHER INFORMATION & GUIDANCE

1. Deploying AS13004 Practitioner Guide available free of charge on the RR Supplier Portal and the AESQ website 2. Available in English, German and Chinese 3. Selection of Rolls-Royce Reference PFMEAs available to external businesses via its Supplier Portal (open to all) 4. Invest in; • Dedicated FMEA IT software • Global PFMEA training is available to support this approach through SAE, Smallpeice Enterprises and Industry Forum

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. AS13004 PFMEA Deployment Steps

1. 2. 3. Select the Upskill the Team using Create a Coaching network to Cross Functional Team AS13004 Approved Training develop the Team’s capabilities

Potential D Potential S Potential Prevention O Detection Process Requirements Failure E C E RPN Effects Causes Controls Controls Modes V C T

Fuel leak Oversize Tool pre- Bore mic leading to 9 4 7 252 OP10 Drill FUEL Hole explosion tool setting at OP 50 Hole too CNC 50mm Diameter Big Spindle Asset Care Weekly Drilling +/- 1.0 mm Scrap part 6 alignment & 3 ball bar 8 189 error Calibration check

Slight Oversize Tool pre- Bore mic increase in 3 2 7 56 tool setting at OP 50 OP20 Drill AIR Hole noise level Hole too CNC 50mm Diameter Big Spindle Asset Care Weekly Drilling +/- 3.0 mm Concession 4 alignment & 1 ball bar 8 28 error Calibration check 4. 5. 6. 7. Develop your Use IT Solution to create Complete the PFMEA with Identify and implement Reference PFMEA Database ‘Shell’ PFMEA the Cross Functional Team improvement actions from the PFMEA

34 AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. Effective Process FMEAs will TRANSFORM YOUR QUALITY PERFOMANCE!

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. Case Study AS13003 Measurement Systems Analysis

Martin Schaeffner Anthony Hartwig Senior VP Corporate Quality Customer Quality Manager MTU Aero Engine Mechachrome

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. Why is MSA so Important?

1. We are reliant upon 4. MSA allows us to measure the Measurement & Inspection to Capability of our Measurement ensure non-conforming and Inspection processes products are detected 5. It helps identify sources of 2. Data from Measurement and variation so that mitigating / Inspection is required to identify improvement actions can be changes to process stability taken to improve capability

3. All Measurement Systems have 6. Many of the required MSA error – we must ensure that this Tests for Gauges is part of the is as small as possible and Calibration Process within agreed thresholds

38 AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. What Types of MSA are there?

Accuracy*

Resolution** Repeatability Reproducibility

Stability = Time Change in Bias over time

Linearity* Stability Attribute Agreement Analysis

*Usually done as part of Gauge calibration **Gauge Selection Criteria

39 AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. AS13003 Measurement System Analysis Overview

Section 7 Section 8 Section 9 Section 10 Measurement Elements to MSA MSA Case System Consider when Audit Checklist Studies Requirements conducting an MSA

The When & the What MSA Design Gauge R&R Acceptance Criteria Sample selection and Gauge R&R for CMM size Attributes Analysis of results, Accuracy Ratio etc. etc.

40 AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. AS13003 Measurement Systems Analysis Overview

Figure 2 : Defines what type of MSA needs to be done

Table 1: Defines when MSA Table 2 : Defines the acceptance needs to be done thresholds for each type of MSA

41 AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. AS13003 MSA implementation Measurement System Analysis deployment Anthony Hartwig Customer Quality Manager Mecachrome FRANCE

42 MECACHROME COMPANY OVERVIEW

• 3000 employees worldwide • Locations France / Canada / Portugal / Tunisia Morocco /Potential Development in USA • 400 Millions Euros in 2018 • Aerostructure / Aeroengine / Energy Space & defence / Automotive Sport Automotive • 1000+ suppliers & sub-contractors • Since 1937: Knowledge and innovation of our teams at the service of our customers for profitable growth

43 A multisectoral know-how – Our Customers

AEROSTRUCTURE AEROENGINE AUTOMOTIVE ENERGY, SPACE & D E F E N C E

56% OF 20% OF 19% OF OF REVENUE 2017 REVENUE 2017 REVENUE 2017 5% REVENUE 2017

44 AS13003 implementation

Before MSA: • Measurements systems choice and use based on historical industrial best practices. • Pillar was the regular calibration. • Data reliability linked to employees skills. • Reoccurring discussions on data’s reliability.

Calibrated So OK to use for what-ever tolerances

45 MSA Implementation

• Mecachrome has decided to go on MSA implementation • Inspection, Quality, Master Black Belt, Engineering, all operational people including customers were involved on the MSA implementation – Several months for the basis of our internal process. – Ongoing discussion with our customers – Key activities : agreement with customers & internal minds change process. i.e.: Agreements for CMM on numbers of repetitions : mini 3 dynamics + 2 statics

46 MSA Implementation

Developing pragmatical approach on “classical devices”. We have more than 10000 of classical devices (just for Aubigny plant).

Not realistic to do R&R studies on each use. National standards applied to create choices matrix.

For adapted classical devices we apply R&R Study and sometimes this gave some surprises i.e. Results above 113%, so complete design was reviewed.

47 What Results did we get?

• MSA allowed us to identify issues which weren’t seen by “basic calibration” → variability root causes. i.e: - broken pin on tooling - design not efficient • CMM is not capable to measure small diameters Before Today • Last but not least: we can trust on our measurements when Gauge R&R is acceptable

48 Insights

• What did we learn about the MSA deployment – Perform continuously – Face skilled people reaction, “why changing what we do since decades” ? – Lead with a multi functional team – Adapt internal communication. “It is a useful tool not another thing to satisfy customers” – Share openly with customers

49 AS13003 Measurement Systems Analysis → Success Factors

• The goal is to make sure that every measurement system (gage + outside influences) used is Fit for Purpose • The AS13003 method summarizes different tools and delivers a standardized approach. • By using the MSA method you get a reliable and understandable statement if you can rely on your results or not • Don’t touch your production processes before you are sure about your measurement • An MSA helps to eliminate influences coming from different measurement strategies • A CMM measurement is not always reliable – accuracy and inspector variance matters • A comparison to an independent reference measurement gives a valuable insight into the production line measurement;

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. Nous saluons le retour (Welcome Back) How to Effectively Deploy Defect Prevention Methods

in the Aero Engine Supply Chain

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and Copyright © SAE International. Further use or distribution is not permitted without permission from SAE confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. Case Study AS13006 Process Control Methods

Pete Teti Product & Process Validation Fellow

Pratt & Whitney Nauset Light Beach, Cape Cod, Eastham, MA (2017)

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. AS13006 Process Control Methods

• Processes must be controlled to maintain stability and capability • Using statistical concepts, processes can be managed to prevent defects • Statistical Process Control is required for Key Characteristics but should also be considered for • Characteristics with marginal or poor capability • Visual inspection operations • SPC allows variation to be identified, controlled and reduced. • The best form of Process Control is Error Proofing • There are a range of Process Control methods available to suit all process types 4 AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. Relationships to otherAS13006 Industry - Process Control Standards Methods - Appendix A Standard Interconnection Overview

The AS standards are available from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Telephone: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), Web address: http://www.sae.org

AS9100

Legend

SAE AS9100 - Quality Management Systems - Requirements for Aviation, Space, and Defense Organizations SAE AS9145 - Requirements for Advance Product Quality Design Risk Planning and Product Part Approval Process Analysis SAE AS9103 - Quality Management Systems - Variation Feedback Management of Key Characteristics SAE AS13002 - Requirements for Developing and Qualifying Key Product Characteristics Alternate Inspection Frequency Plans AS13003 AS13002 AS13004 AS13006 SAE AS13003 - Measurement Systems Analysis Measurement System Alternate Inspection Process Requirements for the Aero Engine Supply Chain Process Flow Process Control Process Analysis Analysis Frequency Plans PFMEA Control Plan Monitoring & Method Selection and Improvement SAE AS13004 - Process Failure Mode and Effects Analysis (MSA) Diagram Control (PFMEA) and Control Plans SAE AS13006 - Process Control Methods Product and Foundational Process Key Activities Characteristics

No export related technical data Copyright @ AESQ Strategy Group, a Program of SAE ITC. This material is provided by SAE "AS IS" and may be reproduced, used and modified under the condition that the user hereby holds SAE harmless from user's manipulation of the forms and indemnifies SAE from any and all claims or damages caused by use, modification or applications thereof. 10 AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. Process Control Methods Guidance Materials

• Practical information to support the implementation of Process Control; • Benefits of process control • Overcoming resistance • Details on Process Control methods • Various control charts applications • Calculating process capability • Managing non-normal data Case Study Example Guidance Table Example • Associated formulas • Case studies based on aerospace applications • Assessment Checklist provides a method to measure the maturity of Process Control Specific Control Method Example Case Study Example

PART A: PART B: PART C: PART D: PART NUMBER: ______890150-1 PART NUMBER: ______890160-1 PART NUMBER: ______890170-1 PART NUMBER: ______DESCRIPTION: ______BUSHING DESCRIPTION: ______BUSHING DESCRIPTION: ______BUSHING DESCRIPTION: ______USL: ______.255 LSL: ______.245 USL: ______.504 LSL: ______.496 USL: ______.980 LSL: ______.970 USL: ______LSL: ______NOMINAL: ______.250 INCH NOMINAL: ______.500 INCH NOMINAL: ______.975 INCH NOMINAL: ______PART: A A A B B B B B C C C C A A A B B B C C DATE/TIME: NOTES: application within the business 1 VALUE: .252 .249 .250 .501 .498 .500 .502 .497 .976 .977 .974 .974 .250 .250 .249 .502 .500 .498 .975 .974 2 NOMINAL: .250 .250 .250 .500 .500 .500 .500 .500 .975 .975 .975 .975 .250 .250 .250 .500 .500 .500 .975 .975 VALUE-NOMINAL 3 (ROW 1 - ROW 2) .002 -.001 0 .001 -.002 0 .002 -.003 .001 .002 -.001 -.001 0 0 -.001 .002 0 -.002 0 -.001 __ 4 MOVING RANGE .003 .001 .001 .003 .002 .002 .005 .004 .001 .003 0 .001 0 .001 .003 .002 .002 .002 .001 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 +.006

(X) +.004 UCLx +.002 • Defined Training Syllabus to help identify

0 NOMINAL - -.002 LCLx VALUE VALUE -.004 -.006 .008 (MR) .006 UCLr suitable courses to support deployment .004

.002

MOVING RANGE MOVING 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Control of multiple part numbers on one chart

6 AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. AS13006 Case Study

Boguslaw Bac Agnieszka Kryściak Quality Director Manager, Part & Process Approval Pratt & Whitney Kalisz Pratt & Whitney Kalisz

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. PRATT & WHITNEY KALISZ AS 13006 OUTSIDE DIAMETER CONTROL CASE STUDY EXPORT CLASSIFICATION Check this box if presentation contains “no technical data” x OR summarize the export classifications of all slides in this presentation as instructed below:

Instructions: Box 1 and one (1) of boxes 2-5 must always be completed Classification: 1. Canadian ECL(s): 2. ECCN(s) (EAR): 3. P-ECCN(s) : 4. USML (ITAR): 5. P-USML:

PROPRIETARY NOTICE This document is the property of Pratt & Whitney Canada Corp. (“P&WC”). You may not possess, use, copy or disclose this document or any information in it, for any purpose, including without limitation to design, manufacture, or repair parts, or obtain TCCA, FAA, or other government approval to do so, without P&WC's express written permission. Neither receipt nor possession of this document alone, from any source, constitutes such permission. Possession, use, copying or disclosure by anyone without P&WC's express written permission is not authorized and may result in criminal or civil liability.

9 EXPORT CLASSIFICATION: NO TECHNICAL DATA PRATT & WHITNEY IN POLAND

P&W Kalisz

P&W Tubes PW 1000 PW 800 APS 5000

P&W Aero Power P&W Rzeszów Airbus A320 NEO Gulfstream 500 Boeing 787

10 EXPORT CLASSIFICATION: NO TECHNICAL DATA PRATT & WHITNEY KALISZ

Produces 1550 P/N Customers: Area Land 150 000 sqm Pratt & Whitney East Hartford Buildings (production & offices) 40 000 sqm Pratt & Whitney Canada Sales 185 M USD Pratt & Whitney Rzeszów Employment 1608 Collins Aerospace

Plant 1 Plant 2 Plant 3 Plant 4

Bevel Gears Stators Carrier FDGS BH#4 NEO

Carrier Main Shaft Input Coupling SMP

11 EXPORT CLASSIFICATION: NO TECHNICAL DATA PRATT & WHITNEY KALISZ NGPF ENGINE CONTENT

Input Cupling ADT & Wind mill gears Small Machining Parts Plant 3 Plant 1 + Bearing housing Plant 4

TIE Shaft Plant 3 Fan Shaft Plant 3

Front hub Torque Frame Carrier Journal Pin Cupling nuts Plant 2 Plant 3 Plant 3 Plant 1 Plant 2 FDGS components 12 EXPORT CLASSIFICATION: NO TECHNICAL DATA PRATT & WHITNEY KALISZ

INTRODUCING NEW PRODUCT Challenges during product implementation: Assuming quick implementation

Spring Bearing PW 1000 Low cost = zero defects engine for A320 NEO Thin-walled part and no experience in machining titanium parts PPAP full approval expectation

Implementation of AS 13006 with associated AS 13004: Proactive process control Identification of Key Characteristics Selection of appropriate process control tools Based on Foundational Activities (making process control achievable)

SAE International AS 13006 (2018, September) 13 EXPORT CLASSIFICATION: NO TECHNICAL DATA PRATT & WHITNEY KALISZ OUTSIDE DIAMETER CONTROL EXAMPLE

OUTSIDE PROCESS PFMEA CONTROL DIAMETER FLOW PLAN CONTROL

TURNING OPERATION HIGH RPN KEY CHARACTERISTIC SHOT PEENING OPERATION

OUTSIDE DIAMETER DEFORMATION

EXPORT CLASSIFICATION: NO TECHNICAL DATA 14 PRATT & WHITNEY KALISZ OUTSIDE DIAMETER CONTROL EXAMPLE

Capability is PRODUCT CAPABILITY understood and drives AS 13006 improvements scope 1st off confirmation checks/ Life / usage Error-Proofing checklists and PROCESS CONTROL controls test pieces devices METHODS

Pre-Control Attribute SPC Run charts – Variable SPC methods charts with limits charts

Maintenance Environment SUPPORTING FOUNDATIONAL ACTIVITIES Training Standard methods Capable Measurement

SAE International AS 13006 (2018, September) Figure 1 – Process control overview EXPORT CLASSIFICATION: NO TECHNICAL DATA 15 PRATT & WHITNEY KALISZ OUTSIDE DIAMETER CONTROL EXAMPLE

Dedicated training Standard method along with TPM sessions scheduled program for engaged utilization of continuous parties improvement tools

Environmental factors Gauge control system in identified and controlled place (calibration and MSA)

Maintenance Environment SUPPORTING FOUNDATIONAL ACTIVITIES Training Standard methods Capable Measurement

16 EXPORT CLASSIFICATION: NO TECHNICAL DATA PRATT & WHITNEY KALISZ OUTSIDE DIAMETER CONTROL EXAMPLE

Pre-Control Attribute SPC Run charts – Variable SPC methods charts with limits charts

Maintenance Environment SUPPORTING FOUNDATIONAL ACTIVITIES Training Standard methods Capable Measurement

SAE International AS 13006 (2018, September) Figure 1 – Process control overview

EXPORT CLASSIFICATION: NO TECHNICAL DATA 17 PRATT & WHITNEY KALISZ OUTSIDE DIAMETER CONTROL EXAMPLE

TURNING Process Control Method SHOT PEENING

Mistake Proofing

automatic offset adjustment based on tool process parameters indicated by CNC measurement results saved on a chip program tool life time management - tool blocking after embedded parameters control with automatic defined wear switch off automatic inspection of tool condition after machining robotic arm ensuring positioning repeatability Life usage controls machine probing - automatic correction of tool paths based on in-process measurements media verification system scheduled and maintained

EXPORT CLASSIFICATION: NO TECHNICAL DATA 18 PRATT & WHITNEY KALISZ OUTSIDE DIAMETER CONTROL EXAMPLE MAIN RULE

TURNING OPERATION Implement data collection from production runs at the production source

CP = 1.85 CPK=1.50 SHOT PEENING

CP = 1.82 CPK=0.11

19 EXPORT CLASSIFICATION: NO TECHNICAL DATA PRATT & WHITNEY KALISZ IMPROVEMENT

Capability SHOT PEENING: TURNING I is understood and drives Fixture modification improvements

Process parameters change PRODUCT CAPABILITY

X1 X2 SHOT PEENING

TURNING II

CP = 2.53 CPK=2.20

20 EXPORT CLASSIFICATION: NO TECHNICAL DATA PRATT & WHITNEY KALISZ SUMMARY

•Fulfillment of project Zero Nonconformance •Implementation of assumptions process control as close Proactive process as possible to production source •Customer satisfaction monitoring

Quick identification of •Employee engagement •On time delivery on every step of Process possible source of Control Activities •PPAP full approval nonconformance •Results prove

FPY first pass yield effectiveness of the Benefits

Learnt method

Benefits

Lesson

Internal Customer

21 EXPORT CLASSIFICATION: NO TECHNICAL DATA Pratt & Whitney Kalisz private & confidential For planning purposes only Export Classification: : this document contains no technical data Do not copy or distribute without permission AS13006 Process Control – Success Factors

1. Strive for Error-Proofing wherever possible 2. Apply SPC where it is required because of the process capability not just because it is a KC 3. Quick feedback from the process to determine if the process has changed – Process Control not Process Analysis! 4. Select the right calculation to determine Process Capability 5. Don’t forget to apply to attribute data too! 6. Ensure you have people in the organisation that are qualified in Statistical Techniques

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. Case Study AS13000 Problem Solving Requirements for Suppliers (8D)

Olivier Castets Brett Withington Quality Manager Components & Accessories Quality Director Safran Aircraft Engines Meggitt

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. Before AS13000 Problem Solving using 8D?

Every body was doing Problem Solving in 7-Step different flavor… …Sometimes in a very poor way RED-X • Solving the wrong problem 8D • Just doing 5 whys (and then what?) APOLLO • Jumping to solutions (because the root causes are known for a long time…) – Forgetting why the containment (control plan) did not work • Forgetting to read across • Forgetting to close the loop back to the FMEA Difficult to find a effective training

26 AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. AS13000AS13000 S tStandardandard Ov Overviewerview

• OverviewOverview o off t hthee s tstructureructure p rproblemoblem so lsolvingving processprocess • ExplanationExplanation o off t hthee r erequirementsquirements of ofea ceachh of tofhe the8 St e8p Stepss • PrescriptivePrescriptive T Templateemplate to to d rdriveive st andardization standardizationand learning from and bes tlearning practice from best • practice8D Check List for each step to use during • 8Dpro bChecklem in vListest iforgat ieachon step to use during • problemStandard Tinvestigationraining Syllabus & Methods Training • StandardAS13000 a Traininglso availa Syllabusble in Fre n&c hMethods. Training • AS13000 also available in French.

275 AESQAE S–QAerospace – Aerospac Enginee Engine Supplier Supplier QQualityuality S tStrategyrategy Gr oGroupup This documentThis docum slideent s ldoeside do notes n containot conta iITARn ITA Ror o rEAR EAR technical technical ddata.ata. TThehe c ocontentntent o fof th thisis pr epresentationsentation slid slidee is p riso pproprietaryrietary and and confidentialconfide ninformationtial informa tofion the of tAESQ.he AESQIt .isIt notis no permittedt permitted to to be be distributeddistributed ttoo a anyny t hthirdird p apartyrty w iwithoutthout the the wr iwrittentten con consentsent of th ofe AthESeQ AESQ.. Enabling the Extraordinary To Fly To Power To Live AS13000 8D IMPLEMENTATION

Meggitt proprietary and confidential. No unauthorised copying or disclosure. Enabling the Extraordinary To Fly To Power To Live

Company overview – Organisation structure Customer-focused organisation aligned to end markets

Airframe Systems Engine Systems Energy & Equipment Services & Support

• Braking Systems • Flow Control • Defense Systems • Americas • Fire & Safety • Thermal Systems • Training Systems • UK & Europe • Power & Motion • Engine Composites • Heatric • Asia Pacific • Avionics & Airframe • Engine Sensors • Energy Sensors & Controls Sensing • Polymer Seals • Fuel Systems & Composites

Meggitt proprietary and confidential. No unauthorised copying or disclosure. 29 Enabling the Extraordinary To Fly To Power To Live

Company overview – Our global footprint 11,000 staff worldwide UK Employees: 2,674 Rest of Europe Sites: 9 Employees: 1,241 Sites: 7 Denmark, France and Switzerland

USA Employees: 6,211 Sites: 23 Rest of World Employees: 1,100 Sites: 6 China, Mexico, Singapore and Vietnam

Meggitt proprietary and confidential. No unauthorised copying or disclosure. 30 Enabling the Extraordinary To Fly To Power To Live

Company overview – Technology Pioneering research in differentiated technology

Braking Fire Thermal Engine Flow Sensing & Systems Protection Systems Composites Control Monitoring

Fuel Defence Electrical Avionics Training Digital Containment Systems Power Systems Manufacturing

Meggitt proprietary and confidential. No unauthorised copying or disclosure. 31 Overview of problem solving activites

AS13000 – 8D problem solving Meggitt is split into 4 customer focussed divisions supporting Airframes, Energy & Equipment, Engines, Services & Support Divisional approaches are different based on the industry and customer approach, leading to a multi-faceted approach to problem solving As each site has a different product / customer family, then there is a significant difference in • The format used to report RCCA • The depth of problem solving techniques • The capability of the sites to effectively problem solve This gives the central quality function difficulty in training the sites in a consistent manner

Meggitt proprietary and confidential. No unauthorised copying or disclosure. Deployment of AS13000

1. Acceptance of the standard, as a Whole Meggitt Standard • AS13000 was introduced by the Engines sites to the Central Quality function • Group Quality reviewed the standard to determine the applicability for ALL Meggitt sites

2. Systemise the Standard • Meggitt has been developing a ‘Global QMS (Quality Management System)’ to standardise the use of quality tools across all divisions & sites • Meggitt procedure MQA-10 Control of Nonconforming outputs embedded the AS13000 standard directly into the Meggitt central procedure • The Meggitt 8D template MFT-4 is the AS13000 8D template

Meggitt proprietary and confidential. No unauthorised copying or disclosure. Deployment of AS13000

3. Whole Business deployment • The control of NC outputs procedure resides on the Q-Pulse database, making the process accessible to ‘ALL’ staff • The system requires Quality leaders to accept the process for adoption into all sites • ALL sites are required to adopt the Global QMS within their businesses • Divisional leadership supports the sites in the deployment of the tool

4. Governance • Central quality complete internal audits of all sites against the Global QMS to ensure compliance

Meggitt proprietary and confidential. No unauthorised copying or disclosure. Results

Current situation The deployment of the AS13000 standard is still fairly early in its deployment across Meggitt in its entirety Our Engines Division have taken a lead in this and are working to develop the tools to help with the wider Meggitt deployment The Division is responding more fully to the customer expectation of utilising the AS13xxx series of standards Lessons Learned The Meggitt procedure for the Control of Nonconforming outputs has the 8D process defined, but during the construction of the process, the use of AS13004 (PFMEA) has been utilised to further strengthen the full process approach to problem solving

Meggitt proprietary and confidential. No unauthorised copying or disclosure. AS13000 - Example

Meggitt proprietary and confidential. No unauthorised copying or disclosure. 36 Insights

The adoption of the AS13000 8D is a major shift across the whole of Meggitt, with 11,000 employees this will take time, effort, and consistent messaging to implement a whole corporation change Some employees are sceptical, especially those that are not within sites that have the standard flown down by customers, they sometimes do not see the need or benefit Leadership is imperative for a global distribution and use of the tool, the leaders are setting the expectation, and then supporting the up skilling of the sites Making a change is difficult, but a tool that adds benefit to the business is worth investing the time and energy in deploying

Meggitt proprietary and confidential. No unauthorised copying or disclosure. Benefits of the AS13000 8D Approach

Standardization of a well known and effective method Not just ‘Another Problem Solving Method!’ Easy change management if your organization was already doing some sort of Root Cause Investigation Called, accepted and prescribed by every customer Standardization of the vocabulary around 8D (escape point, generation point…) Standardization of the template Problem Solving is a Team Sport! Provide a training syllabus Choose your training provider wisely SAE Offer Training in AS13000 Globally

Catherine CATARINA-GRACA Ludovic CHEVET Senior Supplier Quality Manager Lead Supply Chain & Quality Manager Safran Aircraft Engines Airbus An Airbus takes off or lands 19 340 11 763 7 577 every 1.4 seconds Orders Deliveries Backlog

End December 2018

40 9th October 2019 AESQ Supplier Forum - Human Factor Working Group Air traffic The Market Source: Airbus GMF 2018 doubles every 15 years

World fleet wil double in the next 20 years

41 9th October 2019 AESQ Supplier Forum - Human Factor Working Group Supply Chain risks are today one of the greatest concern Cyber Attack Fire Explosion12% Intensified 12% Competition for aviation stakeholders Pollution 35% 12%

Terrorism 12% Business Commodity Price Interruption, Increases Supply Chain 18% 35%

Technoligical Innovation 18% Market Stagnation or Decline Political/Social 30% Upheaval War 20% Changes in Legislation and Regulations Natural Hazards 24% Source: 24% Allianz Risk Barometer 2014

Note: Respondents could select more than one risk

42 9th October 2019 AESQ Supplier Forum - Human Factor Working Group Any link in the Supply Chain Risks… Business Interruption chain can stop propagation of NC to the end customer

Illustration by courtesy of ScandiAvia

43 9th October 2019 AESQ Supplier Forum - Human Factor Working Group Human Errors Human Errors are the origin Notification of most supply Concession of Escape chain issues

Minimizing human Delay Part errors in the supply Shortage chain is key toward product safety, quality and delivery Outstanding Work Damage

44 9th October 2019 AESQ Supplier Forum - Human Factor Working Group Latent Errors Latent Errors are the origin of most supply chain issues

Notification Concession of Escape

Delay Part Shortage

Outstanding Work Damage 45 9th October 2019 AESQ Supplier Forum - Human Factor Working Group Aviation safety will continue to evolve, always putting safety of passengers first by a global understanding of humans’ behaviour and impact on work performance

46 9th October 2019 AESQ Supplier Forum - Human Factor Working Group What is Human Factor ? Human Factor is a science studying how errors occur

47 9th October 2019 AESQ Supplier Forum - Human Factor Working Group What is Human Factor ? Human error Job is not a root cause

Individual Working Group Means

Organisation

48 9th October 2019 AESQ Supplier Forum - Human Factor Working Group The Dirty Dozen Dirty Dozen are primary causes of human error

49 9th October 2019 AESQ Supplier Forum - Human Factor Working Group Just Culture Trust based SMS supports human errors identification

In your work, an error, something forgotten or bad workmanship can cause the death of one or more people. A person who makes an error must report it. An error is a repairable and pardonnable mistake, but hiding it is a crime

50 9th October 2019 AESQ Supplier Forum - Human Factor Working Group 51 PART 145 PART 21 in Human Factor Aviation Value Stream 9th October 2019 October9th Aircraft Design  Maintenance  Human Human Factors Factors AESQ Supplier Forum Forum SupplierAESQ - Human Working Factor Group Manufacturing SupplyChain  Human Airline Flight Test Factors Ops within Airbus Several projects organisations production in reinforced be shall approach Factor Human and Human Factors AESQ project is matching Airbus strategy  Human Factor AESQ requirements 1. Publish a policy on HF 2. Assess leadership behaviour on HF Airbus is taking 3. Consider HF in all business processes active role in it 4. Appointment of an authority on HF 5. Implement a reporting system on HF 6. Have training and awareness program

 Handbook / guidelines / training material will be provided through AESQ website

 Referenced training

52 9th October 2019 AESQ Supplier Forum - Human Factor Working Group Take Away

We are in growth industry We put safety of passengers first

End to End human factor approach is key for collective success

AESQ and Airbus will support the supply chain

Game

53 9th October 2019 AESQ Supplier Forum - Human Factor Working Group Thank you Let’s Talk Deployment…

Erika Grimm Helen Djäknegren Supplier Quality Director Global Supplier Quality & Development GE Aviation GKN Aerospace

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. AESQ journey for proactive quality

AS9145

AS13006 AS13004 AS13003 AS13002 AS13001 AS13000

Reactive Proactive

AESQ driving unified approach to defect prevention 56 AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. Elements of Effective Change Management

Awareness QMS

Strategy & Accountability Organizational Vision Capability

Mindset Execution

People Training Leadership

Commitment Tools

Culture Implementation

57 AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. AESQ Deployment Tools

There are several tools currently available to suppliers to assist in your defect prevention journey … find them on our website (https://aesq.sae-itc.com/)

Mindset:

• AESQ Zero Defect Video – help your organization understand defect prevention and how the AESQ standards support that culture • Industry Impact Page – see real examples of how AESQ and supplier deployment is having an impact on the industry

Execution:

• Standard Guidance and Support Material – find guidance material and templates for issued AESQ standards

• Training Resources – see a list of providers that offer training for each AESQ standard

58 AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. CLOSING REMARKS

Ian Riggs Barbara Negroe Global Quality Executive Executive Sourcing Quality Leader Rolls-Royce Civil Aerospace GE Aviation

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. A380 Final Assembly Line Tour Logistics

Group 1 Description Group 2

Coach pick up at Radisson Blu Hotel Toulouse 08:30 10:00 Airport

Coach Arrives at Museum Aeroscopia (you may 08:45 10:15 store luggage at Museum)

09:00 Tour start A380 FAL Professional Tour by Manatour 10:30

10:00 Tour Ends 11:30

10:15 Coach takes Group back to the Radisson Blu Hotel 11:45

10:30 Arrive at Hotel 12:00

60 AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. Agenda

Safran 08:00 Airbus Aircraft Case Voice Welcome & Engines Studies of the Overview & Introductions Welcome Overview Customer Objectives Ian Olivier Olivier Address Barbara Lisa BREAK Barrie Riggs Castets Balmat Negroe Claveloux Hicklin

Process FMEA Measurement Systems Process Control Problem Solving (8D)

GROUP Welcome Ian Martin LUNCH Back Olivier FACC PHOTO Pete E Teti PW Kalisz Riggs Schäffner Mechachrome 12:00 12:45 Castets Meggitt

Q&A Human Let’s Talk And Deployment Closing Factors A380 FAL 17:00 Remarks Catherine Ludovic BREAK Erika Helen Ian Barbara Tour Information CLOSE & Catarina-Graca Chevet Grimm Djäknegren Riggs Negroe DEPART

AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. Reflections on the Day

62 AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ. Thank You for Attending

Please Return Home Safely

63 AESQ – Aerospace Engine Supplier Quality Strategy Group This document slide does not contain ITAR or EAR technical data. The content of this presentation slide is proprietary and confidential information of the AESQ. It is not permitted to be distributed to any third party without the written consent of the AESQ.