|M.Sc Thesis||Department of Quality Assurance and Reliability|
|Supervisor:||Dr. Jacqueline Asscher|
|Full Thesis text - in Hebrew|
The Carmel Forges factory was founded in 1961. The company produces jet-engine parts of Nickel and Titanium alloys for the aerospace industry all over the world. The major production of the factory is closed die forgings and seamless rolled rings.
In 1994 CF was purchased by the world producer of the aerospace engine parts Pratt & Whitney. Since 1999 Pratt & Whitney implements the ACE standard, with the goal of encouraging the personnel to make efforts in continuous improvement of the production quality and effectiveness at every level in the company. One of its important elements is the periodical accreditation of the employees.
The main goals of the ACE standard:
- zero non-conformity - rejecting products with constant percentage of con-conformities even when the percentage is small
- variance reduction and aiming processes on target
- continuous improvement of the processes
Standard ACE is used for the process certification. The process is called “certified” when it is proved that it is controlled and capable.
The goal of this project is the certification of the Raw Metal Cutting process. The raw material, titanium and steel alloy logs, are cut into different lengths in order to obtain the desired customer’s weight. The permitted deviation during the cutting process is defined in the customer’s order and may only be positive. The cutting process is problematic because of the non-uniformity of the diameter which is used for the indirect measurement of the weight in order to determine the needed cutting length.
During the work on this project other problems were revealed: a defective gauge, lack of capability of the scale to weigh with the required accuracy, tolerance definitions that do not match the customer’s requirements, work not carried out according to the procedures, calculation of process capability indices that is not appropriate to the distribution of the data.
The majority of these problems were solved in this project, with the exception of the problem with the scale (the solution entails high costs).
The project conclusions and recommendations will lead to the certification without additional efforts of more than 33% of all the production which has not already been certified if the personnel works follows work procedures, and if in addition the scale is replaced, the project would lead to the certification of 60% of all production.