Potential FOD Defects on the Composite Material

摘要

This study is focusing in the use of Quality Tools and Lean Six Sigma methodology in composite material manufacturing hand lay-up process improvement in order to identify potential Foreign Object Debris (FOD). Hand lay-up is a process in which individual layers of prepreg are laid up on a tool and then cured. Hand lay-up is a manual process that resulting in numbers of quality defects such as voids, delamination, warpage and the Foreign Object Debris (FOD). This study exclusively deals with the FOD quality defect. In this study some suitable quality tools along with Lean Six Sigma improvement process DMAIC (Define, Measure, Analyse, Improve, Control) approaches are applied on the hand lay-up process to provide a way to the company on how to identify and reduce the numbers of FOD quality defects of composite panels to get high quality components which ultimately fit in the aircraft. As the result of this study, the main source of the the problem is identified and some solutions were purposed. These solutions included, Kaizen, Standard Operation Process and SMED.