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Goals/Objectives:

To transition & integrate Localised Heat Treatment capability into a purpose built world

leading Repair Development Cell (Circa £5.5 Million RR capital investment).

To drive process development to facilitate the first post weld heat treatment of a Material

Addition repaired aerofoils within the Integration & Development Cell by AP9 2011.

Using Rolls-Royce Production System best practice - Achieve MCRL 4 repair process

capability by the end of AP12 2011 (Strand and component level).

Sector/Business Unit: GRS – Repair Integration & Development Cell

Project Title: Localised Heat Treatment Capability Acquisition & Process Improvement Lead Contacts:

Mick Harvey (LHT Process Lead ME)

LHT Global Process Owner

LHT IPT Project Lead

Final Results:

Successful equipment transition into the I&D Cell by AP5 2011.

LHT equipment installed ,commissioned & signed off by all project stakeholders.

LHT Cell HS&E governance fully compliant with R-R procedures.

LHT processing equivalency & validation demonstrated (KPV trials on actual

instrumented hardware).

Bespoke LHT head fully optimised and developed (Patent update pending).

Temperature profile of 600°C +/- 10°C achieved (Specification requirement +/- 30°C).

Locally Heat Treated 21 off weld repaired aerofoils on representative geometry.

All fan aerofoils fully process compliant (Best practice documented & recorded).

MCRL4 gate passed by IPT team in AP11 2011 (Full component level).

2nd component Locally Heat Treated in AP6 2012 (Knowledge capture exercise complete).

Teamwork; Established open, friendly, professional & persuasive lines of communication

between all project stakeholders.

Lessons Learned:

Ensure good lines of communication between project and purchase.

Spurious data capture due to incorrectly wired thermocouple interface in chamber lid.

Welding of thermocouples onto hardware, ensure a sound earth connection at all times.

3rd generation heater endurance test failure; monitor heater resistance readings to reduce

the possibility of element failures and burn out.

2nd generation heater control thermocouple specification incorrect, located in cooler

region of the ceramic filament causing spurious temperature readings.

Argon gas consumption can be drastically reduced when repair reaches temperature set

point (Argon consumption saving of 55% detailed in GRS Yellow Belt project).

Date: 29/09/2012

Original State:

Pre MCRL 4 equipment located in the supply chain at Stork Cooperheat, Southport.

Localised Heat Treatment concept demonstrated, not integrated into a lean manufacturing

processing cell (Repair Development Cell circa £5.5 Million R-R capital investment).

System controller outdated, equipment not compliant with current PUWER regulations.

Localised Heat Treatment KPV development limited by R&T funding & available resource.

What We Did / Tools / How-tos / Building Blocks Used:

Supply chain experimental process development trials circa > 300+ KPV testing hours.

LHT Equipment refurbishment & system upgrades to chamber & controller unit, additional

improvements implemented to ensure HS&E PUWER assessment compliance.

Completed Factory Acceptance Tests & Site Acceptance Tests (in accordance with RRPS

best practice documented in GRS Yellow Belt project).

LHT Cell HS&E governance and risk management (Recognised by AR&O HS&E lead as

best practice, compliance documented in GRS Yellow Belt projects).

Continued KPV development incorporating all lesson learnt during pre MCRL 4 supply

chain experimental testing (full adaptive Leading Edge LHT repair solution demonstrated).

LHT process capability driven by MCRL ME tool kit (Examples include Risk management,

Project planning, PFMEA, SIPOC, LL Logs, PDR reports, Experimental records, Process &

equipment specifications, KPV control, HS&E governance , TI’s and Calibration.

Leadership & People HS&E Workplace Org

Standard Processes Performance management

Visual management

Asset Care Compliance

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X X

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Stage 3:LHT

Process

Control

Stage 1: LHT

Capability

Acquisition

Stage 2: LHT

Process

Improvement

Stage 4: MCRL

LHT Process

Capability