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EUROCOPTER PROCEDURE
DEVELOPMENT UNTIL QUALIFICATION OF TEST BENCHES FOR DYNAMIC COMPONENTS Abstract: This document describes the operating mode, responsibilities and rules for the development of test benches for Dynamic components.
Reference language : English
Ratified:
EC
ECD
Subsidiaries
Approved Repair Centers
Agreements / Certifications ISO
DOA
POA
MOA
Militaire
TRTO
MTO
EC ECD
Working group : Charles GIRAUD, Maurice BLANC, Michel RANCHIN, Pierre FERAUD, Laurent MEUSY, Uwe ZIMMERMANN
Application date :
21/05/2002
Approval : Technical Responsible
Documentation Executive Committee
Signed
Signed C. AUBERT
M. RANCHIN ‘’Ce document est la propriété d’ EUROCOPTER, il ne peut être communiqué à des tiers et/ou reproduit sans l’autorisation préalable écrite d’ EUROCOPTER et son contenu ne peut être divulgué’’. © EUROCOPTER 05/2002
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CONTENTS MODIFICATIONS LIST................................................................................................................................2 1 - SUBJECT................................................................................................................................................3 2 - PROCESS DESCRIPTION...................................................................................................................3 2.1 Initialisation :.......................................................................................................................................3 2.2 Project GREEN LIGHT :..................................................................................................................3 2.3 DEVELOPMENT PROGRAM :......................................................................................................4 2-3-1 SPECIFICATION PHASE.........................................................................................................4 2-3-2 BENCH CARRY-OUT PHASE.................................................................................................4 2-3-3 QUALIFICATION PHASE .........................................................................................................4 3 - RESPONSIBILITIES...............................................................................................................................5 4 - RULES.....................................................................................................................................................5 APPENDIX 1………………………………………………………………………………………….…..6
MODIFICATIONS LIST Issue DATE
A : 21/05/2002
Modified items
CONTENT of the MODIFICATION
New document.
‘’Ce document est la propriété d’ EUROCOPTER, il ne peut être communiqué à des tiers et/ou reproduit sans l’autorisation préalable écrite d’ EUROCOPTER et son contenu ne peut être divulgué’’. © EUROCOPTER 05/2002
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SUBJECT
This document is intended to describe the operating mode to develop and qualify any test bench for dynamic components (DC), to precise and allocate the various responsibilities, and to fix the necessary rules. It must be used for the development of a DC test bench inside EUROCOPTER, or in one subsidiary or in an agreed Mechanical Service or Repair and Overhaul Centre.
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PROCESS DESCRIPTION
See synopsis in appendix 1. 2.1
Initialisation : Needs to be met are transmitted to a member of the Steering Committee by an EUROCOPTER network site. The Steering Committee composed at least of a representative of : -
Mechanical Industrial Competence Centre Industrial test means Technical Customer Support Repair and Overhaul Quality
and completed as much as necessary according to the context ( Program Directorate, Participation, …), states on the opportunity to develop and install a new DC test bench, in consistency with the test bench Policy and the Repair and Overhaul Network Policy. The Steering Committee entrust the Responsible for Industrial Test Means as Project Manager ( or nominates a specific Project Manager if more convenient or necessary ) to draw up the Project.
2.2
Project GREEN LIGHT : The Project Manager, with the help of, at least: - The Design Responsible of the DC to be tested - The Responsible of the Industrial Test Means - A Customer Support Repair and Overhaul representative performs a preliminary technical ,economic and calendar analysis for presentation to the Steering Committee to give the formal green light for launching the Development Program.
‘’Ce document est la propriété d’ EUROCOPTER, il ne peut être communiqué à des tiers et/ou reproduit sans l’autorisation préalable écrite d’ EUROCOPTER et son contenu ne peut être divulgué’’. © EUROCOPTER 05/2002
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DEVELOPMENT PROGRAM : The Project Manager organises a launching review with all the responsible of the tasks, then manages the various Development phases: 2-3-1 SPECIFICATION PHASE -
Detailed definition of the need. Design analysis of each DC to be tested Analysis of all the encountered or foreseen defects of each DC to be tested Specification of the test bench Conditions and Criteria of Qualification of the test bench for each DC to be tested Request for proposal and Selection of the Vendor for the test bench Quality specific requirements or plan
2-3-2 BENCH CARRY-OUT PHASE -
Contractual Specification for the bench ( Order to Vendor ) Acceptance Procedure of the test bench in Vendor’s facilities User’s Manual Maintenance Manual DC Test Procedures in accordance with the technical publications of depot level maintenance. - Acceptance Test Report form When all these tasks are completed, the bench manufactured , accepted and installed, the qualification phase has to be completed: 2-3-3 QUALIFICATION PHASE -
Conformity review of the bench and test results Preliminary clearance (authorisation to use) Probationary test period on the specified number of DC, to confirm the test parameters Process freeze Bench configuration identification and freeze Result analysis and fixing of the tolerances and limitations of the parameters Formal Qualification
A final review with the technical and industrial status, budget balance sheet, and all other interesting experiences has to be presented to the Steering Committee by the Project Manager.
‘’Ce document est la propriété d’ EUROCOPTER, il ne peut être communiqué à des tiers et/ou reproduit sans l’autorisation préalable écrite d’ EUROCOPTER et son contenu ne peut être divulgué’’. © EUROCOPTER 05/2002
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RESPONSIBILITIES
The Steering Committee decides about the strategic opportunity of the needs to be met, intrust the project manager, validate the technical and technical analysis and approve the budget balance. The Project Manager acts as the general responsible, co-ordinates the completion of all the actions of the dedicated people, and reports to the Steering Committee. He prepares and animates all the various reviews. Upon formal approval from the Design Authority and local Quality Responsible, he pronounces the preliminary and final qualification of the test bench. The Design Authority is responsible for all the DC aspects ( Interface drawings, design and defect analysis,…), the conditions and criteria for bench qualification, and the DC Acceptance Test Program. The Design Authority is also responsible for the analysis and approbation of the development and qualification test results, as well as the first 10 production test results. The Responsible for Industrial Test Means is responsible for the bench specifications, design and manufacturing follow-up in the Vendor’s facilities, acceptance, installation. Quality Management is responsible for providing all the necessary early requirements for inspection and Quality Assurance, and to verify their carrying out. Quality is also responsible for the survey of the whole foreseen process. The Repair and Overhaul Directorate of the Customer Service is responsible for all topics dealing with Repair and Overhaul activities, inside EUROCOPTER as well as in the Mechanical 3rd level agreed network.
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RULES
R1
The Steering Committee meets when a request or a need for a test mean is detected.
R2
A test bench cannot be used for production if it has not got at least a preliminary clearance.
R3
The preliminary clearance and the formal qualification can be pronounced only after formal written approval of the Design Authority and the Quality Management.
R4
All agreed centre must send reliability data on discrepancies found during repair and overhaul on regular basis. This commitment is a preliminary condition to get the agreement to use the test bench.
R5
In case of major repair, modification, long use interrupt, removal, a re-qualification has to be performed IAW the directives of the responsible of the industrial test means.
R6
Final qualification is under responsibility of Quality.
‘’Ce document est la propriété d’ EUROCOPTER, il ne peut être communiqué à des tiers et/ou reproduit sans l’autorisation préalable écrite d’ EUROCOPTER et son contenu ne peut être divulgué’’. © EUROCOPTER 05/2002
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APPENDIX 1 Needs to be met 4 Steering Commitee meeting for need strategic analysis and des ignation of the project manager
§ 2.0
Refused Customer information + argumentation : R e s pons abilitie s
Accepted 5+6+ 3+2
1: Industrial M echanical Center 2: Cus tomer Support 3: Des ign Office 4: Steering Commitee 5: Project M anager 6: Industrial Test M eans 7: Purchas ing 8: Quality 9: Cus tomer
Technical + economic + calendar analys is
YES
5
5 Pres entation and agreement of the Steering Committee
§ 2.1
NOK
Review of the project
NO
OK
9
5 Tes t s pecifications, qualification criterias and interface drawings known ?
YES
NO
Gearbox test without restrictions
3 Draw up of the documentation
6+9
OK
Draw up of the tes t bench s pecifications
§ 2.2.1
5+8
FINAL QUALIFICATION 3+8 +9
Freezing of parameters after "X" gearboxes Sub-contractor choice + implementation + monitoring
6+7 +8
YES NO
Corrective actions
6
NOK
Tes ts in sub-contractor's facilities
Temporary authorization
OofUusIe A uthorization of use
Corrective actions
§ 2.2.2
A ll res trictions cleared
Experimental gearboxes tes ts only
3
Delivery + ins tallation in cus tomer facilities + adjus tements
NOK
6
8 +9
OK 6+9
NOK
3
YES Qualification tes t of the bench
OK
With res trictions 6
NO § 2.2.3
6 + 8+ 9 OID LP 22/04/02 ‘’Ce document est la propriété d’ EUROCOPTER, il ne peut être communiqué à des tiers et/ou reproduit sans l’autorisation préalable écrite d’ EUROCOPTER et son contenu ne peut être divulgué’’. © EUROCOPTER 05/2002
