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CARGO DOOR’S Depressor Seal

CARGO DOOR’S Depressor Seal. Depressor Seal. Damaged Depressor Seal. Damaged Depressor Seal. DAMAGED Depressor Seal. Background.

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CARGO DOOR’S Depressor Seal

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  1. CARGO DOOR’S Depressor Seal Depressor Seal

  2. Damaged Depressor Seal Damaged Depressor Seal DAMAGED Depressor Seal

  3. Background • Six Sigmais data – driven business process optimization methodology which aims to reduce variation, elimination non-value added activities and significantly improve process quality.

  4. (DMAIC) How does it work ? Y = f(X) Define What is important to the organization ? 8-Blocker, Fishbone, CTQ, Process Flow Y Measure How much can the existing process improve ? Capability analysis Y Analyze What are the critical factors ? Hypothesis testing, Regression Xs Improve How to reduce variation, time, cost, defects ? DOE, Simulation Y Control YX How to maintain improvement ? SPC

  5. DEFINE & MEASURE

  6. Project Definition • Objective • Reduce depressor seal damage (DSD) by more than 50% • Defect Definition • FWD & AFT Cargo Doors Depressor seal damage (DSD) • Benefits • Reduce maintenance repair cost • Reduce flight delays • Minimize operation interruptions • Constraints • Non-availability of detail data regarding the damage • Non-availability of maintenance repair cost

  7. Team Members Team Members • Saad Nujaim • Adel Sait • Mohammad Fayoumi • Khaild al ghomari Master Black Belt • Saad Nujaim Process Sponsor • GS, MD- GS Strategic Unit

  8. Cause and Effect Environment Materials Methods weather Guiders set up of Hi-Loader Hardness of depressor seal Light Position Hi-Loaders Condition of container Rush Operation Temperature . Using of stoppers in Cargo compartment Depressor Seal Damage (DSD) Training DPU Supervision Fatigue A/F Protection Guiders Shipment Size Different natis License Condition of stoppers in a/c Cargo comprtment Qualification A/C Door size Manpower Measurements Machine

  9. Existing Loading/ Offloading Process

  10. Descriptive Statistics for all DSD (2001 – 1st Qtr of 2008)

  11. Process Capability

  12. Run Chart (2001 – 1st Qtr of 2008)

  13. Calculation of Z-ST & Z-LT

  14. Control Vs Technology 3.0 1.5 0.0 Zst =0.85 Zlt =- 0.66 Zshift = Zst - Zlt = 0.85+0.66 =1.51 Poor control Poor technology Need better control Technology is fine Control (Zshift) Where we are now Control is fine Impove factory or technology World class Goal 0.0 3.0 6.0 Technology (Zst)

  15. ANALYSIS

  16. Depressor Seal Damage Based on A/C Type 86 % of DSD is related to B-747 ,while 14 % is related to other fleet type.

  17. Depressor Seal Damage by Station 53% OF DSD took place in Jeddah and Riyadh stations

  18. Relationship Between DSD And Other Variables Determination of the existence relationship between the number of DSD and some other variables is measured by the value of the correlation coefficient “R”. The Correlation Analysis and its “R” value is shown in the table below: Based on the above table , it is clear that the total number of DSD is linearly correlated to JED & RUH operation and B-747 fleet. Note: Data Source :ARP-TSV

  19. Analysis of DSD Causes One of the major causes of DSD incident is loading and off loading operation on the A/C. B-747 A/C and B-777 A/C are very identical in terms of : 1- Loading / off-loading operation 2- Shipment types and size (ULD’S & Pallets) 3- Equipment used for loading/off-loading operation. * Components Removals for years 2003,2004,2005,2006,2007 data Source :ARP-TSV

  20. Operation Volume Analysis Question :- Does the operation volume of A/C B-747 and A/C B777 is significantly Different ? Test of Hypothesis is used to compare the mean of B-747 NO. revenue dept and the mean of B-777 NO. revenue dept. Analysis of Variance Source DF SS MS F P Factor 1 47383681 47383681 60.17 0.000 Error 54 42525739 787514 Total 55 89909420 Individual 95% CIs For Mean Based on Pooled StDev Level N Mean StDev -------+---------+---------+--------- B-747ALL 28 4086.8 851.0 (---*----) B-777 28 5926.5 922.4 (----*---) -------+---------+---------+--------- Pooled St Dev = 887.4 4200 4900 5600 Answer : Yes Because the P-value = 0.000 , < 0.05 , we conclude that there is a statistical difference between the two means and the mean of B-777 NO. revenue dep. is higher.

  21. Analysis of Loading/offloading and Hi-loader Operation • Following observations were made during the inspections performed in Jeddah and Dhaka (may2008) stations: • No adjustment for Hi-loader’s protection guiders was made • during loading and • off-loading operation.

  22. Analysis of Loading/offloading and Hi-loader Operation • The operator stands • on the right side • of A/C door. • A lot of damaged • ULDs were used.

  23. Analysis of Loading/offloading and Hi-loader Operation • Some of heavy ULDs were handled by the operator alone. • Inadequate supervision

  24. Depressor Seal Damage By Door Location 33 % OF DSD was located on the left side of A/C CGO doors, while 14 % of DSD was On right side of A/C CGO doors.

  25. Conclusion The analysis revealed that: 1- Hi-loader’s protection guiders setting is considered as the major cause of DSD. 2- Damaged and heavy ULDs are another cause of DSD in the absence of proper setting of Hi-loader’s protection guiders and the operator stand alone on the right side of A/C cargo door.

  26. Conclusion B-777 B-747 3- Cargo door of B-777 has less DSD due to : A- Bigger door size in width. B- It has protection guide fitted in A/C’s cargo door (help in offloading).

  27. RECOMMENDATIONS 1. Hi-loader protection guiders must be adjusted within A/C Cargo door width. 2. Damaged ULD’S should not to be used. 3. ULD’S weight must be controlled to avoid loading of heavy ULD’S.

  28. RECOMMENDATIONS 4. Assistance must be requested by the operator in case of facing stuck/heavy ULD’s. 5. Damaged ULD’s should not be loaded side door. 6. Any failure of PDU should be reported by the operator.

  29. IMPROVE & CONTROL

  30. IMPROVEDLoading/ Offloading Process

  31. Depressor Seal damaged Trend

  32. Process Fixes & Control Causes of Variation Control System Process Fix • - The Adjustment of Hi-loader’s protection guiders was not performed • A lot of ULD’S were damaged. • Inadequate Supervision. • Review & study the processes of loading and offloading. • Update GSPM to include the recommendations. • To enhance safety awareness by explaining correct practices to the concerned staff. • GS established licensing & training programs. -Monitor the processes of loading and offloading. - Perform the random inspection. - Monitor DSD trend.

  33. Project Closure Implementation of project recommendations will yield the following :- • Eliminate the maintenance repair cost • Eliminate any related cost to operation interruption and flight delays Financial • Minimize operation interruption • Minimize unexpected flight delays • Improve A/C safety. Operation

  34. Thank You

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