solumina mro: maintenance execution - nsrp€¦ · 3 solumina mro overview & demo •...

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June 21, 2017

Solumina MRO:Maintenance Execution

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Agenda

1 What is the problem we Solve?• Typical Maintenance Landscape

2 What is Solumina MRO?

3 Solumina MRO Overview & Demo• Maintenance Process

Planning and Execution• Quality Management

4 Real-time Reports

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Typical Aircraft Maintenance Landscape

Maintenance Technicians receive maintenance instructions on a spreadsheet (or via paper workbook) and must access separate systems for drawings, tool information and recording data collections.

Can you quickly report where assemblies are in the maintenance process? Are you able to demonstrate full part/assembly traceability (as-maintained) in one system?

Is quality data (i.e. squawks, fault logs, discrepancies) collected in disparate silos? How do you know all fault logs have been cleared and aircraft can be delivered?

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What is the Problem We Solve? Typical MRO Landscape

Quality Data& SPC

Shop Floor Control

WorkInstructions

ToolManagement

Buy Offs

Product History

CorrectiveAction

ProductNon Conformance

PersonnelCertification

AvailableWork Job Start/

Completion

LaborReporting

Material Logistics

Tool Usage

ToolAvailability

ProductDrawings/models

OperationalStandards

Supplier Quality

AuthoredText

RequirementsDocuments

Work OrderChanges

PaperTravelers

Many Applications

Loosely Coupled

GovernmentCompliance

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About iBASEt and Solumina

iBASEt is the creator and distributor of Solumina’s Suite of Products.Headquartered in Foothill Ranch, CAwww.solumina.com

Solumina is a Paperless Product Lifecycle Execution SolutionSpecialized in Complex Discrete Industries:

• Aerospace Manufacturing (Fab and Assembly)• Aerospace Maintenance, Repair, Overhaul and Modifications• Defense Electronics Manufacturing• Defense Electronics Repair & Overhaul• DOE Contracted Mfg + MRO (Weapons & Reactor Cores)• Satellite Manufacturing• Jet Engine Overhaul• Engine Component Manufacturing & Repair• Medical Devices• Launch Vehicles & Launch Operations• Complex Industrial Equipment

http://www.solumina.com/

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iBASEt is a Recognized Leader in Complex Discrete

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Agenda





4 Real-time Reports

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Solumina MRO is an eMaintenance System

that allows for the creation, management,

and control of products needing diagnoses,

repair, or routine maintenance.

End-to-end integrated functionality tracks the

product to the serial level to ensure quality of

work.

Features include:

✓ Easy to use Graphical Interface

for Standard Templates and

Repair Instructions

✓ Embedded workflow approval

cycles

✓ Hyperlinks to Manuals

✓ Discrepancy/squawk

documentation and disposition

✓ Over and Above work management

✓ Change Incorporation (Engineering,

Material, Process)

✓ Product Traceability (As- Maintained

BOM)

✓ Real-time information for supervisor/

executive dashboards

✓ OOB Integration to ERP and PLM

systems

Solumina MRO for Maintenance Execution

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Solumina Functions

Audits and Reporting

Quality Requirements Planning

• Product Characteristics and Requirements

Supplier Quantity Planning

• Product Inspection Definition

Supplier Quality Execution

• Source and Receiving Inspection

Manufacturing Req’ts Planning

• Product Characteristics and Requirements

Process Planning

• Manufacturing Process Definition

Process Execution

• Manufacturing Work Order Execution

MRO Requirements Planning

• MRO Requirements Definition

Process Planning

• MRO Routine Work and Process Planning

Process Execution

• MRO Planned Work Order Execution

Supplier Quality Correction

• Supplier Discrepancies and Corrective Action

Process Quality

• Discrepancy and Corrective Action

Non-routine Execution

• Over and Above, Inspection Findings and Sub-work Approvals

SQA MES MRO

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Agenda





4 Real-time Reports

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Solumina MRO : Maintenance Requirements Definition

Library of:

Data Collections/PMI

Bills of Material

Files – models/specs

Tools

Inspections

Skills and Certifications

Customer signatures

Material Master



Process Planning


Process Execution




MRO

1212

Solumina MRO: Maintenance Planning



Process Planning


Process Execution




MRO

Process Planning


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Solumina MRO: Maintenance Process Planning

Operation Detail

Operation Groupings

Tools required

Data to be collected

Visual aids

Materials required

Certifications necessary

Detailed instruction

Operation sequence

Signatures required

Inspection requirements

• Operation number• Operation title• Department and workcenter• Batch options• Outside process allocation• Time and labor standards• Machine type assignment

• Tool type• Tool quantity• Calibration tracking

requirements

• Upper and lower limits• Selectable• Shelf life/expirations• Calculations• SPC• File upload• File template

• Revision specific or latest• Illustrations• Specifications• Videos• Models• Drawings

• BOM parts• Ad-hoc material• Issued material• Quantities required• Over/under allocation• Backflushed material• Floor stock/General store

items

• Hard stops• Self inspection qualification• Data collection• Signature• Standard text• PPE information• Ad hoc text• Multi-language• Manufacturing/technician• Inspection/quality• Customer• Combinations

• Machine data• NC Programs• Sampling• PPV/FAI

Pro

cess

Pla

nn

ing

•M

RO

Ro

uti

ne

Wo

rk a

nd

Pla

nn

ing

• Module/product assignment• Work scope assignment• Conditional assignment

• Operation grouping• Interoperation sequence• Inter-order sequence

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Solumina Maintenance Execution

Process Execution




Process Planning


Process Execution




MRO

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WYSIWYG: What You See Is What You Get

Manufacturing Engineer View

Technician View

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One Stop Shop Execution

Operators Will:Report Progress

Capture Serial NumbersCapture Variable data

(optional)Request Parts

Record FindingsSign-Off Work completions

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Solumina for Over and Above


• Over and Above, Induction Findings, non-conformance management



Process Planning


Process Execution




MRO

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Execution

•Inspection Orders

•Sampling Orders

•Rework orders

Quality

•First Article Inspection

•Defect and disposition

management

•Supplier Inspection

Process Improvement

•Corrective Actions

•Simple & Detail (8D)

•Metrics

Audits

Continuous Manufacturing improvement through• Closed loop quality and non-conformance tracking• Periodic audit planning and execution• Direct incorporation of process improvements• Integrated quality

Standalone quality solutions can count,

document, and provide metrics but

cannot enforce process control.

Managing Quality

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Day in the Life of a Maintenance Technician

• Execution of a Maintenance Order

• Squawks/ Non-Conformance

Solumina Demonstration

2020

• Product Control• Data and Documentation tied to each unit by

serial or lot number

• Process Control• Operator skills and Certs

• Tools with Calibration dates

• Current process documentation

• Controlled change procedures for process instructions

• SPC

• Disposition Instructions• Authoring

• Execution

• Discrepancy (Non- Conformance) management• Full Integration with Process Execution

• Configurable Workflow

• Dispositioning

Integrated Quality Management

• Inspection and Test Plans

– FAI and PPV

• Quality Metrics

– Six Sigma and Defect Normalization

• Corrective and Preventive Action

– Requests

– Investigation and Action Items

– Verifications

• Audits

Plan… Detect… Resolve

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Embedded CAPA = Consistent Problem Resolution

Add templates to streamline processing and automatically attach to each CA 8D

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Digital Thread

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WIP Tracking

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Track Product Lifecycle

Unit (serial or lot) and

operation detail tracking.

Assembly level project or

shipment tracking.

Supplier or Receiving

shipment tracking

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As Maintained Log

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BACK UP SLIDES

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Typical Data Flow

ERP

Pro

cess

P

lan

nin

gEx

ecu

tio

n &

Q

ual

ity

PD

MTi

me

&

Att

end

ance

Product Definition &

BOMs

Engineering Change

Drawings, specifications,

3D models

Work order execution &

data validation

Quality management,

nonconformance & CA

Product genealogy

As built record

Engineering change

incorporation

Detailed process plan & operation

sequence

Inventory master &

manufacturing Bill of Material

Operations schedule

Work OrderFinished goods inventory and

shipment

Labor time tracking

Data Use Case

Solu

min

a

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SOLUMINA

Data Flow Between Solumina and SAP

Procurementand Inventory Management

(MM)

Item Disposition

SAP

Production Planning and Controlling

(PP)

Process Planning

Process Execution &

Quality

Equipment (QM)

Tool MastermBOMs

Part MasterProcess Routing

WO Request

WO Schedule

Material Issue

Supplier Quality

Purchase Orders

Operation Status

WO Revision

WO Status

WO Issue

WO Split

2929

Solumina MRO - Breakdown

Change Management



Process Planning


Process Execution




MRO

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Close the loop on change management

Change Incorporation

Enter Change Information

Enter Affected and Resulting

Objects

Determine Impact

Analysis

Create an Action Plan

Incorporate the Changes

New Revision of Definition ECO

(PDM)

Determine effectivity

Incorporate Timing (ERP)

Understand Impact to Shop Floor (Solumina)

Close Change Request

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Real time information:• WIP/order status, job assignment, help calls and order

notes provide quick access to information with work flow

Trending reports:• Cycle time, backlog, on time completion, cost of non-

conformance, yield, SPC, and efficiency help spot trends and opportunities for improvement

Product reports:• As-maintained BOM, unit production status, device

history record keep the information flow consistent

Reports