Core Skills Training Manufacturing and Shop Paperwork Instructor Guide
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1 Core Skills Training Manufacturing and Shop Paperwork Instructor Guide Purpose In this module, students learn about two important sets of documentation: the Production Order and the Installation Plan. The students challenge will be learning how these documents are organized and how they can locate the data they need for their job. Information Depending upon the company you work for, there are many different names for common shop paperwork and how information appears. The employees of some companies may have different levels of responsibility or the processes used may be different than what we are sharing The information discussed here may not be used at all aerospace companies. However most companies will use some of these topics or have similar principles or concepts but the nomenclature may vary. Production Order This important document is a communication tool throughout the manufacturing process that is used by everyone who works on a part. No other document, including the blueprint, contains as much information on how to machine, process, inspect, and buy off a part. Installation Plan (IP) This document is the build authority for an airplane. The IP is an essential communication tool used by everyone involved in the assembly and installation of an airplane. No other document contains as much information on parts/assemblies and modules, locations, specific drawings to use, materials, and buy offs. The IP is the key to understanding everything involved with the construction of the airplane. Topics Covered The role of a Production Order, and why it is important How to use a Production Order The role of an Installation Plan, and why it is important How to use an Installation Plan Objectives By the end of this module, you will be able to: Explain the relationship of the Production Order and the Installation Plan Demonstrate how to use a Production Order Demonstrate how to use a Installation Plan Information Sharing Airplane building uses many forms of information that have to be shared among many teams. Designing, planning, and procuring materials consumes much of the airplane production
2 schedule. It can take nearly three years to prepare some parts (such as engines), and an airplane has millions of parts. Manufacturers must produce airplanes at a rate that will keep production facilities and employees busy, yet allow for delays and unexpected events. Keeping costs down requires efficiency, coordination, and information sharing. Yet, the organizations involved in building airplanes are often physically distant, but are still obligated to work from the same data through ordered collections of data, called databases. Database Collections Airplane Manufacturers utilize a collection of databases: libraries of design engineering data and schedules of manufacturing resources. The Production Order and the Installation Plan guide the manufacture and installation of parts on the airplane using these databases. Information flow is as vital as the flow of materials and parts in producing airplanes. The Production Order and the Installation Plan look similar because they are organized and formatted in the same way. The Production Order is the guide to making the parts, and the Installation Plan is the guide to putting the parts into an airplane. Engineering Processes After an airplane is designed, the engineers plan its manufacture, assembly, testing, and maintenance. This requires designing numerous processes and tools. Once the design is complete, planning follows. Planners are Manufacturing Engineers (ME). They develop the manufacture and assembly processes, which include writing the Production Order and Installation Plan. Design and Planning Tools Engineers use a variety of information tools to manage product data and processes. MEs create the IP which lists the steps needed to assemble a sub-assembly or install a part in the airplane, specifying all required parts and tools. The IP is the build authority for the airplane. It provides accountability that the airplane is built in accordance with the design. Manufacturing Fabrication facilities must know what requirements a product must meet, the correct processes to use, and when the product must be delivered. The Production Order is the key to all of these questions. A requirement to manufacture a part initiates a Production Order and indicates when a part should arrive at each work area and describes the work to be performed there, referring to all the procedures, specifications and drawings each operator may use. Part production may happen long before the sale of an airplane that will use the part. Creating the Production Order Process Engineer uses a process plan to put in place the equipment, tools, and fixtures each operator needs for the job Materials Engineers identify the materials for each task and develop processes for working with those materials Tooling Engineers design and manufacture the tools to manufacture and assemble airplane parts
3 Industrial Engineers create information tools and manage moving work packages, whether in-plant or between countries Capacity Planners use the plan to schedule the flow time (how long it takes to complete an operation) Supply Chain Analysts generate the Production Order information, the complete schedule of operations to manufacture a part by the ship date Installation Plan The completed Production Order is a legal record providing objective evidence of product configuration, quality, and content compliance. After parts arrive from fabrication, they are taken to stock rooms where personnel put basic smaller parts into kits. Stock rooms are near the assembly area for quick access. IP s are the build authority for the airplane and are posted near the assembly and installation area and becomes part of the legal record of the airplane. Barchart The barchart is a scheduling tool with timelines for the work done in a shop. The barchart system tracks the assembly process through the Installation Plan. If work falls behind in the schedule, as listed on the barchart, then documentation is given as to why. For example, the documentation might say, Missing parts and then will follow a list of the missing parts. Managers and Production/Team leaders use this tool to make decisions: Do we need more resources? Do we need to work overtime? Not all bar charts are paper-based; some are electronic. The type of barchart you will see depends on the shop. Generally the shop employee will mark off work completed periodically so at a quick glance status can be determined. Production Orders: Overview The purpose of a Production Order is to unify essential communication throughout the manufacturing process among all of those who may work on a part. The primary users are the Shop Mechanic, Inspector, and Process Instructor. Production Orders are instructions on how to produce detail parts/assemblies according to engineering. The Production Order is the one piece of paperwork that includes how to machine, process, inspect and buy off the part and provide: A record of every activity. A legal record of detail parts/assemblies manufacturing Authorization for production of airplane parts Configuration control Detailed cost accounting and administrative record keeping Production Orders can be as few as 10 pages or as many as 200 pages depending on the complexity of the manufacturing process for a particular part. Small Production Orders are usually stapled sheets kept in a plastic sleeve or glassine and large Production Orders are kept in a binder. It is very important to keep the Production Order with its part(s).
4 Typically the Production Order is organized into sections: Order Tracking: Helps manually track the part if the computer system is down Summary: Crosschecks old codes for the part Engineering Geometry: Lists the engineering sheet for drawings relevant to the current process Note: Questions addressed by the ME, typically notes deviations and special instructions Bill of Materials: Lists all the material/parts required to complete manufacturing and assembly Metallic Material: Lists any relevant metallurgical information Operation/Detail: Operation #s and details for each step in the manufacturing/assembly process Using a Production Order When you receive a part, always take the time to review the Production Order before performing the operation. With the Production Order in hand, you are ready to follow these four typical steps: 1. Verify the part ID, quantity, and completion 2. Determine the requirements for the operation 3. Decide how to complete the operation 4. Perform the operation and sign it off Don t forget that no matter how many times you have run a job, you are still responsible for reviewing the Production Order for each individual part or assembly you work on every time. Step 1: Verify Verify the part identification (part number), quantity, and completion first. Ask yourself the following questions: Do you have the right part? Is the quantity correct? Are there any missing or extra items? Was the previous step properly completed? To answer the first question Do you have the right part? check the part number on the Production Order against the number on the part, tag or parts container to verify. Check that the quantity is correct and that there are no missing or extra items. Serial parts are parts that are specifically numbered for tracking purposes and are typically matched sets of parts or critical forgings. Step 2: Determine Determine the requirements for the operation Read the Operations/Detail Section Get any additional information needed, such as specifications or rework pages The Operations/Detail Section defines the operation requirements and is ordered by operation number. This section: Identifies the relevant specifications and procedures Specifies the task number and work center so that it can be cross-checked Describes the specific work to be completed in that work center
5 Indicates the tools available to do this work Tells the anticipated setup and runtime used for scheduling purposes It is common to have additional questions about the operation even though you have read the Operations/Detail Section. In these cases, refer to the Production Order itself. Step 3: Decide Decide how to complete the operation. Make the decisions based on the information gathered. Step 4: Perform Again, if there are any problems do not perform the work. Contact your Team Leader or Supervisor before continuing. Production Order Signoff It is necessary to signoff any operation with a stamp or a signature, with and ID and date. If there are multiple operators, everyone must indicate what work they performed on what date. Stamps are the equivalent of your legal signature, using another operator s stamp is a falsification of records. After stamping, never alter or revise related operations. Installation Plan Overview The IP is used by Mechanics, Inspectors, and others who work in assembly and installation shops where a specific airplane line number identifies the produced assembly or installation. The purpose of the Installation Plan is to be the authority for the build of an airplane. Drawings, specs, or any other separate data, no matter how useful or important, do not authorize the build of the airplane. The IP is the source of information that pulls all the other information together. IPs identify, control, and account for airplane configuration during final assembly and installation. Value of the IP The Installation Plan contains organized build information in a work package for Assembly & Installation shops. These numbered plans are your guide to making assemblies or installations in a logical, safe, manner. They are a legal record of work done. IPs tell you: Type and location of work being performed Part requirements Drawing requirements Work instructions Source of the IP MEs create and maintain IPs by entering and managing data in planning and design software. The Installation Plan typically has many major areas: Final Buy Off (always required) Installation Plan Summary Section (always required) Alert Note Section (if required) Installation Plan Precedence Section (if required) Engineering Geometry Section (if required) Bill of Material Section (if required) Bill of Material Section, Made on Assembly (if required)
6 Raw Material Section (if required) Note Section (if required) Operation Section (always required) Inspection Section (if required)d Tool Section (if required) Step Graphics (if required) Attachment Section (if required) Location Matrix Section (if required) Exception Section (if required) Footer (always required on the bottom of all pages) Bill of Materials An Installation Plan can have up to three materials sections: Bill of Material (BOM), Bill of Material Made-On-Assembly (MOA), and Raw Material. The purpose of the Bill of Material Section is to define the detail parts, assemblies, and materials required to complete the plan. Remember that the BOM provides space for serial numbers. As the Mechanic performs the installation step to install the item, he or she will turn to the Bill of Material Section and enter the serial number of that module into the space circled below. It becomes part of the airplane s permanent record. Made on Assembly No separate Production Order is prepared for Made on Assembly parts. The fabrication instructions are included in the IP with the instructions for the used-on assembly or installation. The fabrication technique must be described in meticulous detail in the operations of the plan and can be effectively used when: The part is made of easily worked material (rubber foam tape, Teflon, aluminum) Detail fabrication and assembly operations can be combined economically Assemblies can be more effectively completed on installation to eliminate fit or adjustment problems. Raw Materials The purpose of the Raw Material Section is to list the materials needed to manufacture the Made on Assembly item. Each piece of raw material listed to be used in the IP is sized (length, width, thickness), including any excess required by the manufacturing process. Standard Work Instructions All the operation steps are in the Operation Section of the IP. Often a mechanic needs more information than is in the step and can use Standard Work Instructions to supplement the Operation Section to provide further detail on how to do the step. Standard Work Instructions are often printed at the end of the IP. Drawing Location Callouts Drawing zone and view callouts are not required to be included in the Operation Section; however, they are useful to aid in focusing the mechanic to a specific location on the hardware or drawing. Drawing zone and view callouts also clarify the work instructions.
7 The Note Section This section is used for commentary to the Mechanic or Inspector. One common item in the Note Section is the Caution Note, designed to alert the shop mechanic, inspector, and supervisor that the plan contains operations that must be performed by certified personnel. Tooling Machine Control Data The Tooling Machine Control Data Section includes general set-up instructions, but not tool usage instructions. The mechanic must already know how to use the tool. The narrative identifies the drawing number showing the layout (roadmap) of tools, such as a process sheet, or their engineering equivalent, such as the Floor Panel Jig Drill Template. Exception Section The ME does not write the operation section information relating to Quality Assuarance or the Exception Section of the IP. Quality Assurance personnel are responsible for listing nonconformance records as required for unacceptable jobs.
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