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This technical session deals with research and development efforts addressing the advancement and applications of Lean methodologies and Quality improvement in the mobility Industry. Papers presented in this session will portray the latest developments in the principles, practices, tools, processes, and applications of Lean and Quality improvement methodologies.
2016-11-14 ...
  • November 14-16, 2016 (8:00 a.m. - 5:00 p.m.) - Tysons, Virginia
Training / Education Classroom Seminars
Internal audits are a requirement of the AS9100 Rev C standard and one of the fundamental requirements of the internal audit program is to verify the compliance of the organization's quality management system to the AS9100 standard. Internal auditors must be knowledgeable of these requirements and the expectations as identified in the standard. In addition, the requirements of AS9101 Standard have significantly changed the way audits are expected to be performed in the Aviation, Space and Defense industries.
Topics Include: Lean Tools and Techniques Lean Implementation Supply Chain (the 4 w’s) Dynamics of Supply Chain Lean Six Sigma
Technical Paper
ByeongUk Jeong, Sang Do Kwak, Cheol Ki Kim
Owing to the enhanced requirement of brake free noise these days, more damping kits should be installed in the braking system. Success of doing this properly causes softness in the brake system which results in the loosened stroke feeling of brake pedal, the increased compressibility by durability. A study for detailed factors to aggravate brake feeling was done as a solution to prevent these from happening. In this paper, we present our work based on experiments to measure compressibility of shims by the influence of variations in different parameters, for example, of adhesive shims (bonding spec., steel and rubber thickness), piston’s shapes (different contact areas to the shims), and the numbers of durability. We installed the brake feeling measurement system extended from brake pedal to caliper. Experimental parameters were compared with brake feelings in vehicle using it. The optimization for brake feeling was determined by design for six sigma (DFSS).
2016-09-12 ...
  • September 12, 2016 (1 Session) - Live Online
  • December 13, 2016 (1 Session) - Live Online
Training / Education Online Web Seminars
In a global economy, aviation, space and defense organizations are presented the challenge of producing and delivering safe and reliable products across a wide range of customer requirements and expectations. In an effort to address diverse quality requirements and expectations while also reducing costs throughout the supply chain, the SAE AS9100 family of standards was developed by international aerospace industry representatives to standardize international aerospace quality management system requirements.
This SAE Aerospace Standard (AS) further defines the requirements for a delegation process identified in Aerospace Quality Management System (AQMS) standards (i.e., AS9100, AS9110, AS9120). This standard establishes minimum requirements for the delegation of product verification to an organization's suppliers; outlining requirements for the initial delegation (qualification/selection), maintenance, and removal/withdrawal of delegations.
WIP Standard
This specification covers engineering requirements for the grinding of tungsten carbide High Velocity Oxygen/Fuel (HVOF) thermal spray coatings applied to high strength steels (220 ksi and above). This process has been used typically to grind tungsten carbide HVOF coatings applied in accordance with AMS 2447 or AMS 2448 to high strength steels for applications requiring wear, heat, and corrosion resistance or dimensional restoration, such as aircraft landing gear components, However, usage is not limited to such applications. This process specification does not cover superfinishing of HVOF applied coatings.
Seeing the Light Achieving Full-Color, Day or Night Readability for Flat-Panel Displays Multiple Node Networking Using PCIe Interconnects PCI Express (PCIe) interconnects, and how they can be used to support multiple node low latency data transfers over copper or optical cables, is gaining momentum in embedded computing solutions. Zero-Emissions Electric Aircraft Theory vs Reality Analyzing Radar Signals With Demodulation Combining Software and Hardware for Highly Specialized Multichannel Spectrum Monitoring Advanced Thermal Management Solutions Thermoelectric Cooling Thermal Ground Planes Thermal Management of Laser Diodes The Effect of Substrate Emissivity on the Spectral Emission of a Hot-Gas Overlayer Process Approach to Determining Quality Inspection Deployment Experimental Setup to Assess Blast and Penetration-Induced Secondary Debris in a Military Operations in Urban Terrain (MOUT) Environment Non-Contact Circuit for Real-Time Electric and Magnetic Field Measurements
General: This document contains recommended practices for the effective control of non-deliverable software. It addresses practices for control during the development, production, release maintenance, and retirement of non-deliverable software, as well as for software procured from outside manufacturers and incorporated in the production, evaluation, test, acceptance or calibration of processes. For the purposes of this document, the terms software and non-deliverable software are considered synonymous. Application: The guidelines in this ARP apply to non-deliverable software that: - directly relates to design, manufacture, inspection, test or calibration of a deliverable product, and - directly affects the configuration, conformity or quality of a deliverable product.
This index is presented to provide a quick reference of international and national quality standards and publications that support general quality system elements. This reference is a list of quality standards a company may with to consider when implementing or improving their quality system.
This Standard is applicable to suppliers of electronic components, assemblies, equipment and related materials. This standard establishes the general requirements to achieve a certified process. The use of this standard is intended for any manufacturing or service company whose goal is to achieve customer satisfaction through continuous improvement.
This document proivdes the guidelines for the utilization of Cpk as a monitor of process performance. This document: -defines the process capability index (Cpk), -outlines some general methods for estimating Cpk, -describes acceptable methods of reporting Cpk, -discusses the advantages, disadvantages, and requirements for some potential applications of Cpk, -addresses the use of similar methods of assessing quality improvement, and -provides some perspective on the value of Cpk and similar techniques. Application of the guidelines in this document should allow businesses to use Cpk or similar techniques to effectively monitor one aspect of quality improvement and to promote strong customer/supplier relationships.
This Specification covers a statistical sampling plan for lot inspection by attributes. It verifies that the customer's specified quality level (SQL) is not being exceeded. The estimate of fraction nonconforming determined by EIA Interim Standard No. EIA-554 is used to select the optimum sample plan for verifying that a given lot meets the specified quality level (SQL).
WIP Standard
1.1.1. This specification defines standardized methods for suppliers to be used when achieving AS9100 compliance. The intent of standardization is to increase supplier efficiency and reduce noncompliance due to from variation in customer to customer detailed requirements for the same basic item.
This standard defines a system for the qualification of standard products for aviation, space, and defense applications. It defines the principles that shall be adhered to when carrying out product qualification; applied in conjunction with the rules and procedures of the CA. The system enables the CA to confirm compliance is achieved and maintained, in accordance with the requirements of its product definition and associated controlling technical specifications by an Original Component Manufacturer (OCM) of standard products. This standard requires an OCM that has been granted product qualification approval to ensure applicable approvals are maintained and renewed in accordance with the CA’s quality system for that qualified product. OCMs and OCM designated Value Added Distributors (VADs) requesting product qualification to this standard, shall as a prerequisite, maintain 9100 standard quality management system certification approval.
WIP Standard
The standard applies to aero engine suppliers operating a self-release process as a delegated activity from the delegating organization. While primarily developed around the aero engine supply chain requirements, this standard can also be used in other industry sectors where a self-release process may be of benefit.
WIP Standard
This specification covers a mixture of liquid hydrocarbons and soluble additives.<p>To provide a standard composition, simulating aviation jet engine fuel. This fluid has been used typically in laboratory tests involving compatibility and interaction with aircraft materials, but usage is not limited to such applications.
Technical Paper
Prabhakar Konikineni, V. Sundaram, Kumar Sathish, Sankarasubramanian Thirukkotti
Abstract Fan shroud is one of the critical components in an engine cooling system. It helps in achieving optimum air flow across the heat exchangers. The major challenge is to design a fan shroud which meets noise, vibration and harshness (NVH) requirements without compromising on air flow targets [1]. An improperly designed fan shroud will cause detrimental effects such as undesirable noise and vibration, which will further damage the surrounding components. In current days, multiple simulations and test iterations are carried out in order to optimize its design. The objective of this paper is to provide a design framework to achieve optimized fan shroud that meets NVH requirements in quick turnaround time using Design for Six Sigma (DFSS) approach [2]. The purpose of the Engine cooling system is to maintain the coolant temperature across the vehicle.
Technical Paper
Manish Dixit, V Sundaram, Sathish Kumar S
Abstract Noise pollution is a major concern for global automotive industries which propels engineers to evolve new methods to meet passenger comfort and regulatory requirements. The main purpose of an exhaust system in an automotive vehicle is to allow the passage of non-hazardous gases to the atmosphere and reduce the noise generated due to the engine pulsations. The objective of this paper is to propose a Design for Six Sigma (DFSS) approach followed to optimize the muffler for better acoustic performance without compromising on back pressure. Conventionally, muffler design has been an iterative process. It involves repetitive testing to arrive at an optimum design. Muffler has to be designed for better acoustics performance and reduced back pressure which complicates the design process even more.
WIP Standard
This specification covers quality assurance sampling and testing procedures used to determine conformance to applicable material specifications of corrosion and heat-resistant steel and alloy forgings.
Technical Paper
Homayoun Ahari, Michael Smith, Michael Zammit, Brad Walker
In order to meet LEV III, EURO 6C and Beijing 6 emission levels, Original Equipment Manufacturers (OEMs) can potentially implement unique aftertreatment systems solutions which meet the varying legislated requirements. The availability of various washcoat substrates and PGM loading and ratio options, make selection of an optimum catalyst system challenging, time consuming and costly. Design for Six Sigma (DFSS) methodologies have been used in industry since the 1990s. One of the earliest applications was at Motorola where the methodology was applied to the design and production of a paging device which Consumer Reports called “virtually defect-proof”.[1] Since then, the methodology has evolved to not only encapsulate complicated “Variation Optimization” but also “Design Optimization” where multiple factors are in play. In this study, attempts are made to adapt the DFSS concept and methodology to identify and optimize a catalyst for diesel applications.
Technical Paper
Abhishek Sharma
Abstract Today open source software is widely used in different domains like Desktop systems, Consumer electronics (smart phones, TV, washing machines, camera, printers, smart watches), Automotive, Automation etc. With the increased involvement of the open source software in the different domains including the safety critical ones, there has been a requirement of the well-defined test strategy to test and verify such systems. Currently there are multiple open source tools and frameworks to choose from. The paper describes the various open source test strategies and tools available to qualify such systems, their features, maintenance, community support, advantages and disadvantages. Target audience would be the software engineers, program managers, using an open source stack for the product development.
Technical Paper
T Sethuramalingam, Chandrakant Parmar, Sashikant Tiwari
Abstract DFSS is a disciplined problem prevention approach which helps in achieving the most optimum design solution and provides improved and cost effective quality products. This paper presents the implementation of DFSS method to design a distinctive cooling system where engine is mounted in the rear and radiator is mounted in the front of the car. In automobile design, a rear-engine design layout places the engine at the rear of the vehicle. This layout is mainly found in small, entry level cars and light commercial vehicles chosen for three reasons - packaging, traction, and ease of manufacturing. In conventional Passenger cars, a radiator is located close to the engine for simple packaging and efficient thermal management. This paper is about designing a distinctive cooling system of a car having rear mounted engine and front mounted radiator.
Technical Paper
Weiguo Zhang, Mark Likich, Mac Lynch, John White
Abstract The noise radiated from the snorkel of an air induction system (AIS) can be a major noise source to the vehicle interior noise. This noise source is typically quantified as the snorkel volume velocity which is directly related to vehicle interior noise through the vehicle noise transfer function. It is important to predict the snorkel volume velocity robustly at the early design stage for the AIS development. Design For Six Sigma (DFSS) is an engineering approach that supports the new product development process. The IDDOV (Identify-Define-Develop-Optimize-Verify) method is a DFSS approach which can be used for creating innovative, low cost and trouble free products on significant short schedules. In this paper, an IDD project which is one type of DFSS project using IDDOV method is presented on developing a robust simulation process to predict the AIS snorkel volume velocity. First, the IDDOV method is overviewed and the innovative tools in each phase of IDDOV are introduced.
Journal Article
Huafeng Yu, Chung-Wei Lin, BaekGyu Kim
Abstract Modern vehicles can have millions of lines of software, for vehicle control, infotainment, etc. The correctness and quality of the software play a key role in the safety of whole vehicles. In order to assure the safety, engineers give an effort to prove correctness of individual subsystems or their integration using testing or verification methods. One needs to eventually certify that the developed vehicle as a whole is indeed safe using the artifacts and evidences produced throughout the development cycle. Such a certification process helps to increase the safety confidence of the developed software and reduce OEM’s liability. However, software certification in automotive domain is not yet well established, compared to other safety-critical domains, such as avionics and medical devices. At the same time, safety-relevant standards and techniques, including ISO 26262 and assurance cases, have been well adopted.
WIP Standard
This specification covers quality assurance sampling and testing procedures used to determine conformance to applicable material specification requirements of wrought corrosion and heat-resistant steel and alloy products and of forging stock.
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