module 3: production planning and control: a400m fal 2011-2012

Module 3:

PRODUCTION PLANNING AND CONTROL: A400M FAL

2011-2012

Máster GSC & AIO 2011-2012GLOBAL SUPPLY CHAIN & AERONAUTICAL INDUSTRY OPERATION

Module 3: PRODUCTION PLANNING AND CONTROL

2

Production Planning and Control: A400M FALBy: Gloria Vicente Vicente

H/O Operative Planning and Performance Management FAL A400M



3

• Planning Starting conditions Programme Planning

• Work Breakdown Structure (WBS)• Development phase. Integrated Planning. Follow up• Series phase

Planning criteria Development phase. Planning Integration Series phase. Production plan

• Planning parameters Real Operative planning: SAP

• Visual management



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Programme Directive

Contract

Product definition

Manufacturing conditions



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PLANNING CONCEPTS

• Planning = time management

• Programme level planning: Master plans

• Task level planning: Operative planning

• Development phase Series phase



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PROGRAMME PLANDEVELOPMENT PHASE

Integrated plann linked to a WBS according to programme milestones

• Master PlanL1: Programme milestones plan• TDBU Milestones: Cascaded through several programme levels. Milestones

imposed by the top organizations.• P2P Milestones: To stablish relationships between two organizations at same

or diferent levels.• Internal milestones: To stablish the plan inside one organization.• All milestones have to be linked to activities.

•



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Legend:

• “Planning only” WP

• “Budget only” WP

PLO

BDO

Industrial & Delivery Centre (MDT)

NOGUERAS R

A400M Head of Programme(MD)

GAUTIER C.

Systems & integration(MDEY)

RICHARD R.

Power Plant(MDEV)

RABIET C.

FAL(MDTT)

SILVA CAMPOS JJ

HTP(MTA)

MEDINA RIVAS J.

Flight Test(MDET)

GUEVARA-MARTINEZ P.

Programme Performance Management

(MDM)ALBERIDO A.

Programme Management(MD)

GAUTIER C.

Customer Services(MDS)

MIEGEL A.

Delivery Centre(MDTT)

N.N.

Industrial Operation(MDTI) BAILEY S.

Design Integration(MDEI)

BOUCHERAT P.

VTP (incl. Rudder)(TTD)

BRENKE M.

Fuselage(TBD)

BRUEGGEMANN K.

CWB(TMB)

DROUVROY S.

Certification & Airworthiness/Q. Dem.

(EIAM)GABET S.

Integrated planning

GERAT M.A.(MDMP)

Conf. ManagementDEHAESE K.(MDMM)

Avionics(MDEY5)

TAURIAC JM.

MIT Military System(MMCM1)KALAK P.

System Engi. Support(MDEYE)

COHEN-BACRIE J.

Cockpit(MDEY1)

PLASSE JY.

Communication(MEY)

SIERRA-BEJARANO F.

Flight Dynamics / Energy(MDEY2)

GODARD E.

Utilities(MDEY3)THEISS V.

Fuel(MDEY4)DAVIS C.

Prog. Mngt(MDEY)

RICHARD R.

Procurement(MDEY)

RICHARD R.

Customer interface & Qualification Mngt.

(MDEC)LLAMAZARES-ALONSO S.

Overall Engineering(MDE)

CASSIER A.

Statics(MDEI)

GROSJEAN E.

Supportability(MDEI)

ROLLAND PC.

Fatigue(MDEI)

GROSJEAN E.

Aerodynamics KITSON B.

OAD(MDEO)

ROBIN D.

PLO

Systems ILS(MDEYS)

BOULANGER A.

Manufacturing Engineering(TMDASM)

SCHIMMELMANN. O

Leading & Trailing Edge(MTA)

MEDINA RIVAS J.

Industrial(TTTN)

VIRKUS U.

Engineering(TTE)

REERS B.

CWB Manufacturing(TMB)

DROUVROY S.

CWB Design Integration (TBEMT)PAGES G.

Continuous Product Dev.(TWMI)Allen J.

Programme Management(TWM)

WOOD G.

Certification(TWMM)

BUSHNELL M.

FAL / Flight Test support(TWMB)GRIER C.

Industrial Operations(TWMB)GRIER C.

Programme Management(TTD)

BRENKE M.

Rudder(TMB)

DROUVROY S.

Cargo Hold(MDEY6)HAHN P.

CoC Struc. Sup. To CoE(MDEI)

GROSJEAN E.

Tech. Data Integrity(MDEI)

ARISTE-ZELISE O.

Programme Quality & Maturity(MDQ)

SCOTT J.

Evac. Test(MDEB)

STUEBEN J.

Loads KORNFUEHRER

Aaeroelastics LAPORTE A.

Performance THEZELAIS S.

Weigh/Balance PONS L.

TBB Assembly(TBBM)

SIEFKEN C.

Engineering Definition Dossier NF (TBEM)

PAGES G.

Programme Management(TBD)

BRUEGGEMANN K.

Industrial Partner Supplier IFA(TBDI)

FOERSTER R.

Engineering Definition Dossier IFA (TBEM)

MECHLER H.

Nose Fuselage Assembly(TBSM)

LEMAITRE O.

Acoustics PERRIN-DECROUX

Test Pyramid(MDEI)

GROSJEAN E.

TECH. INFO & DATA(MDSI) HOWES P...

ILS Technical(MDSI) CURA M.

MATERIAL SUPPORT(MDSI) COLL P.

TID (MSED)GUTIERREZ J.

TID (SEDX)MORAND B.

FLIGHT OPS (STIB)GRESSE

MAINT. ENG. (MSES)GRANDE D.

MAINT. ENG. (SEME)SAFRA JM.

IN-SERVICE SUPPORT(MDSS) BURGAZ J.

INITIAL PROV. (MSTT)KAUFHOLD M.

INITIAL PROV. (SEDX)MORAND B.

SUPPLY PREP. (SMV2)RADMACHER M.

GROUND SYSTEMS(MDSI) TANNER J.

GSS - MDS (MDEYS)BOULANGER A.

GSS - MPRS (MDEYS)BOULANGER A.

TRAINING & TRAI. AIDS(MDSI) GOMEZ R.

T & TA (MSTT)CORCHON JL.

T & TA (STIB)GRESSE JL.

T & TA-S&IT (MDEYS)BOULANGER A.

CS INF SYS(MDSS) LAURENT P.ILS INT. CONF.

(MDSI) VILLARES D.

GND TOOLS (MDEYS)BOULANGER A.

MAINTENANCE PL.(SEMS1) WEBSTER D.

PLO

PLO

AC GND EQUIP.(MDSI) CURA M.

SUPP. ASS.(MDSI) DELPECH S.

ILS CONF LIS. (MSEM)CEREN M.GSS REF.(MSEM)

CEREN M.

LIS & INF SYS. (MSO)LABLANCA J.

INFO SYS. (SVA)LEFLOCH H.

AGE (MSES)GRANDE D.

AGE (SEMS)RAYNAUD O.

PLO

Procurement Management

(PYD)CHRETIEN L. PLO

BDO

BDO

BDO

BDO

BDO

BDO

BDO

PLO

FT & Operations(MDET)

GUEVARA-MARTINEZ P.

Flight Test analysis(MDET)

BARRERE M.

FT Installation(MDET)

VILCOT T.

Ground Support(MDET)

GUEVARA-MARTINEZ P.

BDO

BDO

BDO

BDO

Test Integration(MDEYE)

COHEN-BACRIE J.

PLO



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9

MP L1



10



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P2P Milestones: Clashes reviewFUSELAGE–FAL milestones:



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LONG TERM: PRODUCTION PLAN (APC)

MID TERM(3 YEARS): INTEGRATED PLAN (UP SERIE)

SHORT TERM (3 MONTHS- 1 YEAR): PLANT PLAN (SAP)

PROGRAMME PLAN

SERIES PHASE



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Job card

Work order

A/C / STATION

MP (UP)/APC / A/C Chart (UP)

DPE

Start time /Precedences

SAP PROGRAMMER AVLVISUAL LINE

RE-PROGRAMING

KPI´S

MASTER PLAN

THEORETICAL OPERATIVE PLAN = BUILD PROCESS REAL OPERATIVE PLAN

FAL A400M PLANNING CRITERIA



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Production plan parameters

Working Time

Calendar

Manpower Factor

FAL Lay-out

FAL Lead Times

FAL Learning Curves

FAL Working Party slots

Logistic cycles

Delivery phase



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- Calendar assumes decisions including Spanish Authorities and Trade Unions commitment.- Calendar formal approval will be done by December for coming year.- As average:

- 224 working days- National Holidays: 11- Local Holidays: 3

- Summer Holidays are typically two weeks around first half of August.- Typical working time:

- 2 shift, 8 hrs. per shift- timetable:

shift 1 7:00-15:10. Break : 11:30-11:40

shift 2 15:00-23:10. Break 19:30-19:40

Working time



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Calendar



17



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Process to plan

FAL A400M



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St. 60 Fuselage joint up 27 27 25 8

St. 50 Empennage joint up 19 19 19 8

St. 72/70 St. 72 Wing joint up- struct. 34+ 5,5 34 34 16St. 70 Wing joint up- equip. 15+1,5 15 15 8

St. 40 A/C integration & equipping 26 26 25 8

St. 35 Indoors Ground Tests 54 54 54 16

St. 30 Outdoors Ground Tests 20 20 20 8

St. 25 Powerplant equipping 25 25 15 8

St. 20 Furnishing & Powerplant install. 15 15 15 8

Cargo Hold customer inspection n/a 1 1 1

Structural Ground Tests 44 n/a n/a

EMI/EMC 3 3 n/a n/a

St. 15 Fligth Line 19 19 19 14

St. 10 Painting 6 12 12 10

Handover 10 8 8 2

Customer acceptance n/a n/a 30 15

OPTIONS n/a ? ? ?

FAL A/C Lead Time (working days)

rate 2,5Station no. Sta. description MSN 1* MSN 6 MSN 7

St. 45 Software Loading 10+10 10 10 8

MSN 2

27

1934+3,515+1,5

26

54

20

25

15

1

3

19

12

8

n/a?

10

MSN 4

27

1934+3,515+5

26

54

20

25

15

1

3

19

12

8

n/a

10

MSN 3

27

1934+3,515+1

26

54

20

25

15

1

3

19

12

8

n/a?

10

MSN 5

27

1934+3,515+1

26

54

20

25

15

1

3

19

12

8

n/a

10



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• Tn= Tref* c (ln n/ref)/ ln3

comparacion curvas entrenamiento

0

5

10

15

20

25

30

35

1 6

11 16 21 26 31 36 41 46 51 56 61 66 71 76 81 86 91 96

rank

wd

84% 21 wd en 1

80% 29 wd en 1

72% 21 wd en 9

65% 29 en 9

66% 25 en 9



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old 5.1 & 25

old 4.1 old 4.2 old 5.2 old 6 old 7

old 1.3.1/1.3.2

50

60

40 30 2035 1015 8

72/70

FuselageAD-Bremen

Nose FuselageAF-St. nazaire

SponsonsSOCATA-Tarbes

NLGM.Dowty

MLGM.Dowty

WFF Set 1& 4DENEL

OWAUK-Filton

CWBAF-Nantes

PYLONS EQUIPPING

(MTAD)

PODDING (MTAD )

Engine CowlsMTAD-Cadiz

PylonsAF-St. Eloi

Engine Cowls

HTPMTAD-Seville

VTPAD-Stade

PowerplantEPI

WFF Set 2,3,5&6DENEL

MLG DoorsSONACA

NLG DoorsSOCATA

Pylons

FAL Scope

WFF ongletsDENEL

old 1.1

old 1.2

old 2/3

Engine Dressing (MTAD)

45 Software loading

PropellersRatier-Figueac

Parts to plan (CAP)



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All A/C

FAL on dock FAL in jig(*)

Logistic cycle time

FAL Station installation Logistic cycle time40 20 wd45 10 wd20 15 wd

All other stations 10 wd

In jig: FAL Ref Station

1

2 - Transport

5 - in jig

6

3Availability at supplier On dock:Latest arrival at FAL

FAL

3 to 6

Transport

2

SupplierCalendar

1Milestone

4 – Inspection

max. 5 w.d.

3 w.d.

2 w.d.

Main CA´s

Equipment & LI

LOGISTIC CYCLES (CAP)



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Production plan L1 = FAL Production Plan



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Theoretical build process

Station duration

Job cards

Workers by job card: max-min

Job card LT

Workload

Work station/Skill/Competences

Workshop exceptionsResources availability

Skills and CompetencesCalendar exceptions

Missing parts

Operative planning per A/C

Needs of:

Resources

Training,

etc

Changes in:

Precedences

Times

Work station/Skill

LT

WORKSHOP PROCESS

OPERATIVE PLANNING

Out of Sequence Works



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WORK ORDERS AT WORKSHOP


Módulo Nº: 21


OUT OF SEQUENCE WORKS



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DPE SAP APC

PLANIFICATRON

Start Times

Precedences

Work Order

OsW

Calendar

MSN Location

Capacity

Stations dates

PLANNING SET UP

PLANIFICATRON “AVL”JOB CARDS PLAN



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Planificatron-1



29

Planificatron-2



30

Planificatron-3



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TASKS MONITORING



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BACK UP



33

RTD Curve



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0500

100015002000250030003500400045005000

18/01/201120/01/201124/01/201126/01/201128/01/201101/02/201103/02/201107/02/201109/02/201111/02/201115/02/201117/02/201121/02/201123/02/201125/02/201102/03/201104/03/201108/03/201110/03/201114/03/201116/03/201118/03/201122/03/201124/03/201128/03/201130/03/201101/04/201105/04/201107/04/201111/04/201113/04/201115/04/201119/04/201125/04/201127/04/201129/04/201104/05/201110/05/201112/05/201116/05/2011

Closed

Ongoing

Pending

Operations Status Per Date



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% RTD FAL% RTD FAL until Current Station

0% < RTD < 5%

5% =< RTD < 10%

RTD >=10%

0% < RTD < 3%

3% =< RTD < 5%

RTD >=5%

Legend of colors : indicator % RTD Global

Legend of colors : indicator % RTD per Station

2,87%

ST92 ST72 ST70

0,00% 0,00% 1,15%

ST93 ST50 ST40 ST35

0,00% 0,00% 0,66%

ST91 ST60

0,00% 0,99%

% RTD FAL hasta Estación actual

2,1%6,9%

2,9%

Tipo de Operaciones lanzadas

EstandarAOC

TOTALES

0,0%

2,0%

4,0%

6,0%

8,0%

10,0%

12,0%

14,0%

16,0%

INDICADOR GRADO DE AVANCE FAL

RTD FAL Total hasta Estación Actual



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Módulo Nº: 21

Follow up: Planning Robustness


Módulo Nº: 21

Follow up :TOP 10 on the route to TC / IOC


Módulo Nº: 21

Follow up : TOP 10 on the route to TC / IOC


Módulo Nº: 21

Follow up : TOP 10 on the route to EIS

RACI for planningMilestones MDTI FAL DC MCA RemarkAll customer inspections for MSN 7 achieved A R C R At section and at FAL level

FCO Quality gate L for MSN 7 achieved A R C QG L: A/C ready for H/O to delivery centre

All SCN-CI for IOC fully functional and installed on MSN 7 A R I R

All SCN-CI provisions up to SOC3 fully installed, certifiable and set inoperationable A R I R

R ResponsibleC ConsultedI Informed

Pending to be included in UP:

Available in UP:

module 3: production planning and control: a400m fal 2011-2012

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