Risk Management in Product Development at GKN Aerospace: Challenges of Becoming More Proactive
Independent thesis Advanced level (professional degree), 20 credits / 30 HE creditsStudent thesis
Risk Management is becoming an integral part of Quality Management. For example, in the new revision of ISO 9001, which will be released by the end of 2015, the incorporation of risk-based thinking is considered to be the largest update.This master thesis have has been conducted as a case study at GKN Aerospace Sweden AB in Trollhättan. The company produces complex high-tech components that can be found in 90% of the civil aircrafts produced today. The strict flight safety requirements and long time-to-market creates a need for effective and proactive risk management practices. GKN Aerospace has therefore been considered as a suitable case to study in order to understand how companies can work with product risk management to become more effective and proactive.D-FMEA:s and traditional product risk management tools have naturally been given a large focus. However, the study has had an open and exploratory approach in order to identify alternative practices, which reduces uncertainties and creates proactivity. This has led to an investigation of how Robust Design, Design for Manufacturing and Lessons Learned can be integrated effectively to the current Risk Management Processes.A literature, survey and interview study have been conducted in order to create an understanding of the current product risk management practice at GKN Aerospace. These results have then been used in a less extensive benchmarking study at Autoliv and Volvo Construction Equipment in order compare alternative practices and develop suggestions for improvements. This has lead to the following conclusions:- In order for risk management to be effective there must be a demand. If there is no demand from the customer it must be created internally.- Clearly specifying the process, working continuously and increasing the risk management education are ways to avoid a situation where FMECA:s are filled in reactively and therefore loose both their purpose and potential.- Many at GKN perceive FMECA:s as time-consuming, complex and hard to get a holistic perspective of. This problem decreases by creating a “Master- FMECA” where generic risks are used as input, which allows focus to be directed to where the biggest risks are; new content and changes.- Increasing the basic educational level within risk management is effective, but not sufficient for those leading the risk management work. An additional educational level of how the work should be managed is needed.- It is fully possible to include Robust design in the FMECA:s, but complementing parallel process flow is recommended in that case.- The Manufacturing department should be required to always be involved in the FMECA work, in order to early include a producibility perspective. There should also be a clear process flow between the FMECA and P-FMEA.- Lessons learnt may effectively be used as input to the risk management process, but it is hard and something all three organisations struggle/have struggled with.
Place, publisher, year, edition, pages
2015. , 97 p.
Social Behaviour Law
Samhälls-, beteendevetenskap, juridik, Quality Management, Product Risk Management, Proactivity, FMEA, FMECA, Robust Design, Design for Manufacturing, Producibility, Lessons Learned
IdentifiersURN: urn:nbn:se:ltu:diva-54813Local ID: bbfc7f6d-67d9-4adf-98d4-f8fa13c62aefOAI: oai:DiVA.org:ltu-54813DiVA: diva2:1028195
Subject / course
Student thesis, at least 30 credits
Industrial and Management Engineering, master's level
Validerat; 20150821 (global_studentproject_submitter)2016-10-042016-10-04Bibliographically approved