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Overcoming difficulties will become stronger and stronger. The rainbow will be seen in the wind and rain
2019/5/6
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————Documentary on the quality control process of Anhui Haery Aviation Engine Development Process
In the past three years since its establishment, Anhui Haery Aviation Engine Team has taken the path of self-research and development of aviation engines by Chinese people, with its momentum of self-improvement and the spirit of innovation and transcendence, and has overcome all obstacles to foster the dream of aviation power and achieved great successes. It has faced difficulties and forged ahead on the road of independent development of aviation engines. The team has overcome eight key common technologies under development, completed 29 research projects, filled the gap in small and medium-sized power in China, and the local parameters of engine performance have reached the international advanced level.
As we all know, an aircraft engine is a "industrial pearl" composed of multiple disciplines and multiple components and systems. The expected functional implementation of each component and each system, as well as the interrelationship or interaction between components and systems, directly affects the overall function of the engine. The Haery Engine team used process methods to optimize and continuously improve the aircraft engine development process, which better achieved process value-added and improved management effects.
1. Use the "process method" to plan the panoramic view of the company's quality management system
The definition of "process" in GJB9001C is: "a set of activities that use input to achieve the interrelated or interactive results." Any activity that converts received input into output by utilizing resources and implementing management can be considered a process. For example, design, trial production, and testing can all be regarded as a process. The development process of aero engines is huge and complex. According to the tasks completed, it is divided into four first-level processes: design process, production trial process, bench test process and scientific research test flight verification process.
The quality management system established by the company in accordance with the GJB9001C-2017 standard is composed of interrelated processes, and activities are understood and managed as a system composed of interrelated and coherent processes, so as to obtain consistent and predictable results more effectively and quickly.
2. Quality planning of the development process
The development process planning proposes the quality goals for engine development in accordance with the requirements of development agreement, contract, market VOC report, product competitiveness analysis report, etc., and prepares the "Quality For Outline" for aviation engine development, and plans and prepares the top-level quality control documents such as quality plans and quality management for each stage of aviation engine development. The top-level quality management documents are used as the output of the planning and sent to each unit to undertake the development task for implementation.
At the same time, the development process also integrates military standard requirements and implements planning and control activities such as product standardization outline, six-dimensional work requirements, software development management, technical status management, risk management, quality information collection and analysis, etc.
3. Quality control method for the development process
3.1Design process quality control
Because the reliability of the engine is designed, quality hazards are eliminated from the source of the design and quality control is implemented.
3.1.1According to the "Product Development First-level Process", "Product Implementation Planning Control Program", "Design and Development Control Program", "Technical State Management Program" and other related requirements for design quality control will be included in the "Quality For Outline" and the "Six-Nature Outline" such as "Quality For Outline" and trustworthiness, and will be organized and implemented during the design process.
3.1.2In view of the characteristics of different engine development stages, targeted feasibility analysis and design reviews have been planned and carried out, and the argumentation stage review report, plan stage review report, development stage review report, and finalization stage review report are formed. After each stage of design is completed, a cross-module design quality review will be organized, and relevant units will be organized to rectify the problems and suggestions raised during the review process to achieve closed-loop management.
3.1.3Establish a feedback system for the implementation of physical technical status. In order to control the product technical status, in accordance with relevant requirements of technical status management, in order to achieve "five in place" changes, it will be implemented in five aspects: design drawings and technical documents, process documents, products in-products, inventory parts, and installation parts, so as to control the product technical status.
3.2Quality control of production trial process
If design quality is compared to the innate birth of product quality, then manufacturing quality is acquired cultivation. It is not possible to just have "innate" without paying attention to "acquired". The manufacturing process is connected and the design process, and the process test of design is "trial production". The production trial process focuses on controlling the production of key processes, special processes and the production of newly developed products. In a word, "the entire production and manufacturing process is a process of faithfully implementing process specifications."
3.2.1Incoming parts materials
The quality department prepares inspection procedures based on the drawings and inspection inputs output from the product. The inspection procedures involve the required dimensions, appearance, performance, weight and cleanliness requirements, etc., in combination with the relevant requirements of GJB and the Haery third-level document "HR-QCZ901-Incoming Material Inspection Measures". Incoming materials inspections are subject to 100% inspection and corresponding re-inspection before leaving the factory. In order to control the quality status of the parts, the unqualified parts found in the inspection will be reviewed in accordance with the "HR-QCZ821-Unqualified Product Review Management Measures" to ensure that the incoming materials meet the product requirements.
3.2.2Assembly process quality control
During the assembly process, the test assembly personnel assemble according to the "Assembly Adjustment Instructions", and during the process, key parameters such as clearance and bolt torque are recorded in the "Assembly Record Report". Quality personnel participate in tracking the assembly process of some key parts. If there are quality problems during the assembly process, the quality personnel will record and promote them in accordance with the "Failure Quality Control Procedure". At the same time, for all quality problems found, the quality department will organize relevant personnel to review and analyze them as soon as possible until the problem is solved.
3.2.3Quality control of bench test process
“Aero engines are not only designed, but also tested. "The test session can be said to be auscultation and pulse for the engine. Through a series of complex "physical examinations", the reliability and safety of the engine are improved. Its responsibility is heavy and there is no need to be careless.
1) According to the fourth-level verification procedure, the bottom parts are gradually verified to the top assembly. The test verification uses a four-level system for key components, subsystems, whole-machine-level, and powertrains with paddles to establish standards. After the introduction of the European standard, it combines the requirements of independent development, national military standards, airworthiness standards, and three-pole verification (tolerance, working conditions, and environment) to form a set of relatively complete performance and trustworthiness standards.
2) Export the test items and plans from DVP to form a list of test plans; prepare a test outline based on the test items before the test, and there is a method to follow for the test process.
3) Before the experiment, organize relevant units to conduct pre-test preparation status inspections, focusing on checking the technical status of the test parts, the status of the test equipment and test equipment at the test site, the status of the participants, the status of the emergency plan and other preparation status, and promptly rectify the problems found. At the same time, experts in the industry are organized to review the engine technical status, test outline, emergency plans, etc. After the test is completed, the test results are reviewed to evaluate the validity of the test results.
4) For large-scale tests, while completing the above work, before the test, the technical difficulties and risks during the test should be analyzed, overall planning should be carried out, and a special test quality control plan should be formed.
3.2.4Establishment of quality files of the whole machine:
In order to ensure that all records of each engine can be queried, the company's quality control module plans quality files, and uses distribution as the outline, extracts the parts supplier report and incoming material inspection report, and summarizes five parts, including assembly process records, test process records, and whole machine delivery inspection records, and compiles them into a book and signature archive to form engine quality files for subsequent inquiries.
3.3Quality control of scientific research test flight verification process
The test flight is a key link in testing the reliability of engine performance and is an important task for the engine assembly aircraft to fly safely. It has a heavy responsibility and a arduous mission.
3.3.1Special quality review before delivery: According to the requirements of the "Quality For Outline", quality review is organized before the first flight. This is not only a re-check, confirmation and filling of the gaps in the trial production process, but also a feed-forward quality work for engine delivery, subsequent tests and test flights.
3.3.2Delivery Review: After the product is inspected and passed, the quality of the product and its quality are subject to multi-faceted and systematic reviews for work before delivery, and are carried out through the on-site acceptance and delivery review meeting.
3.3.3Deliver the first test flight engine, set up a test flight support team, formulate the "Test Flight Support Management Measures", etc., which provide strong support for aircraft test flight safety.
3.4Supplier quality management
By evaluating and certifying suppliers, a procurement management quality system is established and the company's materials are supplied under a controlled state.
3.4.1Develop a quality plan:From the supplier's product design, manufacturing process, quality control, technical assistance, etc. It is necessary to coordinate the capabilities of both supply and demand parties equally. The coordination method is to formulate a joint quality plan. The joint quality plan generally includes several aspects such as cost, technology, quality, and management.
3.4.2Control of key parts:For the critical dimensions of key and important parts, the supplier's own capabilities are based on the production equipment, testing equipment and factory management of key characteristics, and systematic improvement methods are made to identify existing risk points, so that the mass production of parts is controlled.
3.4.3Supplier quality in order to improve activities:
1) During the project stage, the supplier will start tracking, monitor the supplier's production process, and conduct 100% inspection when leaving the factory. In order for the parts to meet the requirements, the company will also conduct 100% inspection within the company, and conduct on-site tracking of the supplier's risky parts to the supplier;
2) Keep abreast of changes in the supplier's production conditions, such as major changes in product design or structure, major changes in manufacturing processes, major changes in inspection and testing equipment and procedures, etc., and require suppliers to actively report and explain the situation. After receiving the report on procurement quality, we should carefully analyze and evaluate the relevant departments. If necessary, we should go to the supplier to understand it directly. We should mainly clarify the impact on product quality to reduce risks;
3) Formulate an audit plan and flight inspection, and pass audit supervision, it is conducive to grasping the supplier's comprehensive capabilities in multiple aspects, discovering its weak links in a timely manner and requiring them to improve, so as to make the supply quality in a system.
4. Continuous improvement of the development process
Determine the specific items, measurement methods, frequency and judgment criteria for monitoring and measuring the development process based on the characteristics of the aircraft engine, evaluate the suitability and effectiveness of the process capabilities, and comply with the characteristics requirements of this type of aircraft engine, take corrective measures in a timely manner for the problems found, and track their effectiveness, in order to meet the requirements of the product's development goals, and in order to meet the requirements of the product's development process.
The product development process forms a list of quality uniqueness and is managed by quality engineers. Quality engineers regularly prepare TOP quality problems cases and organize learning from one example to another; listen to user opinions, implement corrective measures based on user opinions, improve procedures and processes and other continuous improvement activities to prevent the recurrence of quality problems.
V. Conclusion
Against the backdrop that "in-depth development of military-civilian integration" has been elevated to a national strategy, my country has provided favorable policy support for enterprises in many aspects such as R&D investment, project investment, industrial chain control, and intellectual property protection. New opportunities and new challenges have come to the forefront. Anhui Haery will face difficulties, deeply promote the development of military and civilian dual-use technology, break through the "bottleneck" technology in the field of aviation engines in my country, and build a more reliable product quality that users can trust in. For the system, we will strive to create global advanced aero engine products!
