Goodrich Rescue Hoist Cable Update

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Goodrich Rescue Hoist Cable Update Goodrich
Users Conference 2007
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Goodrich Rescue Hoist Cable UpdateAgenda

• Historical Review
• Cable Supply Risk Mitigation Activities Update
• User Returns Report
• New Rejection Criteria

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Goodrich Rescue Hoist Cable Historical Review
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Goodrich Rescue Hoist Cable UpdateHistorical
Review

• Goodrich had historically relied on two primary
  suppliers for its 19x7 rescue hoist cables
• Stainless Steel (CAT I) Carolina Cable in USA
• Galvanized (CAT II) CPP in France
• Both suppliers were lost
• Carolina Cable closed in 2003
• CPP became unreliable in 2004
• Goodrich qualified a new supplier beginning in
  2003 using Mil-W-83140 as the technical guide
• Although the supplier passed all requirements,
  the number of cable returns increased from
  historical rates
• Goodrich launched a program to improve the cable
  situation in 2004/5
• Team focused on
• Production configuration refinement
• Production management refinement
• Goodrich demand management

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Goodrich Rescue Hoist Cable Cable Supply Risk
Mitigation
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Cable Supply Risk MitigationProduction
Configuration Refinement

• Undertook parametric investigation of build
  configuration details vs performance results
• Fifty (50) geometric and material based
  configuration parameters monitored from lot to
  lot
• Built proprietary theoretical engineering models
  to explain relationship between configuration and
  performance
• Conducted cycling tests of improved configuration
  

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Cable Supply Risk Mitigation Production
Configuration Refinement

• In order to increase test program sample size,
  testing was stopped at 1000 cycles on each cable
• This gave us the confidence to issue a 300 cycle
  warranty for cables produced in 2005 and after

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Cable Supply Risk Mitigation Production
Configuration Refinement

• Goodrich is not done with its configuration
  improvement program
• Although fewer in number, we are still seeing
  cable returns
• Information from field returns is being collected
  in a database and trends are being closely
  analyzed (More on this later in this briefing.)
• Engineering models are being refined with growing
  body of knowledge
• Experiments with alternate configurations are
  still being conducted
• We will never be done improving

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Cable Supply Risk Mitigation Production
Management Refinement

• With the total cooperation of its new source, a
  Goodrich Supplier Development team promoted a
  production process management improvement program
• Committed to establishing AS9100 certified
  business process controls at the supplier
• Supplier processes were reviewed, refined and
  re-documented
• Process and facility work flow improvements
  implemented (Complete.)
• Capital investments made (Some items complete.
  More to go.)
• Policies, procedures and work instructions
  drafted (Complete.)
• Improved data management systems (Some items
  complete. More to go.)
• Two Goodrich audits show continuing progress
  toward desired end state

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Cable Supply Risk Mitigation Production
Management Refinement

• Goodrich, and its supplier, are not done with the
  Production Management Refinement program
• Completion of internal training and self-audit
  process implementation still open
• Additional infrastructure improvements planned
• Definite gains have been made and Goodrich has
  high confidence in its suppliers production
  controls, but.
• Together we are striving to virtually eliminate
  the risk of a production process failure
• We will never be done improving

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Cable Supply Risk Mitigation Goodrich Production
Demand Management

• The normal manufacturing lead time for cable
  assemblies is approximately 4 months
• Availability of cable assemblies is highly
  dependent on the size of the wire rope batch size
  committed early on
• Unforeseen arrival of additional, short term
  cable assembly demands can not readily be
  accommodated by the production process
• There is only so much wire rope committed in a
  production run
• Arrival of high priority demands have
  historically led to deferrals on some lower
  priority cable assembly orders (Unsatisfactory)
• Goodrich can improve its production demand
  management

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Cable Supply Risk Mitigation Goodrich Production
Demand Management

• Recognized two primary improvement opportunities
• Stabilize demands (and consequently production
  rate)
• Improve forecasting to produce ahead of orders at
  an acceptable rate

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Cable Supply Risk Mitigation Goodrich Production
Demand Management

• Stabilizing Demand
• Providing a stable lead into the supplier allows
  them to more easily manage the upstream flow of
  materials and processing
• A stable production rate also supports quality
  objectives
• Goodrich is implementing a constant, monthly wire
  rope production rate
• Forecasting the Correct Production Rate
• Goodrich has recently conducted a statistical
  analysis of all demands over the last three (3)
  years by P/N
• Goodrich is speculatively purchasing a constant
  production rate of wire rope that will cover the
  forecasted 2007 demands with some additional
  buffer
• Decisions on individual cable assembly part
  number orders will be managed based on demand
  projections and emerging inventory status
• The result is, Goodrich intends to carry more
  cable assembly inventory in advance of forecasted
  demands

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Goodrich Rescue Hoist CablesCable Returns Report
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Cable Returns Report Total Returns By
Manufacturing Year

• Chart aligns cable returns with the year they
  were manufactured
• Total return count, and percentage of delivered
  cables returned, are running on a favorable trend

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Cable Returns Report Total Returns By
Manufacturing Year

• All cable assembly part numbers are manufactured
  from the same wire rope (i.e. only the length and
  markings vary between P/Ns)
• As a percentage of total deliveries, data
  suggests atypical experience with 42325-162 and
  44301-351 users
• Rejections as a percentage of total deliveries is
  improving but still too high
• Closer investigation is necessary

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Goodrich Rescue Hoist CablesCable Rejection
Criteria
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Cable Rejection Criteria Existing Rejection
Criteria Situation

• Guidance from Industry Standards and CMM
• Guidance developed during a time when rescue
  hoist cables were less closely monitored and
  general level of concern was lower
• Broad statements that generally characterized
  potential faults were satisfactory
• Present, heightened level of concern regarding
  cable health has led to dis-satisfaction with the
  lack of specific rejection criteria for cable
  inspections
• How big does a flat spot have to be?
• Is this nick in a wire too large?
• Is this loosening strand a cause for rejection?
• Goodrich is pursuing an improved set of criteria

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Cable Rejection Criteria Improving Rejection
Criteria

• Goodrich Improvement Plans
• Conduct tests to increase detailed understanding
  of the impact of certain faults on cable
  performance
• Some testing completed to determine affect of
  wire breaks on overall rope integrity
• Establish a visual reference guide for cable
  inspections
• Visual reference guide development initiated
• Substantial effort is required to completely
  fulfill this plan
• More tests are to be done
• Utilize scrapped returned cables to determine
  reduction in performance
• Continually capturing photographs of returned
  cables
• Developing scale of actual fault significance is
  dependent on actual condition of returned cables
  and subsequent test results

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Cable Rejection Criteria Improving Rejection
Criteria Situation

• Based on test results to date Goodrich is
  releasing the following partial change to its
  rejection criteria
• Two (2) or more adjacent wires in the same strand
  with 50 or greater reduction in cross sectional
  area of each wire
• Two (2) adjacent strands with one (1) or more
  wires with 50 or greater reduction in cross
  sectional area of each wire
• Will be implemented in next CMM revision cycle

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Summary

• Much has been accomplished this past year
• Testing and reduced failure reports indicate the
  configuration is improved
• Collaboration with the supplier has resulted in
  substantial progress toward AS9100 certification
• Goodrich has committed itself to producing cable
  at a constant rate sufficient to meet forecasted
  quantities and a buffer stock
• We still have some problem reports, so we are not
  done.
• We are committed to continually improving the
  product and process